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Integrating Third-Party ABB S800 I/O Modules into SIMATIC PCS 7 via PROFIBUS GSD

Integrating Third-Party ABB S800 I/O Modules into SIMATIC PCS 7 via PROFIBUS GSD

When integrating third-party ABB S800 remote I/O modules (such as AI810 analog input boards) into SIMATIC PCS 7 with an S7-410-5H controller via PROFIBUS DP, the 'Edit Symbols' dialog in HW Config displays only 'BOOL' because generic GSD files declare module I/O spaces in raw byte lengths rather than structured words. To read 16-bit analog values, manually override the data type in the STEP 7 Symbol Table or HW Config by changing the symbol data type from BOOL to WORD (e.g., IW 678 as WORD). In CFC, map the word address directly to the PV_In input of an APL channel driver (Pcs7AnIn or FbAnIn) and configure manual scaling.

Table of Contents

Executive Summary

In industrial automation retrofit projects, plant owners frequently require integrating existing third-party remote I/O systems—such as ABB S800 I/O (e.g., AI810 8-channel analog input modules connected via a CI840 / CI801 PROFIBUS DP communication interface)—into a modernized SIMATIC PCS 7 system running an S7-410-5H controller. While the third-party GSD file installs cleanly in HW Config, engineers encounter a major stumbling block when attempting to assign symbols: right-clicking the analog module slot and selecting 'Edit Symbols' offers only discrete BOOL data types in the dropdown, failing to offer WORD or INT. This occurs because generic modular GSD descriptors specify memory footprints in bytes. Manually typing WORD in the symbol table and connecting addresses to APL channel drivers establishes complete analog integration.

Architecture and Fundamental Mechanics

The integration of third-party PROFIBUS DP modular I/O involves understanding GSD memory descriptors and PCS 7 channel processing:

1. PROFIBUS GSD Modular Memory Descriptors

In standard PROFIBUS DP architecture:
- A device manufacturer's GSD file defines module configurations using standardized byte codes.
- For an 8-channel 16-bit analog input module like the ABB AI810, the module footprint is $8 \times 2 = 16\text{ bytes}$ of input data.
- In generic GSD files, the manufacturer frequently declares the slot as a generic data block (e.g., 16 Bytes Input) rather than declaring individual typed words.
- When STEP 7 HW Config parses this generic definition, the 'Edit Symbols' wizard defaults to displaying bit/byte rows (BOOL). However, the STEP 7 symbol database is not locked: the engineer can overwrite BOOL by manually typing WORD into the Data Type column.

2. PCS 7 Driver Generation Limitations for Third-Party Hardware

Standard Siemens remote I/O lines (ET 200M, ET 200SP HA) are tightly coupled with the PCS 7 'Generate Module Drivers' wizard, which automatically creates diagnostic blocks (MOD_...).
- Third-party devices defined via external GSD files lack Siemens diagnostic block descriptors.
- When compiling CFC, the driver generator will display warnings: Module is not supported by driver generator.
- Consequently, engineers must either deploy FbAnIn (Field Device Analog Input driver for generic PROFIBUS DP PA profiles) or Pcs7AnIn with manual quality code mapping and scaling.

Step-by-Step Implementation Procedure

To successfully configure and scale ABB S800 analog I/O in SIMATIC PCS 7:

Step 1: Install ABB GSD File in HW Config

  1. In SIMATIC Manager, open HW Config for the S7-410-5H station.
  2. Select Options -> Install GSD Files....
  3. Browse to the ABB GSD file (e.g., ABB_CI801.GSD or ABB_CI840.GSD) and complete installation.
  4. Select Options -> Update Catalog.

Step 2: Configure the ABB Station on the PROFIBUS DP Master System

  1. From the hardware catalog (PROFIBUS DP -> Additional Field Devices -> I/O -> ABB), drag the slave interface into the PROFIBUS network.
  2. Assign the PROFIBUS node address matching the hardware dip-switches on the ABB station.
  3. Insert the analog input module (e.g., AI810) into the slot.
  4. Note the allocated peripheral input addresses (e.g., IW 678 to IW 692 for 8 channels).

Step 3: Define 16-Bit Word Symbols in the Symbol Table

  1. Close HW Config and open the Symbols table under S7 Program in SIMATIC Manager (or right-click the module in HW Config -> Edit Symbols).
  2. Locate the base address (e.g., IW 678).
  3. In the Data Type column, manually type WORD (do not select from the dropdown; type the word directly into the cell).
  4. Assign symbolic names for each 2-byte channel:
    - IW 678: ABB_AI810_CH0 (Data Type: WORD)
    - IW 680: ABB_AI810_CH1 (Data Type: WORD)
    - IW 682: ABB_AI810_CH2 (Data Type: WORD)
  5. Save the Symbol Table.

Step 4: Map and Scale in CFC Using APL Channel Drivers

  1. Open the target CFC chart.
  2. Place an APL channel driver: Pcs7AnIn (FB1869) or FbAnIn (FB1813).
  3. Connect the symbol ABB_AI810_CH0 (or IW 678) to the PV_In input.
  4. Configure raw analog scale limits: standard ABB S800 raw count range is $0$ to $27648$ (or $0$ to $32767$ depending on ABB datasheet).
    - Set Scale.High = 100.0 (Process engineering units).
    - Set Scale.Low = 0.0.
  5. Connect driver output PV_Out to downstream process blocks (PIDConL).
  6. Compile CFC and download to the AS.

Verification

To confirm third-party signal processing:

  1. HW Config Online Status:
    - Switch HW Config to online mode; confirm the ABB PROFIBUS slave shows normal operational status (no red slash).

  2. Analog Scaling Verification:
    - Connect a current loop calibrator to Channel 0 on the physical ABB AI810 module, injecting $12.0\text{ mA}$ ($50\%$).
    - In CFC online test mode, inspect Pcs7AnIn.
    - Confirm that raw input reads $\approx 13824$ raw counts and PV_Out.Value displays exactly $50.0\%$ with Good quality ($16#80$).

Limitations and Operational Precautions

Operational limitations and precautions:

  1. No Automated Diagnostic Driver Support: The PCS 7 'Generate Module Drivers' tool will not auto-generate MOD_... diagnostic blocks for ABB modules. Channel health and wire-break alarms must be evaluated using the raw status bytes provided by the ABB GSD.
  2. Raw Numerical Representation: ABB analog modules may use different raw integer scaling ranges than Siemens ($0\text{--}27648$ vs $0\text{--}32000$ or two's complement); verify the exact bit representation in the ABB S800 hardware manual.
  3. PROFIBUS Bus Parameters: Ensure bus speed and target rotation time ($T_{tr}$) in NetPro accommodate third-party slave timing requirements.
  4. Commercial Disclaimer: Verify all hardware components, controller licensing, and communication software with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why does HW Config only offer BOOL data types for ABB analog modules?

The generic GSD file defines the module space in raw bytes. The Symbol Editor defaults to BOOL rows, but engineers can manually type WORD into the Data Type column.

Can Siemens PCS 7 generate module drivers for third-party ABB I/O?

No. The PCS 7 Generate Module Drivers wizard only supports Siemens released I/O families. Third-party GSD signals are mapped to channel drivers without automated diagnostic blocks.

Which channel driver block should be used for ABB analog inputs?

Either Pcs7AnIn (FB1869) with raw input addressing or FbAnIn (FB1813) designed for generic PROFIBUS field devices.

How many bytes does an ABB AI810 analog input module consume?

The AI810 has 8 analog channels, consuming 16 total bytes (2 bytes per 16-bit analog word).

What raw integer range does ABB S800 I/O use?

Most ABB S800 analog inputs utilize standard 0 to 27648 raw counts (similar to S7 standards) or 0 to 32000; verify against the specific ABB module datasheet.

Technical References

Related Articles

Related Tags

  • ABB S800 I/O
  • PROFIBUS GSD
  • Pcs7AnIn
  • Third-Party Integration
  • HW Config Symbols
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