Reconfiguring Process Data Words (PCD5 and PCD6) on SINA_GS in Drive ES PCS 7 APL

Reconfiguring Process Data Words 5 and 6 (PCD_5 and PCD_6) on the SINA_GS block from the Drive ES PCS 7 APL library enables reading auxiliary status words, drive digital inputs, or analog variables from SINAMICS drives. By default, SINA_GS uses standard telegram configurations (such as Telegram 352 with 6 PZD input/output words). In the drive configuration tool (STARTER or Startdrive), route the drive's digital input word (parameter r722) or auxiliary telemetry to PZD word 5 or 6 in the transmit telegram. On the SINA_GS block in CFC, the raw data appears at output parameters PCD_5 or PCD_6. To evaluate individual digital input bits, connect the output word to a bit-demultiplexing block (such as W_BO or WordToBits from the APL library).

Executive Summary

The Drive ES PCS 7 APL block library provides seamless, deep integration between Siemens SINAMICS drives (such as G120, S120, and G150) and SIMATIC PCS 7. The core drive interface block SINA_GS communicates via cyclic PROFIBUS DP or PROFINET IO telegrams. In applications where drive digital inputs (e.g., local disconnect switches, belt break sensors, or local pushbuttons) must be monitored by the PCS 7 controller without installing separate distributed I/O racks, engineers can leverage spare process data channels (PCD 5 and 6). Configuring parameter interconnection in STARTER and decoding the received data words in CFC maximizes hardware efficiency while preserving complete diagnostic transparency.

Architecture and Fundamental Mechanics

Cyclic communication between a PCS 7 AS and a SINAMICS drive is structured into Process Data (PZD) words within predefined PROFIdrive telegrams:

Telegram Structure (e.g., Standard Telegram 352):
* PZD 1: Control Word 1 (STW1) / Status Word 1 (ZSW1)
* PZD 2: Main Setpoint (NSOLL_A) / Main Actual Value (NIST_A - Speed)
* PZD 3: Control Word 2 (STW2) / Actual Current (IACT)
* PZD 4: Reserved / Actual Torque (MACT)
* PZD 5 (PCD_5): Freely assignable Process Data Word
* PZD 6 (PCD_6): Freely assignable Process Data Word
Drive-Side Signal Routing via BICO Technology:
* SINAMICS drives use Binet-Cinet (BICO) technology to interconnect internal drive parameters.
* The digital input terminals of the Control Unit (CU) are consolidated into parameter r722 (CO/BO: Digital Inputs Status). Bit 0 corresponds to DI 0, Bit 1 to DI 1, etc.
* By setting the drive's communication parameter p2051[4] (PZD 5 transmit word) to r722, the drive packs the 16 digital input states into PZD 5 during every cyclic communication frame.
SINA_GS Block Architecture in CFC:
* SINA_GS reads the incoming PZD stream from the configured I/O address.
* While standard control and speed variables are mapped to dedicated block pins (ActSpeed, ActCurrent, Status1), words 5 and 6 are output directly as 16-bit WORD values on pins PCD_5 and PCD_6.
* In the CFC environment, an auxiliary conversion block (W_BO - Word to 16 Boolean outputs) expands PCD_5 into individual boolean channels (Bit0 through Bit15) for use in plant interlocks.

Step-by-Step Implementation Procedure

Follow these configuration steps to map and read drive digital inputs via PCD_5 on SINA_GS:

Configure Hardware Telegram in HW Config:
* Open HW Config in SIMATIC Manager.
* Select the SINAMICS drive on the PROFIBUS DP or PROFINET network.
* Verify that the configured telegram is Standard Telegram 352 (6/6 words) or a Free Telegram with PZD-6/6.
* Note the start I/O address assigned to the drive (e.g., address 512).
* Save and compile HW Config.
Configure PZD Transmission in STARTER / Startdrive:
* Open the drive in STARTER or Startdrive.
* Navigate to Communication > PROFIBUS / PROFINET > Transmit direction (Drive -> Controller).
* Locate Process Data Word 5 (p2051[4]).
* Change the interconnection of p2051[4] to parameter r722 (CO/BO: Digital Inputs Status).
* If analog telemetry (such as motor temperature r0035) is desired on PZD 6, interconnect p2051[5] to r0035.
* Copy RAM to ROM on the drive to persist the parameters.
Instantiate and Parameterize SINA_GS in CFC:
* Open the target CFC chart.
* Insert the SINA_GS block from the Drive ES PCS 7 APL library.
* Configure the LAddr parameter with the base input/output address from HW Config.
Demultiplex PCD_5 into Discrete Digital Bits:
* From the PCS 7 Basis Library or APL Mathematical blocks, insert a W_BO (FB 1888 or standard conversion block) next to SINA_GS.
* Connect parameter SINA_GS.PCD_5 to W_BO.In.
* Interconnect the individual output bits (W_BO.Bit0, W_BO.Bit1, etc.) to the plant interlock blocks or indicator logic.
Compile and Download:
* Compile the CFC chart with 'Generate module drivers' enabled.
* Download changes to the AS controller.

Verification

Toggle a physical digital input on the SINAMICS drive terminal strip (e.g., DI 0). In STARTER, verify that parameter r722.0 transitions to 1. In the CFC chart in online test mode, observe that SINA_GS.PCD_5 reflects the updated hexadecimal word (e.g., 16#0001), and W_BO.Bit0 switches to TRUE. Confirm that the interlock or display responds instantaneously without transmission delay.

Limitations and Operational Precautions

Ensure that the Drive ES PCS 7 APL library version is compatible with your installed PCS 7 version (e.g., Drive ES PCS 7 APL V9.0 SP3 for PCS 7 V9.0 SP3). Modifying telegram lengths in HW Config requires a complete hardware download, which requires the AS CPU to be stopped unless Type Update in RUN (TCiR) with CPU 410-5H is supported.

Engineer FAQ

What is the difference between standard Telegram 1 and Telegram 352?

Telegram 1 contains only 2 PZD words (Control Word and Speed Setpoint/Actual). Telegram 352 provides 6 PZD words, including Current, Torque, and two freely configurable process data words (PCD 5 and 6).

Can PCD_5 be used for sending control commands to the drive?

Yes. If configured in the receive direction (p2050[4]), the AS can send custom control words or setpoints to the drive via SINA_GS.PCD_5_O.

What parameter in SINAMICS holds the onboard digital inputs?

Parameter r722 holds the bit states of all onboard and optional terminal digital inputs on the Control Unit.

Do I need a separate Drive ES license to use SINA_GS?

Drive ES PCS 7 is an optional engineering package that requires an engineering license on the ES; runtime blocks consume standard AS Process Objects (POs).