C135 PCS 7 (PCS7)
6C
6 Cielo Ciencia y Tecnología
·Publicada en C135 PCS 7 (PCS7)

Resolving Bad Quality (Bad=1) on ET 200SP PROFINET I/O Modules with CPU 410-5H in PCS 7 V8.1

Resolving Bad Quality (Bad=1) on ET 200SP PROFINET I/O Modules with CPU 410-5H in PCS 7 V8.1

In SIMATIC PCS 7 V8.1 SP1 with CPU 410-5H, ET 200SP channels outputting Bad = 1 and ST = 16#00 occur when standard/basic ET 200SP interface modules are used instead of released High Feature (HF) variants, when the ET 200SP PCS 7 Library is uninstalled, or when module driver generation fails to link the MODE parameter. Resolve this by installing the ET 200SP PCS 7 Library, compiling with 'Generate module drivers', and verifying the MODE parameter.

Table of Contents

Diagnostic Overview and Symptom Analysis

In process automation systems utilizing the SIMATIC PCS 7 CPU 410-5H Process Automation controller operating on firmware V8.1 and SIMATIC PCS 7 V8.1 SP1, engineers frequently integrate distributed I/O stations over PROFINET IO using the SIMATIC ET 200SP product line.

A recurring fault frustrates commissioning engineers:
* In STEP 7 HW Config, the ET 200SP interface module (e.g. IM 155-6 PN) and subordinate I/O cards are inserted, configured, and downloaded without hardware faults.
* In CFC charts, input channels are connected to standard Advanced Process Library (APL) channel driver blocks: Pcs7AnIn or Pcs7DiIn.
* The engineer compiles charts with Generate module drivers enabled.
* In runtime, every channel driver persistently reports Bad = 1 with Signal Status ST = 16#00 (Bad).
* Process values remain greyed out or frozen at substitute values, even though field transmitters are properly powered and sending valid 4-20 mA current loops.

Because HW Config shows no bus faults, engineers suspect wiring issues. In reality, the failure is software-driven: the PCS 7 Driver Wizard failed to generate valid diagnostic connections for the ET 200SP sub-modules.

ET 200SP Release Boundaries in PCS 7 V8.1 SP1

Understanding this issue requires reviewing the integration timeline between PCS 7 and the ET 200SP hardware family:

  1. ET 200SP Interface Module Variants (Standard vs. High Feature):
    * IM 155-6 PN Standard / Basic (6ES7155-6AU00-0BN0 / 6ES7155-6AR00-0AN0): Engineered primarily for standard factory automation (TIA Portal / STEP 7 Classic). They lack the system redundancy, time-stamping, and comprehensive NAMUR NE 107 diagnostics required by PCS 7.
    * IM 155-6 PN High Feature (HF) (6ES7155-6AU00-0CN0 or 6ES7155-6AU01-0CN0): The only variant released for process automation in PCS 7 V8.1/V8.2.

  2. The ET 200SP PCS 7 Driver Library Prerequisite:
    * Standard PCS 7 V8.1 SP1 shipped before ET 200SP module drivers were integrated into the core system driver catalog.
    * To support ET 200SP, Siemens released an add-on software package: SIMATIC PCS 7 Basis Library - ET 200SP Component (or specific Hardware Support Package HSP).
    * Without this library installed on the Engineering Station, the Driver Wizard does not know which diagnostic block (MOD_HA, MOD_D8_4) services ET 200SP cards.

  3. Unlinked MODE Parameter Behavior:
    * When the Driver Wizard cannot identify the hardware, it leaves the channel driver's input MODE unlinked (16#00000000).
    * If MODE is 0, Pcs7AnIn evaluates the card as uninitialized or unsupported, immediately driving Bad = 1 and ST = 16#00 to prevent unvalidated field values from entering plant control logic.

Step-by-Step Resolution and Library Integration Workflow

1. Verify Physical Hardware Order Numbers (MLFBs)

  1. Inspect the physical ET 200SP head module installed in the field cabinet.
  2. Confirm the module is the High Feature (HF) model:
    * 6ES7155-6AU00-0CN0 (or modern successor 6ES7155-6AU01-0CN0).
    * If a Basic or Standard module is installed, replace it with the High Feature variant.

2. Install the ET 200SP PCS 7 Library Add-On

  1. Download the SIMATIC PCS 7 Basis Library Add-On for ET 200SP from Siemens Industry Online Support (SIOS Entry ID 109780813 / 109485969).
  2. Close all SIMATIC Manager editors and run setup on the Engineering Station.
  3. In HW Config, select Options > Install GSD Files... if using specific device revision updates, followed by Options > Update Catalog.

3. Configure from the PCS 7 Catalog Profile

  1. In HW Config, open the hardware catalog.
  2. In the profile drop-down, select PCS 7 V8.1.
  3. Navigate to: PROFINET IO > I/O > ET 200SP > IM 155-6 PN HF.
  4. Verify modules are placed from this profile (never from generic GSD folders).
  5. Execute Station > Save and Compile.

4. Execute CFC Compilation and Validate MODE Wiring

  1. Open the CFC chart containing the channel drivers.
  2. Select Chart > Compile > Charts as Program.
  3. Ensure Generate module drivers is CHECKED.
  4. Select Scope: Entire program.
  5. Once compiled, inspect Pcs7AnIn:
    * Confirm the input MODE is now interconnected to a system diagnostic block in @(1).
    * For a standard 4-20 mA analog input, MODE should evaluate to 16#80000203 (or equivalent).
  6. Download the program to CPU 410-5H; confirm Bad = 0 and ST = 16#80 (Good).

ET 200SP Interface Module Compatibility Matrix

Interface Module ModelOrder Number (MLFB)PCS 7 V8.1 SP1 StatusSystem Redundancy (S2)Module Driver SupportET 200SP PN Basic6ES7155-6AR00-0AN0UnsupportedNoFails (MODE unlinked, Bad=1)ET 200SP PN Standard6ES7155-6AU00-0BN0Unsupported in PCS 7NoFails (MODE unlinked, Bad=1)ET 200SP PN High Feature6ES7155-6AU00-0CN0Fully Released (with Library)SupportedFull automated driver generationET 200SP HA (Modern)6DL1155-6AU00-0PM0Released in modern PCS 7Full R1/S2 RedundancyNative Process Automation standard

Verification

  1. In CFC, inspect Pcs7AnIn block monitoring a live field transmitter.
  2. Confirm parameter Bad evaluates to 0 (FALSE).
  3. Confirm parameter PV_Out.ST evaluates to 16#80 (Good).
  4. Disconnect the field transmitter wire; verify Bad transitions to 1 and ST becomes 16#00.
  5. In WinCC Runtime, confirm the faceplate displays live process engineering units with zero yellow warning banners.

Limitations and Operational Precautions

  • Third-Party GSD Limitations: If ET 200SP is integrated using generic GSD files instead of native STEP 7 catalog modules, the Driver Wizard cannot construct module diagnostic links. Always install native Siemens catalog updates.
  • Manual MODE Override Hazard: While an engineer can temporarily force MODE = 16#80000203 in CFC to bypass Bad = 1, running subsequent compilations with 'Generate module drivers' may overwrite or unbind manual parameters. The correct solution is installing the official library.
  • PROFINET Device Name Parity: Ensure the PROFINET device name assigned in HW Config matches the physical name stored in the ET 200SP memory card.

Engineer FAQ

Why did HW Config show green healthy LEDs if the channel driver was bad?

HW Config verifies basic Ethernet link connectivity and cyclic frame exchange. The channel driver verifies semantic diagnostic parameters (MODE, module status words). If the driver cannot parse module diagnostics, it marks the signal Bad for safety.

What does MODE 16#80000203 mean?

In PCS 7 channel drivers, 16#80000203 designates an active 2-wire transmitter measuring 4-20 mA with standard HART/NAMUR measuring range limits.

Can I use ET 200SP with standard S7-400H controllers as well as CPU 410-5H?

Yes, ET 200SP High Feature modules can be connected via PROFINET to any S7-400 controller supporting PROFINET IO controller functionality.

Technical References

Related Articles

Related Tags

  • ET 200SP
  • CPU 410-5H
  • Pcs7AnIn
  • QBAD
  • Bad=1
  • PCS 7 V8.1
6 respuestas