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Resolving DES_DIAG (FB628) Driver Wizard Compilation Errors During PCS 7 Project Upgrades

Resolving DES_DIAG (FB628) Driver Wizard Compilation Errors During PCS 7 Project Upgrades

In SIMATIC PCS 7, compilation aborts with 'DES_DIAG [FB628] [Driver wizard]' errors when upgrading projects (e.g. from V6.1 to V7.0 or V8.x) because Drive ES PCS 7 driver blocks in the offline block container mismatch the newer PCS 7 Driver Wizard templates. Resolve this by installing the matching Drive ES PCS 7 library version on the engineering station, updating block types via 'Options > Block Types', and compiling with 'Generate module drivers'.

Table of Contents

Diagnostic Overview and Project Migration Context

When upgrading a legacy SIMATIC PCS 7 project (such as migrating from PCS 7 V6.1 to PCS 7 V7.0, V8.0, or V8.1) containing variable frequency drives integrated via Drive ES (e.g., MICROMASTER 440, SIMOVERT MASTERDRIVES, or SINAMICS), automation engineers frequently encounter a fatal compiler stoppage:
* The STEP 7 hardware configuration compiles cleanly in HW Config.
* When compiling the CFC charts with Generate module drivers enabled, the compilation aborts with a red error:
Error: [DES_DIAG] FB628 [Driver wizard] under DRVPCS7[V6.1] LIBRARY (or block interface mismatch).
* The Driver Wizard fails to generate system diagnostic charts, and the entire compilation terminates.

This error occurs because the project still contains legacy block definitions from an older version of the Drive ES PCS 7 library (DRVPCS7), while the newer PCS 7 Driver Wizard requires updated parameter interfaces and diagnostic data structures to interconnect the drive with the controller operating system.

The Role of FB628 DES_DIAG in Automated Driver Generation

Understanding why FB628 causes compilation failure requires examining how PCS 7 automates drive diagnostics:

  1. The Diagnostic Backbone of Drive ES (FB628 DES_DIAG):
    * In Drive ES PCS 7, FB628 (symbolic name DES_DIAG) is the master diagnostic block.
    * During CFC compilation, the Driver Wizard analyzes the drive slave properties in HW Config and instantiates FB628 inside system chart @(1) or @(2).
    * FB628 handles cyclic diagnostic evaluation, acyclic DPV1 parameter reading via SFB52/SFB53 (RDREC/WRREC), and monitors communication health between the CPU and the drive inverter.

  2. Interface Discrepancy Across PCS 7 Generations:
    * As PCS 7 evolved from V6.1 to V7.0 and V8.x, the internal structure of diagnostic words (such as MODE, QualityCode / ST, and LADDR structures) was updated.
    * If a project is migrated by copying blocks or opening an older archive without updating the block types from the newly installed Drive ES library, the Driver Wizard encounters an old block header for FB628 that lacks required internal pins.
    * Because the compiler cannot wire the expected diagnostic signals, it issues a fatal interface error and halts compilation.

  3. Software Package Dependency:
    * Upgrading the PCS 7 base software does not automatically update optional packages like Drive ES.
    * If the engineering workstation has PCS 7 V7.0 installed but lacks the matching Drive ES PCS 7 V7.0 installation package, the Driver Wizard cannot locate the required block templates.

Step-by-Step Resolution and Library Migration Workflow

1. Verify and Install Matching Drive ES PCS 7 Software

  1. Verify the installed version of PCS 7:
    * For PCS 7 V7.0: Install Drive ES PCS 7 V7.0 (or latest Service Pack).
    * For PCS 7 V8.x: Install Drive ES PCS 7 V8.0/V8.1 (Classic or APL style).
  2. Install Drive ES PCS 7 from the official licensed media. Ensure the license is present in Automation License Manager.

2. Update Drive ES Block Types in the Multiproject

  1. Open SIMATIC Manager and open your migrated project.
  2. Open any CFC chart in the project.
  3. Select menu Options > Block Types....
  4. In the dialog, set the source to the newly installed Drive ES library:
    * Select File > Open > Libraries > DRVPCS7.
  5. In the block list, select:
    * FB628 DES_DIAG
    * FB620 SIMO_MM4 (or your specific drive blocks)
  6. Click the arrow button --> to transfer the blocks to your chart folder.
  7. CFC will prompt: 'Block type FB628 already exists. Do you want to update all instances?'
  8. Click Yes. CFC updates all instances and reconciles internal interface parameters across the entire multiproject.

3. Verify Hardware Configuration and Telegram Consistency

  1. Open STEP 7 HW Config.
  2. Select the drive slave on the PROFIBUS DP line.
  3. Verify that the configured PPO telegram type matches the block requirements (e.g. PPO Type 1 or PPO Type 3).
  4. Execute Station > Save and Compile.

4. Execute CFC Compilation with Module Driver Generation

  1. In the CFC editor, select Chart > Compile > Charts as Program.
  2. Check the box Generate module drivers.
  3. Select Scope: Entire program.
  4. Click OK.
  5. Verify that compilation completes with 0 Errors and @ system charts are generated cleanly.

Drive ES PCS 7 Version and Compatibility Matrix

PCS 7 VersionRequired Drive ES ReleaseTypical Master Diagnostic BlockDriver Wizard CompatibilityOperating System BaselinePCS 7 V6.1Drive ES PCS 7 V6.1FB628 DES_DIAGCompatible with V6.1 Driver WizardWindows XP SP2/SP3PCS 7 V7.0Drive ES PCS 7 V7.0FB628 DES_DIAG (V7.0 interface)Compatible with V7.0 Driver WizardWindows XP SP3 / Server 2003PCS 7 V7.1Drive ES PCS 7 V7.1FB628 DES_DIAGCompatible with V7.1 Driver WizardWindows XP / Server 2003PCS 7 V8.0 / V8.1Drive ES PCS 7 V8.0 (Classic)FB628 DES_DIAG (V8.x update)Compatible with V8.x Driver WizardWindows 7 SP1 (64-bit)PCS 7 V8.x / V9.x (APL)Drive ES PCS 7 APLFB... MOD_DRV / APL driversFull APL Driver Wizard integrationWindows 7 / Windows 10

Verification

  1. In SIMATIC Manager, check the offline Block folder; verify FB628 reflects the updated date and version stamp matching the installed Drive ES library.
  2. Open CFC and execute Chart > Compile > Entire Program with Generate module drivers enabled.
  3. Confirm compilation concludes with 0 Errors.
  4. Open system chart @(1) in the CFC editor; confirm that FB628 DES_DIAG has been automatically placed and interconnected with the drive's diagnostic address.
  5. Download to S7-PLCSIM or physical controller; confirm the drive operates without communication faults.

Limitations and Operational Precautions

  • Never Delete FB628 from the Symbol Table: Deleting FB628 or its symbol DES_DIAG from the Symbol Table severely destabilizes the Driver Wizard, resulting in dozens of unresolvable compilation aborts.
  • Classic vs APL Library Mixing: When upgrading to PCS 7 V8.x, decide whether to retain Classic Drive ES blocks (using the Classic upgrade package) or migrate to Drive ES APL blocks. Mixing both styles on the same drive object causes driver generation collisions.
  • Licensing Compliance: Drive ES PCS 7 software is commercially licensed. Ensure that appropriate upgrade licenses (e.g. 6SW1700-8JD00-0AA4) are acquired when migrating across major versions.

Engineer FAQ

Why can't I just copy FB628 from my old PCS 7 V6.1 project?

Copying the block retains the obsolete V6.1 internal interface structure. The PCS 7 V7.0 Driver Wizard requires updated header attributes and diagnostic parameters that only exist in the V7.0 library version.

Where does the Drive ES PCS 7 library get installed on my PC?

Drive ES libraries are installed under <Step7-Install-Path>\S7LIBS\DRVPCS7\ or <Step7-Install-Path>\S7LIBS\DriveES_PCS7\.

Can I compile without 'Generate module drivers' to bypass the error?

Unchecking 'Generate module drivers' will allow compilation to complete, but the drive will not receive hardware status words or diagnostic alarms, causing channel blocks to remain in a fault state (Bad = 1).

Technical References

Related Articles

Related Tags

  • DES_DIAG
  • FB628
  • Drive ES
  • Driver Wizard
  • PCS 7 Upgrade
  • CFC Compilation
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