Resolving ET 200SP Hardware Import Errors in SIMATIC Plant Automation Accelerator (PAA)

In SIMATIC Plant Automation Accelerator (PAA 3.0.1 with COMOS DB 10.2.2), importing PCS 7 HW Config XML files containing ET 200SP stations causes multiple GSD-related import errors because native ET 200SP object models were not integrated into the legacy COMOS database. Manually importing raw ET 200SP GSD files into the COMOS '@LOCAL' structure will not resolve the issue. To fix this, upgrade to PAA V3.1 or PAA V3.1 SP1 (with COMOS DB 10.3+), which introduces full native data models and hardware typicals for ET 200SP and ET 200SP HA.

Executive Summary

SIMATIC Plant Automation Accelerator (PAA) serves as the integrated engineering bridge between plant design in COMOS and automation engineering in SIMATIC PCS 7. PAA enables bidirectional data exchange, allowing hardware configurations, signal lists, and control module types to transfer seamlessly via XML export and import.

A frequent roadblock encountered in PAA V3.0 and V3.0.1 occurs when attempting to import a PCS 7 HW Config XML file containing modern SIMATIC ET 200SP distributed I/O stations (such as IM 155-6 PN interface modules and associated digital/analog base units). The import terminates with extensive error logs indicating missing GSD components. Automation engineers commonly attempt to resolve this by downloading standard GSDML files from Siemens Online Support and importing them into the COMOS @LOCAL hierarchy, but the import errors persist unabated. This article explains the underlying architectural mismatch between raw GSD files and COMOS base data objects, providing the official migration path to PAA V3.1 to achieve flawless hardware synchronization.

Architecture and Fundamental Mechanics

The data exchange architecture of SIMATIC Plant Automation Accelerator differs fundamentally from standard Step 7 hardware catalog ingestion:

Native COMOS Hardware Object Model vs GSDs: In Step 7 / PCS 7 HW Config, third-party field devices can be integrated purely via textual GSDML descriptor files. In COMOS / PAA, however, hardware components are full-featured object-oriented engineering entities. A COMOS hardware object contains graphical symbols for cabinet layouts, terminal wiring diagrams, electrical power calculations, and channel-to-signal mapping logic. Generic GSD files contain only communication telegram structures and lack the graphical and electrical metadata required by COMOS.
The PAA 3.0.1 Limitation: PAA V3.0.1 (built on COMOS Database 10.2.2) included native object definitions for legacy ET 200M, ET 200S, and early PROFINET devices, but lacked the comprehensive object modeling and symbol libraries for the modular ET 200SP line (such as Push-In BaseUnits, dark/light terminal boxes, and server modules).
The Ineffectiveness of @LOCAL GSD Imports: While importing a GSD into @LOCAL creates a basic bus-device stub in COMOS, the PAA XML import engine specifically searches the COMOS Base Data catalog for native PAA hardware typicals. When importing an ET 200SP rack exported from PCS 7, the XML parser fails to map slot sub-modules to electrical base data objects, generating false 'Missing GSD' and 'Object type mismatch' exceptions.
Native Resolution in PAA V3.1 / V3.1 SP1: With the release of PAA V3.1 and V3.1 SP1 (paired with COMOS DB 10.3.3 / 10.4), Siemens integrated complete, certified hardware typicals for the entire ET 200SP and ET 200SP HA product families into the base data repository, enabling 100% automated XML import and bidirectional synchronization.

Step-by-Step Implementation Procedure

Follow these steps to upgrade PAA and successfully import ET 200SP hardware configurations from PCS 7:

Audit Current Software and Database Versions:
- In COMOS / PAA, select 'Help > About' from the main menu.
- Check the installed PAA software version (e.g., PAA 3.0.1) and COMOS Database version (e.g., DB 10.2.2.0.0).
- Confirm that the existing database lacks native ET 200SP base data.
Clean Up Invalid GSD Files from @LOCAL:
- In the COMOS project tree, switch to the 'Base Objects' tab (or @LOCAL hierarchy).
- Locate and delete any raw ET 200SP GSD/GSDML files previously imported into the local project structure. This prevents database reference conflicts after upgrading.
Upgrade to SIMATIC Plant Automation Accelerator V3.1 or V3.1 SP1:
- Procure the PAA V3.1 / V3.1 SP1 installation media and matching database update packages (e.g., COMOS DB 10.3.3 or higher).
- Back up the existing COMOS/PAA project database (*.mdb or SQL Server database).
- Execute the PAA V3.1 setup wizard to upgrade the client binaries.
- Open the COMOS DB Update tool and run the database migration scripts to incorporate newly released hardware libraries, including ET 200SP and ET 200SP HA typicals.
Export Hardware Configuration XML from PCS 7:
- On the PCS 7 Engineering Station, open SIMATIC Manager.
- In the Component View, select the target AS station containing the ET 200SP racks.
- Select 'Options > Plant Automation Accelerator > Export to PAA...'.
- Select 'Hardware Configuration' and export the XML file to a shared network directory.
Import XML into PAA V3.1 Project:
- Open your project in PAA V3.1.
- Navigate to the Automation tree.
- Select 'Import / Export > PCS 7 > Import from PCS 7...'.
- Point to the generated XML file.
- Click 'Start Import'. The PAA V3.1 import engine recognizes the ET 200SP interface modules (IM 155-6 PN), BaseUnits, and I/O modules, automatically mapping them to native COMOS objects without GSD errors.

Verification

In the PAA Automation and Units view, verify that the ET 200SP station appears in the project tree with all configured slots, BaseUnits, and signal channels intact.
Open the hardware properties of an imported ET 200SP analog input module: confirm that order numbers (MLFBs), terminal assignments, and channel addresses match HW Config in PCS 7.
Open the generated cabinet wiring diagram in PAA: confirm that the graphical terminal symbols and module footprints reflect accurate ET 200SP hardware dimensions.
Perform a test export from PAA back to PCS 7: verify that HW Config imports the updated XML without schema or module mismatch warnings.

Limitations and Operational Precautions

Do not attempt to mix database schema versions; migrating to PAA V3.1 requires upgrading both the application binaries and the COMOS database simultaneously. Customized user attributes attached to hardware objects in PAA 3.0 must be verified against the new V3.1 schema. Ensure that all PCS 7 and PAA software update agreements and engineering licenses are verified through an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why did importing GSD files into COMOS @LOCAL fail to fix the errors?

COMOS and PAA require full object-oriented hardware typicals with graphical, electrical, and channel models. Raw GSDML files provide only basic communication descriptions and lack COMOS engineering metadata.

Which version of PAA natively supports ET 200SP?

SIMATIC Plant Automation Accelerator V3.1 and V3.1 SP1 natively support the complete line of ET 200SP and ET 200SP HA modules.

Can PAA import ET 200SP HA modules used in PCS 7 V9.0 SP3 / V9.1?

Yes. PAA V3.1 SP1 specifically integrates comprehensive support for ET 200SP HA redundant interface modules, terminal blocks, and ex-I/O modules.

What format does PAA use to exchange data with PCS 7?

PAA and PCS 7 exchange engineering information using structured XML schema definitions through the PAA-PCS 7 interface tool.

Does upgrading PAA require upgrading PCS 7?

Not necessarily. PAA V3.1 supports data exchange with PCS 7 V8.2, V9.0, and V9.1. Consult the PAA compatibility matrix for specific service pack combinations.