Resolving Module Driver Generation Failures with ET 200SP Interface Modules and Generic GSD Configurations

In SIMATIC PCS 7, compilation errors where CFC fails to generate module drivers and channel blocks (Pcs7DiIn, Pcs7AnIn) cannot interconnect occur when ET 200SP distributed I/O stations are configured using generic GSD/GSDML files from the 'Standard' hardware catalog profile. The PCS 7 driver generator requires modules to be selected exclusively from the 'PCS 7' hardware catalog profile (e.g., PCS7_V90) containing native Siemens diagnostic manifests. Generic GSD entries lack the internal EDD metadata required to instantiate MOD_D1, RACK, and diagnostic blocks. To resolve this: install the certified PCS 7 Library for ET 200SP or ET 200SP HA, update Hardware Support Packages (HSP), select released interface modules (e.g., IM 155-6PN/2 HF) from the PCS 7 catalog profile, and recompile CFC charts with 'Generate module drivers' enabled.

Executive Summary

During the engineering of distributed I/O in SIMATIC PCS 7 V9.0, engineers frequently incorporate compact ET 200SP remote stations featuring high-feature interface modules such as the IM 155-6PN/2 HF (6ES7155-6AU01-0CN0). When HW Config displays only older firmware revisions (e.g., V3.3 instead of V4.2) under the PCS7_90 profile, engineers often install vendor GSD/GSDML files and configure the station under the 'Standard' catalog profile. However, subsequent CFC compilation fails: APL channel drivers fail to connect to physical I/O addresses, and module driver generation aborts. This article clarifies the strict catalog profile rules enforced by PCS 7 and provides the procedure to achieve seamless driver generation.

Architecture and Fundamental Mechanics

The SIMATIC PCS 7 driver generator is an automated compiler subsystem that bridges hardware configuration with software application logic. During CFC compilation with 'Generate module drivers' selected, the compiler performs the following tasks:
1. Scans HW Config addresses (L-addresses / P-addresses) linked to channel driver blocks (Pcs7DiIn, Pcs7AnIn, Pcs7DiOu, Pcs7AnOu).
2. Queries the internal PCS 7 Device Database (EDD / system manifests) associated with the specific hardware order number (MLFB).
3. Automatically instantiates hardware diagnostic blocks (such as MOD_D1, MOD_HA, RACK, and OB_DIAG1) in dedicated diagnostic CFC charts.
4. Connects module diagnostic outputs (DXCHG, OOS, Mode) to the channel drivers to deliver field diagnostics (wire-break, short-circuit, module pulled).

When a station is inserted via a generic GSD/GSDML file under the 'Standard' profile, STEP 7 treats it as a non-technological third-party device. The hardware database lacks the proprietary PCS 7 diagnostic driver rules. Consequently, the driver generator skips the station entirely. The channel drivers remain unconnected, field values evaluate to invalid quality code (16#00), and compilation halts with diagnostic binding errors.

Step-by-Step Implementation Procedure

Verify Module Release Status for PCS 7:
a. Consult the Siemens Industry Online Support (SIOS) document 109767525 ('Released modules for SIMATIC PCS 7').
b. Confirm that the exact ET 200SP interface module (e.g., 6ES7155-6AU01-0CN0) and I/O slice modules (DI, DQ, AI, AQ) are listed as released for the installed PCS 7 version.
Install the Certified PCS 7 ET 200SP Block Library and HSPs:
a. Download and install the dedicated 'SIMATIC PCS 7 Library for ET 200SP' or 'SIMATIC PCS 7 Basis Library' update from SIOS.
b. In STEP 7 HW Config, close all projects and select Options -> Install Hardware Updates....
c. Search online or browse to downloaded Hardware Support Packages (HSPs) for the IM 155-6PN/2 HF V4.2, select them, and click 'Install'.
Switch HW Config to the PCS 7 Profile:
a. In HW Config, locate the dropdown menu for 'Profile' in the right-hand hardware catalog pane.
b. Change the profile from 'Standard' to 'PCS7_V90' (or the active PCS 7 version profile).
c. Navigate to: PROFINET IO -> I/O -> ET 200SP -> IM 155-6PN High Feature.
d. Confirm that the native, released IM module appears in the catalog.
Reconfigure Remote I/O Station and Reassign Addresses:
a. Delete the generic GSD-based ET 200SP station from the PROFINET line.
b. Drag and drop the native ET 200SP station from the PCS 7 catalog onto the PROFINET IO system.
c. Insert the released I/O modules into the virtual rack and configure hardware addresses.
d. Save and compile HW Config.
Recompile CFC Charts with Driver Generation:
a. Open SIMATIC Manager and launch the CFC Editor.
b. Select Chart -> Compile -> Chart as Program....
c. Ensure 'Generate module drivers' is CHECKED and execute a full compile.

Verification

Open the CFC compile log: confirm that the driver generator processed the ET 200SP rack with 0 errors and 0 warnings.
Open the chart containing Pcs7DiIn or Pcs7AnIn: verify that input parameters Mode, DataXchg, and MS are automatically interconnected to generated MOD_D1 or MOD_HA blocks.
In S7-PLCSIM or test bench, trigger a channel wire-break: confirm the channel driver reflects bad quality (16#00 or 16#28) and generates an alarm on the WinCC faceplate.
Check the CPU Diagnostic Buffer: confirm OB82 (Diagnostic Interrupt) and OB86 (Rack Failure) execute cleanly without unhandled exceptions.

Limitations and Operational Precautions

Standard ET 200SP modules that are not officially released in the PCS 7 hardware catalog cannot utilize automated module driver generation; integrating unreleased third-party or standard automation modules requires either custom driver programming or manual signal routing without hardware diagnostic blocks. Procurement of approved ET 200SP and ET 200SP HA components should be confirmed with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why did installing a GSD file fail to solve the module driver problem?

GSD files provide standard PROFINET communication definitions for generic PLCs but lack the proprietary diagnostic metadata required by the PCS 7 module driver generator.

Can I use ET 200SP HA modules in standard ET 200SP stations?

No. ET 200SP HA (High Availability) modules use different terminal blocks, backplanes, and interface modules designed specifically for process automation and cannot be mixed with standard ET 200SP.

What happens if I compile CFC with 'Generate module drivers' disabled?

CFC charts will compile without errors, but channel driver blocks will not connect to diagnostic blocks, leaving field failures, wire breaks, and module removals completely undetected.

Where can I find the list of released modules for PCS 7?

Siemens publishes and regularly updates SIOS entry 109767525, which details every approved I/O module, interface module, and firmware version.

Does updating the HW Config catalog require an engineering license?

Installing Hardware Support Packages (HSPs) is free of charge and requires no additional licensing, provided the base PCS 7 engineering license is active.