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Resolving SIRIUS 3RW44 Driver Generation Errors (Error 400ad / IN_01-1) Caused by CP 342-5 in PCS 7

Resolving SIRIUS 3RW44 Driver Generation Errors (Error 400ad / IN_01-1) Caused by CP 342-5 in PCS 7

The fatal compiler error 'Der Adresswert IN_01-1 für das Hardwareobjekt AS** ist bereits vorhanden' (Error 400ad) during module driver generation occurs when the SIRIUS 3RW44 Soft Starter block library is compiled in a project containing a CP 342-5 communications processor. The CP 342-5 is a classic SIMATIC S7-300 module that is not released for SIMATIC PCS 7. When the SIRIUS driver XML parser scans the hardware configuration, it encounters ambiguous address definitions in the unreleased CP 342-5 slave table. To resolve this error, remove the CP 342-5 from HW Config, use PCS 7 approved communication components such as a DP/DP Coupler or CP 443-5 Extended, and compile exclusively using the certified 'PCS 7' catalog profile.

Table of Contents

Executive Summary

When integrating smart motor control equipment such as the Siemens SIRIUS 3RW44 Soft Starter via PROFIBUS DP into a SIMATIC PCS 7 V7.1 or V8.x system, automation engineers must install the dedicated PCS 7 block library (e.g. PCS 7 Soft Starter 3RW44). However, upon installing the library and compiling CFC charts with Generate module drivers, the compiler frequently aborts with fatal error:

Der Adresswert IN_01-1 für das Hardwareobjekt AS** ist bereits vorhanden. (Fehlermeldung 400ad: Die Steuerdateien enthalten mehrdeutige Definitionen)

Crucially, this compilation failure occurs even if the SIRIUS soft starter has not yet been placed in HW Config. Investigation reveals that the presence of an S7-300 communications processor (CP 342-5) configured as a PROFIBUS DP slave triggers the fault. This technical article explains why unreleased modules corrupt driver generation and provides compliant migration paths.

Root Cause Analysis: Why CP 342-5 Triggers Error 400ad in the Driver Generator

The SIMATIC PCS 7 Module Driver Generator (GEN_MOD) executes an automated global hardware audit during compilation:

  1. Library Driver Rules: When the SIRIUS 3RW44 library is installed, it injects custom XML hardware driver generation rules into the Step 7 system directory. These rules instruct the compiler to parse all DP master systems and slaves to map diagnostic submodules.
  2. Unreleased Module Structure: The CP 342-5 is an S7-300 communication processor designed exclusively for classic STEP 7 machine architectures. It does not possess a standardized PCS 7 diagnostic data structure or standard module descriptor.
  3. Ambiguous Address Collision (400ad): When the driver generator scans the CP 342-5 slave configuration, the driver parser misinterprets the CP 342-5 internal byte buffers as an unassigned diagnostic submodule and generates an internal pointer labeled IN_01-1. When it encounters another hardware component or re-reads the slot, it detects a duplicate definition and halts with error 400ad.
  4. Why Deleting the CP Resolves It: Removing the CP 342-5 eliminates the ambiguous hardware descriptor from the HW Config database, allowing GEN_MOD to parse the remaining approved components cleanly.

The Role of HW Config Catalog Profiles: 'PCS 7' vs 'Standard'

A foundational principle of PCS 7 engineering is maintaining strict catalog profile discipline:

  • The 'Standard' Catalog Profile: Contains every module ever manufactured for SIMATIC S7-300, S7-400, C7, and ET 200. Most of these modules lack PCS 7 driver blocks, fail-safe compatibility, and diagnostic alarm integration.
  • The 'PCS 7' Catalog Profile: Contains only modules officially released, certified, and tested by Siemens for SIMATIC PCS 7. The CP 342-5 is intentionally omitted from the PCS 7 catalog profile.
  • The Trap: Engineers who switch the HW Config catalog profile to 'Standard' to configure unsupported hardware inadvertently introduce unreleased modules that break driver generation.

Approved Architecture for Integrating S7-300 Subsystems into PCS 7

When process plants require data exchange between a central PCS 7 automation station (S7-400 / CPU 410) and an S7-300 machine skid:

  1. DP/DP Coupler (Recommended for PROFIBUS):
    * Utilize a SIMATIC DP/DP Coupler (6ES7158-0AD01-0XA0).
    * The PCS 7 controller connects to Side 1 (configured as a standard DP slave using release-compliant driver blocks).
    * The S7-300 CP 342-5 connects to Side 2 in its own independent network.
    * Complete electrical and protocol isolation ensures the CP 342-5 never appears in the PCS 7 AS hardware configuration.
  2. PN/PN Coupler (Recommended for PROFINET):
    * Connect the systems via a PN/PN Coupler (6ES7158-3AD10-0XA0) for high-speed deterministic Ethernet data exchange.
  3. Direct Industrial Ethernet (CP 443-1 to S7-300 CP 343-1):
    * Establish an S7 connection in NetPro using standard Send/Receive (BSEND/BRCV) blocks.

Step-by-Step Remediation Procedure

To clear error 400ad and successfully generate module drivers for the SIRIUS 3RW44 soft starter:

  1. Switch HW Config Catalog Profile:
    * In HW Config, navigate to Options -> Select Catalog Profile.
    * Select PCS 7_V71 (or corresponding system version). Verify that only released components are visible.
  2. Remove the CP 342-5 Slave:
    * Locate the unreleased CP 342-5 module in the PROFIBUS DP line of the S7-400 station.
    * Delete the module from the configuration.
  3. Insert an Approved DP/DP Coupler:
    * From the PCS 7 catalog profile, navigate to PROFIBUS DP -> Gateway -> DP/DP Coupler.
    * Assign unique, non-conflicting input/output byte ranges.
  4. Clean Symbol Table and Chart Folder:
    * Open the S7 Program Symbol Table and delete any orphaned symbols referencing IN_01-1.
    * In the CFC Chart container, delete any orphaned @ diagnostic charts left from previous compilation aborts.
  5. Save and Compile:
    * Execute Station -> Save and Compile in HW Config.
    * In CFC, execute Chart -> Compile -> Charts as Program with Entire program and Generate module drivers checked.

Hardware Compatibility and Driver Generation Matrix

The following table summarizes communication interface compatibility with the PCS 7 Module Driver Generator:

Communication ModuleCatalog ProfileDriver Generator Compatible?Error Symptom if InsertedCertified PCS 7 RemediationCP 342-5 (S7-300 DP)Standard (Unreleased)No (Fatal collision)Error 400ad / IN_01-1 already existsReplace with DP/DP Coupler (6ES7158-0AD01-0XA0)CP 443-5 ExtendedPCS 7 ProfileYes (Fully certified)Clean compilation with MOD_D1Standard S7-400 PROFIBUS communication moduleDP/DP CouplerPCS 7 ProfileYes (Fully certified)Clean compilation with DP_NORMStandard isolation gateway between AS and machine skidsSIRIUS 3RW44 (via DP)PCS 7 Profile / GSDYes (With 3RW44 Lib)None when using certified mastersStandard motor starter integrationCP 343-1 (S7-300 PN)Standard (Unreleased)No (Direct in AS rack)Unrecognized module in AS containerConnect via PN/PN Coupler or S7 connection

Verification

Confirm that hardware driver generation has been restored:

  1. CFC Compilation Log: Confirm that CFC compilation with Generate module drivers completes with 0 errors and zero 400ad messages.
  2. Check Generated @ Charts: Open the newly created diagnostic charts in CFC. Confirm that @ charts exist and that diagnostic blocks are cleanly linked to the DP/DP Coupler and SIRIUS 3RW44 driver blocks.
  3. Online Communication Test: Download HW Config and CFC to the CPU. In CFC Test Mode, verify that driver block outputs (QBAD, QMODF) are FALSE and that process communication is healthy.

Preventive Hardware Engineering Rules for PCS 7 Projects

To maintain compiler health and system certifiability across the project lifecycle:

  • Never Switch Catalog Profile to 'Standard': Maintain the 'PCS 7' catalog profile permanently locked in HW Config across all engineering stations.
  • Use Electrical Isolation Couplers for Third-Party Skids: Never attach third-party or machine-level PLCs directly into the primary PCS 7 AS controller rack or primary DP master line without a physical gateway (DP/DP or PN/PN Coupler).
  • Verify Hardware Release Status: Cross-check all device part numbers against the PCS 7 Released Modules list before procurement.

Limitations and Operational Precautions

Never disable Generate module drivers to bypass compiler error 400ad. Bypassing driver generation leaves the entire automation station without hardware fault detection (OB82, OB83, OB86), disabling diagnostic alarms and causing process faceplates to fail silently.

When sizing DP/DP Couplers, communication modules, or SIRIUS soft starters, verify part numbers, baud rate limitations, and bus cable terminations against official Siemens catalogs and confirmed through an authorized Siemens distributor quotation.

Engineer FAQ

Can a CP 342-5 ever be used directly in a PCS 7 AS?

No. The CP 342-5 is physically and architecturally incompatible with S7-400 backplanes and lacks PCS 7 driver generator support.

Why did the 3RW44 library cause the error if the soft starter wasn't added yet?

Installing the library adds global driver parsing scripts. During compilation, the compiler parses all existing hardware in the project, uncovering the unreleased CP 342-5.

What does error code 400ad mean?

Error 400ad indicates that the driver generation control files contain ambiguous or contradictory hardware slot definitions.

Does a DP/DP Coupler isolate baud rates between two PROFIBUS networks?

Yes. A DP/DP Coupler provides complete galvanic and protocol isolation, allowing both sides to run at different baud rates without interference.

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