Updating Hardware Catalog with HSPs in SIMATIC PCS 7

Installing Hardware Support Packages (HSPs) to update the STEP 7 HW Config catalog in SIMATIC PCS 7 is an additive, non-destructive operation: downloading and installing HSPs will never overwrite, modify, or delete existing hardware modules or configured stations. HSPs simply add new module profiles, updated firmware revisions, and newly released Siemens devices to the catalog tree. However, in PCS 7 environments, simply having a module in the hardware catalog does not guarantee driver support; using new I/O modules with older library versions (e.g., Library V6.1 on PCS 7 V8.1) causes 'Generate Module Drivers' compilation failures.

Nature and Safety of Hardware Support Packages (HSPs)

In STEP 7 HW Config, the hardware catalog contains the digital descriptions, parameter definitions, and diagnostic rules for every supported Siemens and third-party automation component. As Siemens releases new I/O modules (such as new ET 200SP or ET 200M variants) or newer firmware revisions, engineers update the engineering station using Hardware Support Packages (HSPs).

A common anxiety among plant maintenance engineers is whether updating the hardware catalog might overwrite existing, running hardware definitions, alter legacy I/O configurations, or cause station compilation mismatches in active projects. In STEP 7, catalog updates are strictly additive and backward-compatible.

Hardware Catalog Additions vs Existing Project Integrity

Understanding the architectural mechanics of HSP installation reassures engineers:

Additive Schema: HSPs install new database records into the STEP 7 hardware repository. They do not delete or replace legacy module profiles. An ET 200M module configured five years ago retains its exact configuration and parameter assignment.
Isolation from Project Files: The hardware catalog resides in the STEP 7 system installation tree, not inside your project *.s7p file. Updating the catalog does not alter any existing project data until you deliberately insert new hardware into a rack.

The Critical Role of PCS 7 Driver Library Compatibility

While installing an HSP is completely safe for HW Config, using newly introduced hardware in a PCS 7 project introduces a crucial distinction documented in PCS 7 Compendium Part D (Chapter 4.1):

STEP 7 Support vs PCS 7 Driver Support: STEP 7 HW Config only defines the physical parameterization and address space of a module. However, SIMATIC PCS 7 requires corresponding channel driver blocks (Pcs7AnIn, Pcs7DiIn, MOD_D16) to process alarms and diagnostics automatically.
Library Version Mismatch: If you install an HSP for a brand-new 2018 I/O card but your CFC project utilizes an obsolete block library (such as PCS 7 Library V6.1), the CFC compiler's Generate Module Drivers function will not recognize the new module's hardware ID. Compilation will abort with the error: 'Module not supported by driver generator.'
Resolution: To use new hardware in PCS 7, ensure that the PCS 7 Driver Library / Master Data Library is updated to match the module release.

Comparison of HW Config Updates Across Engineering Tools

The table below compares different methods of introducing new hardware into SIMATIC PCS 7.

Update MechanismSource & ActionOverwrites Existing Modules?PCS 7 Driver Generator SupportRecommended UseHardware Support Package (HSP)STEP 7 HW Config Options -> Install HW UpdatesNever (Purely additive)Supported if PCS 7 library is compatibleStandard for all Siemens hardwareGSD / GSDML Device ProfileOptions -> Install GSD FilesNever (Added to Additional Field Devices)No automated PCS 7 driversThird-party slaves / drivesPCS 7 Library Update / HotfixOfficial Siemens PCS 7 Library installerUpdates Master Data Library blocksRestores / extends driver supportMandatory when adding new I/O familiesFirmware Update in HW ConfigModule properties firmware selectionReplaces selected module profile in rackSupported if library supports firmwareUpdating firmware revisions

Step-by-Step Procedure to Update the Hardware Catalog

Follow this procedure to safely update the HW Config catalog in SIMATIC Manager:

Download Hardware Updates:
- In SIMATIC Manager, open HW Config for any station.
- Select menu Options -> Install HW Updates.
- Choose Download from Internet (or copy from a local directory if the ES is offline) and click Execute.
Select and Install Updates:
- In the list of available updates, check the boxes for the required modules (or select all).
- Click Install. Confirm the warning dialog that HW Config will close all open stations.
- Wait for the installation progress bar to finish.
Update Catalog Tree:
- Reopen HW Config.
- Select Options -> Update Catalog to refresh the graphical catalog tree.
- Navigate to the newly installed module in the catalog (e.g., under ET 200M or ET 200SP).
Verify Driver Support in CFC:
- Insert the module into a spare rack slot and assign addresses.
- In CFC, interconnect a test channel driver (Pcs7DiIn) to the new address.
- Run CFC compilation with Generate module drivers checked: ensure compilation completes with 0 errors.

Verification

Verify catalog update success through the following checks:
1. In HW Config, search the catalog for the specific 16-character MLFB: verify that the new module appears with correct firmware options.
2. Open an existing station: verify that existing I/O modules, power supplies, and CPs retain their original parameters without change.
3. Compile HW Config: confirm that compilation finishes with 0 errors.
4. Check the CFC driver generator log: confirm that newly placed modules are assigned valid diagnostic blocks (MOD_...).

Limitations and Operational Precautions

Never interrupt an HSP installation while in progress, as corrupting the STEP 7 hardware database requires reinstalling STEP 7. Additionally, before specifying newly released I/O modules for an operational plant, consult the PCS 7 Released Modules appendix to confirm that your specific PCS 7 version and installed library version natively support automatic driver generation.

Engineer FAQ

Will installing an HSP require a CPU stop?

Installing an HSP updates the offline engineering catalog on the workstation and has zero impact on the online CPU. Downloading hardware changes that use the new module may require a CPU stop or CiR depending on system topology.

Can I delete an installed HSP from the catalog?

No. STEP 7 does not provide a direct 'uninstall' function for HSPs because they are purely additive. If an HSP is damaged, reinstall the base STEP 7 software.

Why does CFC driver generation fail on a module that is in the hardware catalog?

The hardware catalog is maintained by STEP 7, while driver generation is maintained by PCS 7. If the PCS 7 Driver Library is older than the module, the driver generator cannot create diagnostic blocks for it.