Configuring MM440 and ABB ACS550/800 Profibus Communication with S7-400

This technical reference covers the complete engineering workflow for integrating eight Siemens MICROMASTER 440 (MM440) inverters and ten ABB ACS550 / ACS800 drives on a single Profibus-DP network, controlled by a SIMATIC S7-400 CPU, with data displayed on WinCC faceplates. It expands the PPO4-only approach with explicit parameter numbers, normalization math, SFC14/SFC15 wrappers, and a reusable Function Block (FB) template for SCADA-driven Start/Stop, direction, and feedback.

1. System Architecture Overview

The network is a classical DP-V0 master/slave topology. The S7-400 (e.g., CPU 414-3 PN/DP or CPU 416-3) acts as the Class 1 master. MM440 drives connect through a Profibus option module (order code 6SE6400-1PB00-0AA0), and ABB ACS550/ACS800 drives connect through a RPBA-01 Profibus adapter. WinCC v7.x runs on a PC station connected via Industrial Ethernet or MPI for operator visualization.

2. Prerequisites

1. STEP 7 v5.5 or TIA Portal V15.1+ with the HSP (Hardware Support Package) for the S7-400 and the GSD files for MM440 (SIEM808F.GSD via 6SE6400-1PB00-0AA0) and ABB (ABB0810.GSD for RPBA-01).
2. MM440 firmware ≥ 3.2 for full PPO4 consistency on 6-word PZD (verify with r0019 = drive firmware).
3. ABB ACS550 standard firmware (550-01) and ACS800 system firmware ≥ ASXR7210 for type 4 PPO support.
4. WinCC v7.4 SP1 or TIA WinCC Professional V15.1, plus a configured PC station routed to the S7-400.
5. Import the ABB Drives function blocks for Siemens PLCs - Quick start-up guide (A_A4) for the proven FB template and TIA example project.

3. PPO Type Selection - Why PPO4

PPO (Parameter Process Object) telegrams split the cyclic payload into PKW (parameter channel) and PZD (process data). For drives that are fully configured at commissioning and operated exclusively through process data, PPO4 (0 PKW + 6 PZD) is the universal choice: it is supported on MM440 firmware 3.2+ and on ABB ACS550/ACS800 with the RPBA-01 adapter.

With PPO4 active, the first PZD word on the input side is always Status Word 1 (ZSW1) and the first output PZD is always Control Word 1 (STW1). The remaining 5 PZD words are freely mapped using vendor-specific BICO-style connectors (P2051 on Siemens, parameter group 51 on ABB).

4. MM440 Parameter Configuration

Set the following parameters via the BOP-2, STARTER, or the SIMATIC Manager drive commissioning tool. Each drive on the bus needs a unique Profibus address (default 0 → set per drive to avoid DP address conflict).

On the receive side, MM440 returns the data in the order you bind through P2051 INx:

4.1 Normalization Reference Values (Siemens)

Siemens drives send process data as integers with reference to the values set in P2000–P2004. The native Siemens protocol uses 0–16384 (4000_hex) for 0–100% of the reference value. Use 4000_hex for the speed setpoint in the PLC program to start at 100% and scale linearly.

For example, if a motor nameplate is 5.5 kW and you set P2004 = 150%, then 100% power on the bus = 1.5 × 5.5 kW = 8.25 kW. Adjust to suit panel metering.

5. ABB ACS550 and ACS800 Parameter Configuration

ABB uses a parameter group 51 (51.xx) and 52 (52.xx) for process data. With RPBA-01, PPO4 is the supported type for both ACS550 and ACS800. The Profibus node address is set with parameter 51.02 (range 1–126).

5.1 ABB PZD Mapping (PPO4)

Unlike Siemens, the ABB mapping is fixed for the first two words but configurable for the remainder through 52.xx:

5.2 ABB Normalization

ABB uses different scaling depending on the signal:

6. S7-400 Hardware Configuration (HW Config)

1. Open SIMATIC Manager → your S7-400 station → HW Config.
2. Insert the CPU (e.g., 6ES7416-3XR05-0AB0) on rail 0, slot 3.
3. Drag the MM440 GSD file (Profidrive Drive V3.1) from the catalog → set to PPO type 4 (slot 0: PPO type 4).
4. Drag the ABB ACS550 / ACS800 GSD (RPBA-01 v2.x) → set PPO type 4.
5. Assign unique DP addresses (e.g., MM440 #1 = 4, MM440 #2 = 5, …, ABB #1 = 12, …, ABB #10 = 21). The address MUST match the drive's parameter 51.02 (ABB) or Profibus address set via the DIP switch on the MM440 Profibus option board.
6. Read the I-address and Q-address ranges. For a PPO4 slave they are 12 bytes of inputs and 12 bytes of outputs (6 PZD × 2 bytes).

Example mapping for the first MM440 (DP address 4) with PPO4:

7. SFC14 / SFC15 Programming on S7-400

Although you can read PIW/PQW directly for diagnostic or simple I/O, the recommended pattern for DP slaves with consistent user data > 4 bytes is to use SFC14 (DPRD_DAT) and SFC15 (DPWR_DAT). PPO4 (12 bytes) exceeds the 4-byte consistency limit, so SFC14/15 is mandatory for any guarantee of atomic reads/writes.

7.1 Sample SFC15 / SFC14 Call (Structured Text)

// Drive DB: "DRV_DB_MM4" (instance DB of FB_CTRL_MM4)
// Inputs:  iDP_Addr (BYTE) = 4   (logical DP address from HW Config)
// Outputs: DriveData_IN[0..5] (6 WORDs) populated by SFC14

// --- WRITE (PLC → drive) ---
DriveData_OUT[0] := iControlWord;        // STW1
DriveData_OUT[1] := iSetpointRaw;        // 4000h = P2000
DriveData_OUT[2] := 16#0000;             // STW2 (unused)
DriveData_OUT[3] := 0;
DriveData_OUT[4] := 0;
DriveData_OUT[5] := 0;

ret := DPWR_DAT(
    LADDR  := WORD#16#100,               // logical base address of slave (= 256 dec)
    RECORD := DriveData_OUT,             // ANY pointer to 12 bytes
    RET_VAL := wWriteRetVal);            // return code (0 = OK)

// --- READ (drive → PLC) ---
ret := DPRD_DAT(
    LADDR  := WORD#16#100,
    RECORD := DriveData_IN,              // 12 bytes, 6 WORDs
    RET_VAL := wReadRetVal);

// After return, wReadRetVal = 0 → DriveData_IN valid
iStatusWord     := DriveData_IN[0];      // ZSW1
rActualFreq_Hz  := WORD_TO_REAL(DriveData_IN[1]) / 16384.0 * 50.0;
rActualCurrent  := WORD_TO_REAL(DriveData_IN[3]) / 16384.0 * P2002_Motor;
rActualPowerPct := WORD_TO_REAL(DriveData_IN[4]) / 16384.0 * P2004_Pct;

7.2 Error Codes SFC14/15

8. Normalization Math and Scaling

8.1 Siemens 0–16384 (4000_hex) Reference

Siemens uses a 14-bit signed raw value where 4000_hex = 16384_dec represents 100% of the configured reference (P2000, P2002, P2003, P2004). For a motor with P2000 = 50 Hz and a raw value 0x4000 received on NIST:

rActualFreq_Hz = (NIST_raw / 16384.0) * P2000
              = (16384 / 16384.0) * 50
              = 50.0 Hz

For P2002 = 12.0 A and raw 0x4000 on IAIST, current = 12.0 A. For P2004 = 150% and raw 0x4000 on PAIST, power = 150% of motor rated. If the motor is 7.5 kW, that is 11.25 kW.

8.2 ABB 0–20000 Reference

ABB drives with default Drive Profile use 0–20000 = 0–100% of the reference speed (parameter 99.08). For a motor with 50 Hz rated:

rActualFreq_Hz = (Actual1_raw / 20000.0) * RatedFreq_Hz

For a raw value of 10000, frequency = 25 Hz. For motor current with reference = 99.06 (motor nominal current) and raw 0–10000, use the same divide by 10000 multiplication by 99.06.

9. Reusable Function Block for SCADA Faceplates

To reduce engineering time across 18 drives, wrap SFC14/15 calls in a single FB. The FB takes only the DP address and returns typed engineering values. This pattern is also used in the ABB Drives function blocks for Siemens PLCs quick start guide.

FUNCTION_BLOCK FB_DRIVE_CTRL
VAR_INPUT
    iDP_Addr       : BYTE;        // logical DP address from HW Config
    iRatedFreq_Hz  : REAL := 50.0;
    iRatedCurrent  : REAL := 10.0;
    iRatedPowerPct : REAL := 150.0;
    iCmdStart      : BOOL;        // from HMI
    iCmdStop       : BOOL;
    iCmdReset      : BOOL;
    iSetpoint_Hz   : REAL;
END_VAR
VAR_OUTPUT
    oReady         : BOOL;
    oRunning       : BOOL;
    oFault         : BOOL;
    oActualFreq_Hz : REAL;
    oActualCurrent : REAL;
    oActualPowerPct: REAL;
    oActualEnergy  : WORD;
    oControlWord   : WORD;
    oStatusWord    : WORD;
END_VAR
VAR
    sCtrl : WORD;
    sSetp : WORD;
    sOut  : ARRAY[0..5] OF WORD;
    sIn   : ARRAY[0..5] OF WORD;
    sRW   : INT;
END_VAR

BEGIN
    // 1. Compose control word (STW1) and setpoint
    sCtrl := 16#047E; // ready, no coast, no fault (set 0x047E for READY state)
    IF iCmdStart THEN sCtrl := sCtrl OR 16#000F; END_IF;
    IF iCmdStop  THEN sCtrl := 16#047E; END_IF;          // OFF1 (ramp stop)
    IF iCmdReset THEN sCtrl := 16#04C7; END_IF;          // Fault acknowledge bit 7
    sSetp := REAL_TO_WORD((iSetpoint_Hz / iRatedFreq_Hz) * 16384.0);

    sOut[0] := sCtrl;
    sOut[1] := sSetp;
    sOut[2] := 0;
    sOut[3] := 0;
    sOut[4] := 0;
    sOut[5] := 0;

    // 2. Write to drive (SFC15)
    sRW := DPWR_DAT(
        LADDR  := WORD#16#100 + INT_TO_WORD(iDP_Addr - 1) * 12,
        RECORD := sOut,
        RET_VAL := sRW);

    // 3. Read from drive (SFC14)
    sRW := DPRD_DAT(
        LADDR  := WORD#16#100 + INT_TO_WORD(iDP_Addr - 1) * 12,
        RECORD := sIn,
        RET_VAL := sRW);

    // 4. Decode status
    oStatusWord := sIn[0];
    oRunning    := (sIn[0] AND 16#0007) = 16#0007;  // bits 0,1,2 = RUNNING
    oFault      := (sIn[0] AND 16#0008) <> 0;      // bit 3 = fault active
    oReady      := (sIn[0] AND 16#0001) <> 0;      // bit 0 = ready to switch on

    // 5. Decode engineering values (Siemens 0–16384)
    oActualFreq_Hz  := WORD_TO_REAL(sIn[1]) / 16384.0 * iRatedFreq_Hz;
    oActualCurrent  := WORD_TO_REAL(sIn[3]) / 16384.0 * iRatedCurrent;
    oActualPowerPct := WORD_TO_REAL(sIn[4]) / 16384.0 * iRatedPowerPct;
    oActualEnergy   := sIn[5];
    oControlWord    := sCtrl;
END_FUNCTION_BLOCK

10. WinCC Faceplate Integration

1. Create a WinCC tag for each drive's control and feedback. With SFC14/15 + a drive DB, point each tag at the DB word/byte.
2. Use the ABB faceplate template from the ABB quick start-up guide (A_A4) as a reference for Siemens and ABB.
3. Build a multi-instance faceplate that takes the drive index and displays: oActualFreq_Hz, oActualCurrent, oActualPowerPct, oActualEnergy, fault code, and the Status Word (raw + decoded bits).
4. Configure a bit-level display: oReady, oRunning, oFault → colored indicators.
5. Add a fault reset button bound to iCmdReset with a momentary pulse of 1 s.

11. Common Fault Codes (MM440, ACS550, ACS800)

To surface the active fault code on the WinCC faceplate, map a free PZD slot (e.g., IN PZD3 on Siemens MM440 by setting P2051.2 = 53 for ZSW2, then bit-decode, or for direct fault number use a separate read through the PKW channel on a PPO2 slave if PPO4 is insufficient).

12. Troubleshooting Matrix

13. Commissioning Procedure (Step-by-Step Verification)

1. Power the bus with one drive at a time. Confirm BF (Bus Fault) LED is off on each MM440 Profibus option and on the RPBA-01.
2. In HW Config, set the slot PPO type to 4 and download the configuration. Verify the S7-400 displays the slave in "Online → DP Master System → Bus Nodes".
3. Open a VAT table and call SFC14 for the first drive. Confirm RET_VAL = 0 and ZSW1 (DriveData_IN[0]) is non-zero (e.g., 16#0E31 for "Ready, Voltage Enabled, No Fault").
4. Write STW1 = 16#047E (Ready to switch on). Verify the drive displays state "rdy" and ZSW1 reflects bit 0 set.
5. Write STW1 = 16#047F (ON command). Verify motor spins at 0 Hz. Increment setpoint word; verify frequency rises in proportion (NIST feedback).
6. Scale-setpoint loop: send 4000h setpoint, confirm NIST = 4000h ± 10. Repeat for 2000h, 1000h, etc.
7. Apply a step in load to verify ZSW2 and IAIST response. Confirm current normalization (P2002) gives the expected A value when fed with 4000h raw.
8. Trigger a fault (e.g., unplug the encoder for closed-loop drives) and verify F0070 (MM440) or FB PAR ERR (ACS550) appears in the fault word on the bus.
9. Test fault reset: write STW1 = 16#04C7 momentarily. Verify drive exits fault state.
10. Once one drive is verified, replicate the FB to all 18 slaves by changing only the iDP_Addr input.

14. Multi-Drive Loopback Test (Telegram Inspector)

With the S7-400 in STOP, the CP 443-5 extended can be set to a diagnostic mode where it echoes the bus telegrams. Use this to confirm the slave is responding. Alternatively, capture telegrams with a Profibus monitor (e.g., Profinet / Profibus diagnostics hardware) and confirm:

• PLC → drive: 6-word output telegram with STW1, NSOLL matching program values.
• Drive → PLC: 6-word input telegram with ZSW1 indicating drive state, NIST = actual frequency in normalized form.
• No slot error in slave diagnostics (SFC13 returns no fault, status = 0x32 for OK).

15. ABB Function Block Library Reference

The ABB Drives function blocks for Siemens PLCs quick start-up guide (PDF) provides:

• A complete SIMATIC Manager and TIA Portal example project (S7-300/400 compatible).
• Pre-built FBs (FB100–FB103) for ACS550/ACS800 PPO4 control.
• HMI tag list and a WinCC faceplate.
• Standard S7-300/400 GSD for the RPBA-01 module.
• Default 51.xx and 52.xx parameter settings for one-click commissioning of the ABB drive.

Use this as the starting point if you have many ABB drives; the same template can be applied to MM440 with parameter adjustments from sections 4 and 5.

16. Glossary

17. FAQ