SINAMICS G150 PCS 7 V5.2 Integration: Drive ES & Custom Blocks

Overview

The SINAMICS G150 is a Siemens cabinet-style, air-cooled (or optional liquid-cooled) low-voltage drive designed for single-motor applications such as pumps, fans, compressors, extruders, and mills in the 75 kW to 2700 kW power range. It is the cabinet-format sibling of the SINAMICS G130 chassis unit and uses the same CU320-2 Control Unit firmware stack as the broader SINAMICS G/S/V family. Communication with the higher-level automation system is supported natively over PROFIBUS DP (via the CBE20 or CBP2 communications module) or PROFINET (via CBE20), using the PROFIdrive application profile (PNO profile V3.1 / V4.0 / V4.2 depending on the drive firmware).

When the SINAMICS G150 is integrated into a SIMATIC PCS 7 process control system, the typical project expectation is to use the standard PCS 7 driver block library and the WinCC faceplate generator so that the drive is automatically visible in the SFC, ALG (Alarm Logging), and OS picture hierarchy. PCS 7 V5.2 is the issue: the SINAMICS G150 hardware was released after the V5.2 driver library was frozen, so no drv_G150 CFC block, no @G150 faceplate, and no master_G150 APL block ship in the V5.2 DVD. The fix is to combine:

1. Drive ES PCS 7 (the official Drive Engineering System add-on), and
2. A custom CFC block and WinCC faceplate built around the standard PROFIdrive telegram 1 / telegram 20 structure.

Prerequisites

System Topology

The SINAMICS G150 connects to the PCS 7 AS via a PROFIBUS DP segment (typical for brownfield PCS 7 V5.2 plants) or PROFINET. A representative topology for an ET 200M-based AS station is shown below.

Why PCS 7 V5.2 Does Not Ship a G150 Block

The PCS 7 driver block library is closely tied to the AS runtime catalog that ships with each major version. PCS 7 V5.2 supports the SIMATIC MASTERDRIVES (VC / MC) family and the early SINAMICS G120 / S120 blocks, but the G150 family was not formally added until PCS 7 V6.1 (and fully reworked into the APL_2 block style in PCS 7 V7.0+). Attempting to use a drv_sin block on a G150 will compile and download, but the symbol binding and the I/O data areas are sized for the older SINAMICS telegram, and no automatic faceplate is generated by the @SFC / @PCS 7 OS project editor.

Integration Path 1 – Use Drive ES PCS 7 (Recommended)

Drive ES PCS 7 is the official Siemens add-on for embedding SINAMICS, SIMOVERT MASTERDRIVES, and MICROMASTER drives into PCS 7. It is delivered as a separate installation DVD (e.g., Drive_ES_PCS7_V5.4) and is installed on the same engineering station that hosts the PCS 7 ES.

1. Install Drive ES PCS 7 on the ES. The installer adds new entries to the SIMATIC Manager (menu Options > SINAMICS) and registers the G150 GSD/GSDML in HW Config.
2. Add the G150 to the PROFIBUS/PROFINET network in HW Config. Open the device properties, switch to the Drive configuration tab, and select the Drive ES object type "SINAMICS G150".
3. Run the Drive ES Basic configuration from the HW Config right-click menu. This writes the necessary system data blocks (SDB), creates a DRIVE_ES master object, and seeds the CFC chart for the drive.
4. Insert the driver block from the SINAMICS library (SINAMICS_Blocks > SIN_G150). On PCS 7 V5.2 the library block that the Drive ES wizard inserts is the V5.2-compatible G150 block delivered with the Drive ES DVD; it links to the standard WinCC faceplate provided in the same library.
5. Compile the OS and verify the faceplate appears in the standard drive picture.

Where the formal SINAMICS G150 block is not present in the Drive ES DVD, the next two sections describe how to build a compatible driver block and a working faceplate by hand.

Integration Path 2 – Build a Custom CFC Block

The minimum contract that PCS 7 expects from a drive block is:

• Two WORD I/O points for STW1 and ZSW1 (control / status word 1, PROFIdrive).
• One INT / REAL for NSOLL (speed setpoint, normalized 0x4000 = 100 %).
• One INT / REAL for NIST (speed actual, same normalization).
• Optional: STW2 / ZSW2 (control / status word 2) and one of the encoder channels if the position profile is required.

For a G150 on PROFIBUS with standard telegram 1 (PZD-2/2), the data map is exactly six words:

For telegram 20 (PZD-6/6) the additional pair STW2 / ZSW2 and the encoder channel are appended, giving 12 words (24 bytes) total. The telegram type is set in STARTER under Communication > PROFIBUS/PROFINET > Telegram configuration on the Control Unit, and it must match exactly the I/O assignment configured in HW Config on the DP/PN slave.

Step-by-Step Block Construction

1. Create a new CFC chart in the plant view (e.g., Unit_G150_Pump_01). Insert a CH_DI chart input and a CH_DO chart output block for each I/O symbol (STW1, NSOLL, ZSW1, NIST) – the address of the chart I/O must match the HW Config address of the G150 PZD slot.
2. Insert a custom driver block (call it DRV_G150_V52). The block should expose:
   • SP_SPEED (REAL, percent of p2000)
   • OP_ON / OP_OFF1 / OP_OFF2 / OP_OFF3 (BOOL)
   • FAULT_ACK (BOOL, edge-triggered)
   • CTRL_BYP (BOOL, control bypass)
   • STW1_OUT (WORD), ZSW1_IN (WORD)
   • READY, FAULT, RUNNING, AT_SETPOINT (BOOL)
   • ACT_SPEED (REAL, % of p2000)
   • ACT_CURRENT, ACT_TORQUE (REAL) – pulled from r0027 / r0031 over the free PKW channel
3. Implement the STW1 / ZSW1 bit logic in the CFC using AND/OR blocks. The bit assignments follow the PROFIdrive profile; see the table below.
4. Add an alarm block (MSG_ACK + USF) connected to the FAULT output. The G150 raises a single high-level fault via PROFIdrive bit 3 (fault active) plus the diagnostic fault number; map the number to a PCS 7 message ID in the ALG editor.
5. Mark the chart for OS compilation and add the OS_Comment and Unit_Comment attributes so the chart is visible in the standard SFC hierarchy.

PROFIdrive STW1 / ZSW1 Bit Mapping

The following bit assignments are mandatory for any PROFIdrive-compliant G150. They are also documented in chapter "Function diagrams – PROFIdrive" of the SINAMICS G130/G150 List Manual.

The default PCS 7 control sequence is therefore:

STW1 = 0x047E   (ON, no OFF2/3, enable operation, enable RFG, setpoint enable, PLC control)
STW1 = 0x047F   (+ bit 0: drive starts)

and the corresponding acknowledgment edge is bit 7 of STW1, generated as a 0→1 transition in the CFC.

Communication — Setpoint Normalization

SINAMICS G150 normalizes speed setpoints on the basis of reference speed p2000. A PLC value of 0x4000 (16384 decimal) corresponds to 100 % of p2000. The two's-complement representation allows reversing by writing negative values (0xC000 = -100 %).

• Setpoint word size: 16 bits (INT).
• Reference value: p2000 (default = rated motor speed, in rpm).
• Resolution: 1/0x4000 = 0.0244 % per LSB.
• Drive displays the normalized value scaled by p2000; the WinCC faceplate should use a per-thousand (‰) display rather than Hz, to make the normalization transparent to the operator.

Faceplate Design (WinCC V5.1)

The PCS 7 V5.2 faceplate engine expects a 24 × 24 standard picture plus a supplementary window. The G150 faceplate is normally composed of:

1. Header: tag name, unit, mode (MAN/AUTO/OUT), current operator authorization level.
2. Process view: bar graph for ACT_SPEED with NSOLL overlay, numeric field for ACT_CURRENT / ACT_TORQUE.
3. Command view: ON, OFF, ACK buttons, SP_SPEED I/O field, CTRL_BYP checkbox.
4. Message strip: bound to the MSG_ACK block; displays the active G150 fault number decoded from r0947[0].
5. Trend view: ACT_SPEED, ACT_CURRENT, ACT_TORQUE in a 1-minute / 10-minute / 1-hour window.

To register the faceplate in the OS, edit the @PCS7Typicals.pdl or the relevant plant picture and insert the new G150 picture window. The block instance name follows PCS 7 conventions: Unit_G150_Pump_01/DRV_G150.

Verification Procedure

1. Compile the S7 program (Options > Compile). No warnings should remain on the new G150 chart.
2. Download the program to the AS. Open the chart online in CFC and verify that ZSW1_IN shows 0x0231 (ready to switch on, ready to operate, switch-on inhibit active) once the drive has powered up and completed initialization.
3. Send STW1 = 0x047E to clear the switch-on inhibit, then STW1 = 0x047F to start. Within 200 ms (typical for a G150 with default ramp-up time p1120 = 10 s) the drive should report ZSW1 = 0x0237 (running) and NSOLL should be echoed in NIST.
4. Inject a controlled fault by writing 0x0000 to STW1 (OFF1); ZSW1 should drop to 0x0230. Re-issue 0x047E and an acknowledge edge on bit 7 to clear the switch-on inhibit.
5. Open the OS faceplate from the standard drive picture. Verify the bar graph, the trend view, and that pressing the on-screen ON button generates the same bit sequence as the manual test above.
6. Archive the parameter set in STARTER (Drive > Load to file) and the S7 program (Options > Archive). Keep a copy of the GSD file and the custom block FB source in the project library.

Fault Code Cross-Reference

Troubleshooting Matrix

Migration Considerations

If the project is scheduled to migrate to PCS 7 V7.1 / V8.x in the medium term, the custom G150 block can be written against the APL_2 symbol set from the outset, so that the subsequent port is a property-only change rather than a logic rewrite. Note that the Drive ES block for G150 in PCS 7 V6 (entry 17822754) uses the same PROFIdrive PZD-6/6 layout and is structurally identical to the V5.2 design, so the migration is largely an I/O remap and an OS picture re-compile.

Field-Proven Caveats

• Watch the ramp-function generator: p1120 / p1121 (ramp-up / ramp-down) default to 10 s, which is far slower than the typical PCS 7 faceplate update rate. For a 1-rpm change the response will look sluggish in the OS trend; tune p1120/p1121 to the process requirement before commissioning.
• Local / Remote key switch on the G150 cabinet AOP30 must be in Remote for STW1 bit 10 to take effect. If the switch is in Local, the drive ignores all PROFIdrive control bits and only the AOP30 START/STOP are honoured.
• Bumpless transfer from STARTER to PCS 7: STARTER sets p0850 (control by PLC) implicitly when commissioning. Verify p0850 = 1 before the first PROFIdrive start, otherwise STW1 will be ignored.
• Safety STO wiring on the SINAMICS G150 must be terminated at X120 even if no external safety chain is used in V5.2; an open STO will hold the drive in switch-on inhibit regardless of STW1.
• Setpoint sign reversal: for a four-quadrant load (e.g., winder) drive bit 11 (reversing) is more reliable than a negative NSOLL; the latter is sometimes masked by the p1100 setpoint pre-processing.

FAQ