Configuring ES-to-OS Compile Parameters with IE General and CP 1623 Interfaces in PCS 7

When compiling an OS from an Engineering Station (ES) equipped with an ordinary commercial network card (IE General) to an OS Server equipped with a dedicated Siemens CP 1623 or CP 1628, configure the ES PC station in HW Config with 'IE General' and map the Plant Bus connection to 'Industrial Ethernet' using Named Connections. On the OS Server PC station, insert the 'CP 1623' hardware object. During the OS Compile wizard in SIMATIC Manager, select the Named Connection path for AS-OS communication, ensuring that Station Configurator on each respective node matches the hardware addresses assigned in STEP 7.

Executive Summary

A frequent architecture in SIMATIC PCS 7 deployments pairs an Engineering Station using standard commercial Ethernet hardware (IE General / SOFTNET) with high-availability OS Servers equipped with dedicated coprocessor communications cards (CP 1623 / HARDNET). During OS compilation and project transfer, engineers often receive connection mapping errors, missing Named Connection targets, or runtime driver disconnects. This guide clarifies the correct HW Config topology, Station Configurator mapping, and OS Compile parameters necessary for seamless communication between dissimilar ES and OS network interfaces.

Architecture and Fundamental Mechanics

Network Topology and S7 Connection Mechanics Across ES and OS:

Engineering Station Interface (IE General / SOFTNET):
The ES typically connects to the plant bus using an onboard Gigabit Ethernet port or commercial PCI-Express NIC.
In STEP 7 HW Config, this interface is defined as IE General.
Uses the SOFTNET protocol stack, with protocol processing handled by the host PC operating system CPU.
Operator Station Interface (CP 1623 / CP 1628 / HARDNET):
The OS Server runs high-volume cyclic tag logging and alarm polling across multiple AS stations.
In STEP 7 HW Config, this interface is configured as CP 1623 (or CP 1628 for IPsec encrypted traffic).
Uses onboard communications coprocessors running HARDNET-IE S7 REDCONNECT firmware, offloading network traffic from Windows.
Named Connections (S7 Connections):
In PCS 7, runtime tag communication between OS and AS must use Named Connections managed via NetPro.
The ES does not require a CP 1623 to compile or download to an OS Server that utilizes a CP 1623, provided NetPro specifies the correct connection endpoints for each PC Station.

Step-by-Step Implementation Procedure

Step-by-Step Procedure to Configure and Compile ES-OS Communications:

Configure the ES PC Station in SIMATIC Manager:
- Insert a SIMATIC PC Station named identically to the ES Windows Computer Name.
- In HW Config: Slot 1 = WinCC Appl. (if running local simulation/test), Slot 2 = IE General.
- Assign IP address and subnet mask corresponding to the Plant Bus.
Configure the OS Server PC Station:
- Insert a SIMATIC PC Station named identically to the OS Server Windows Computer Name.
- In HW Config: Slot 1 = WinCC Appl. (or WinCC Appl.(stby) for redundant pairs), Slot 2 = CP 1623.
- Assign IP address matching the OS Server's physical plant bus network adapter.
Establish S7 Named Connections in NetPro:
- Open NetPro in SIMATIC Manager.
- Select the OS Server's WinCC Appl. object -> insert a new connection to each AS (S7-400 or CPU 410-5H).
- Set Type to S7 connection (or S7 connection fault-tolerant for redundant H-systems).
- Save and Compile NetPro ('Check and Compile Everything').
Match Station Configurator on Both PCs:
- On the ES: Station Configurator index 2 must match IE General.
- On the OS Server: Station Configurator index 2 must match CP 1623.
Execute OS Compile:
- In SIMATIC Manager, right-click the OS object -> Compile.
- In Wizard step 'Select network connection': select the Named Connection (Named Connections) routing through the plant bus.
- Select compilation scope: 'Tags and messages' -> 'Entire OS' (or 'Changes only' for subsequent updates).
- Complete compilation and verify zero errors.

Verification

To verify the configuration:
1. Open WinCC Explorer on the OS Server (or ES in simulation mode).
2. Expand Tag Management -> expand 'SIMATIC S7 PROTOCOL SUITE' -> 'Named Connections'.
3. Verify that the AS connection icons appear without exclamation marks.
4. Start WinCC Runtime and launch the 'Channel Diagnosis' tool (WinCCChannelDiagnosis.exe); verify that the Named Connection shows state 'OK' and counter packets incrementing.

Limitations and Operational Precautions

Operational precautions:
- Never configure the ES with a virtual CP 1623 in HW Config if the physical ES PC only possesses a commercial NIC; this causes Station Configurator mismatch errors.
- For fault-tolerant connections (S7-400H) over an IE General card on an ES, a 'SOFTNET-IE S7 REDCONNECT' license is required; standard SOFTNET does not support redundant communication paths.
- Always verify that TCP port 102 (ISO-on-TCP) and port 135 (RPC) are unblocked by Windows Defender Firewall across the Plant Bus.

Engineer FAQ

Does the Engineering Station need a CP 1623 to compile an OS project for a CP 1623 server?

No. The ES only compiles the project configuration into the OS database; it does not require identical physical hardware to the server.

What connection driver should be selected in the OS Compile wizard?

Always select 'Named Connections' for standard PCS 7 process communication.

Why does Tag Management show 'TCP/IP' instead of 'Named Connections'?

This occurs if the connection in NetPro was configured as a standard S7 connection over TCP/IP instead of a PCS 7 Named Connection originating from WinCC Appl.

Can an ES download PC Station configuration to an OS Server remotely?

Yes, by configuring 'Configure' and 'Download' in SIMATIC Manager Station Configuration editor, provided both nodes share identical workgroup or domain security.

What happens if Station Configurator slot indexes do not match HW Config?

The PC Station download will fail with error code 'Station configuration could not be loaded'.

Technical References

Related Tags

OS Compile
IE General
CP 1623
Named Connections
Station Configurator

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Configuring ES-to-OS Compile Parameters with IE General and CP 1623 Interfaces in PCS 7