C135 PCS 7 (PCS7)
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Configuring NetPro S7 Fault-Tolerant Connections and Station Configurator for ES to AS-OS Downloads

Configuring NetPro S7 Fault-Tolerant Connections and Station Configurator for ES to AS-OS Downloads

To establish reliable communication for downloading engineering changes from an Engineering Station (ES) to a redundant S7-400H controller (AS) and an Operator Station (OS), you must configure an S7 Fault-Tolerant Connection in NetPro and align the Station Configuration Editor (SCE). In HW Config, configure the PC Station for the WinCC Application and communication processors (CP 1623 or IE General). In NetPro, select the WinCC Application, insert a new connection, select the S7-400H controller, and choose 'S7 fault-tolerant connection'. On the physical target stations, open Station Configurator and ensure the component names and rack index slots (e.g., Index 1: WinCC Appl., Index 2: CP 1623) match HW Config identically. Finally, compile and download NetPro configurations to both AS and PC stations.

Table of Contents

Executive Summary

In SIMATIC PCS 7 distributed architectures consisting of an Engineering Station (ES), redundant S7-400H automation systems (AS), and Operator Stations (OS Server / OS Single Station), establishing rock-solid network communication is the foundational prerequisite for system loading and runtime operation. Engineers frequently encounter download failures, greyed-out target systems, or connection aborts when attempting to transfer configurations from the ES to the AS or OS.

These communication failures typically stem from misaligned network configurations in NetPro, mismatched component index assignments in the local Station Configuration Editor (Station Configurator / SCE), or improper selection of connection types. While standard S7 connections suffice for non-redundant controllers, S7-400H systems require 'S7 fault-tolerant connections' configured directly from the WinCC Application object to both redundant CPUs. This guide details the complete configuration process in NetPro, explains Station Configurator index matching, outlines PG/PC interface parameters, and provides step-by-step verification commands to guarantee flawless multi-station engineering downloads.

Architecture and Fundamental Mechanics

PCS 7 utilizes the SIMATIC NET PC Station communication architecture to manage inter-station messaging across the Plant Bus (Industrial Ethernet):
1. Virtual PC Station Model: In HW Config, each physical computer (ES, OS Server, OS Client) is represented as a 'SIMATIC PC Station'. The station contains a virtual rack with indexed slots:
* Index 1: User application (e.g., WinCC Appl. or WinCC Appl. (stby) for redundant servers).
* Index 2 / 3: Physical or virtual communication processors (e.g., CP 1623, CP 1613, or IE General with Softnet-IE).
2. Station Configuration Editor (SCE): On each physical PC, the Station Configurator represents the local runtime image of this virtual rack. If the station name, component names, or slot index numbers in SCE do not match HW Config with character-for-character precision, SIMATIC Manager cannot route download packets to the station.
3. NetPro Connection Routing: NetPro compiles the logical routing tables and network endpoints. For high-availability S7-400H systems, standard S7 connections cannot maintain bumpless communication across CPU failover. By selecting 'S7 fault-tolerant connection', NetPro configures four underlying communication sub-paths between redundant CPs in the AS and redundant CPs (or softnet interfaces) in the OS.
4. Download Sequencing: NetPro network configuration (XDB file or direct download) must be downloaded to the PC Station before attempting to download the WinCC OS project. Once the PC Station and NetPro connections are active, the ES communicates with the AS and OS via the local PC Internal.local.1 or configured network adapter.

Step-by-Step Implementation Procedure

Step 1: Configure the SIMATIC PC Station in HW Config

  1. In SIMATIC Manager, open your PCS 7 project or multiproject.
  2. In the component view, insert a SIMATIC PC Station.
  3. Rename the PC Station object so its name exactly matches the Windows computer name of the target machine (e.g., OS_SRV01).
  4. Open the PC Station in HW Config:
    * In Slot 1, insert WinCC Application (or WinCC Appl. (stby) for the standby server).
    * In Slot 2, insert the appropriate network interface: CP 1623 (for Hardnet) or IE General (for standard Ethernet adapters with Softnet).
  5. In the network interface properties, assign the static IP address and subnet mask of the Plant Bus, and attach it to the Industrial Ethernet network object.
  6. Save and compile HW Config.

Step 2: Configure the S7 Fault-Tolerant Connection in NetPro

  1. In SIMATIC Manager or HW Config, click the NetPro toolbar icon to launch the network configuration tool.
  2. In NetPro, select the WinCC Appl. object in the PC Station (Slot 1).
  3. In the lower connection table, right-click an empty row and select Insert New Connection.
  4. In the dialog, expand the tree, select the target S7-400H controller, and select the CPU object.
  5. In the 'Type' dropdown, select S7 fault-tolerant connection.
  6. Click Apply / OK to open the connection properties.
  7. In the Connection Properties dialog, confirm that both sub-connections (connecting to CPU 0 and CPU 1 via their respective CP 443-1 cards or onboard PN interfaces) are displayed and configured.
  8. Note the connection name (e.g., S7_Connection_1). This connection name is automatically used by the OS compiler.
  9. In NetPro, select Network > Save and Compile > Compile and check everything.

Step 3: Configure the Physical Station Configuration Editor (SCE)

  1. On the physical OS or ES computer, open the Station Configuration Editor (Station Configurator) from the Windows system tray or Start menu.
  2. Click the Station Name button and ensure the station name matches the HW Config PC Station name identically.
  3. Add components to match HW Config slot allocations:
    * In Slot 1: Click Add, select WinCC Application, and click OK.
    * In Slot 2: Click Add, select your network card (IE General or CP 1623), and click OK.
  4. Ensure the status indicators for all configured components show a green checkmark or 'RUN'.

Step 4: Configure the PG/PC Interface on the ES

  1. On the Engineering Station, open Windows Control Panel and launch Set PG/PC Interface.
  2. Set the 'Access Point of the Application' to S7ONLINE (STEP 7).
  3. Set the interface parameter assignment to PC Internal.local.1 (if downloading via Station Configurator) or to your dedicated network adapter (e.g., TCP/IP -> [NetworkCard]).
  4. Click OK to apply.

Step 5: Download NetPro Configuration and Programs

  1. In NetPro, select the S7-400H controller and click Download to Current Selection to transfer connection tables to the AS.
  2. Select the PC Station in NetPro and click Download to Current Selection to download the PC Station configuration to the physical machine.
  3. In SIMATIC Manager, perform an OS Compile and download the OS project to the target PC Station.

Verification

  1. In the physical Station Configurator on the OS, verify that both the WinCC Application and network interface display the status 'RUN' without diagnostic error badges.
  2. Launch SIMATIC Shell on the ES and OS: verify that both stations appear in the station list and that the security handshake succeeds.
  3. In SIMATIC Manager, right-click the S7 Program or CFC charts, select Target System > Download, and verify that the target S7-400H CPU is reached immediately.
  4. In WinCC Explorer on the OS, open Tools > Channel Diagnosis: verify that the S7 fault-tolerant connection displays status 'Ready' with green checkmarks indicating active communication to both S7-400H partner CPUs.

Limitations and Operational Precautions

  1. S7 fault-tolerant connections require appropriate hardware communication licenses: Softnet-IE S7 REDCONNECT or Hardnet CP 1623 with S7-REDCONNECT license package.
  2. Station Configurator component names and slot indexes must match HW Config with absolute precision; any discrepancy will cause error 15124 or prevent station identification.
  3. Do not run Station Configurator configuration changes while WinCC Runtime is active on the target station.
  4. Network firewalls must allow SIMATIC NET ports (including TCP port 102 for S7 communication and UDP port 161/162 for SNMP).

Engineer FAQ

Why can't I use a standard S7 connection for an S7-400H controller?

A standard S7 connection connects to only one CPU. If that CPU stops or fails, communication halts. An S7 fault-tolerant connection establishes redundant communication sub-paths across both CPUs, ensuring bumpless failover.

What is the function of Station Configurator?

The Station Configurator (Station Configuration Editor) acts as the virtual backplane on a PC station, mapping physical network adapters and software applications (WinCC) to logical slots recognized by SIMATIC Manager.

Why does the PC Station download fail with 'Station not obtainable'?

This occurs when the computer name does not match the HW Config PC Station name, the PG/PC interface is incorrectly set, or SIMATIC Shell network adapters are misconfigured.

Do I need an S7-REDCONNECT license for an S7 fault-tolerant connection?

Yes. Operating an S7 fault-tolerant connection from a PC Station requires a SIMATIC NET S7-REDCONNECT license (for Softnet or Hardnet). Consult an authorized Siemens distributor or the Siemens Industry Mall for exact license requirements.

Can I download NetPro connections while the S7-400H is running in redundant mode?

Yes. S7-400H supports downloading NetPro connections and hardware configuration changes in RUN (CiR - Configuration in RUN) mode without stopping the controller.

Technical References

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Related Tags

  • NetPro
  • S7-400H
  • Fault-Tolerant Connection
  • Station Configurator
  • PC Station
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