Configuring SIMATIC IPC427D Microbox RTX Bundles in SIMATIC PCS 7 v8.2

SIMATIC IPC427D Microbox RTX bundles (such as 6ES7654-0UE23-0XX1) do not use standalone GSD files for controller integration in SIMATIC PCS 7 v8.2. If the specific bundle order number is missing from the PCS 7 'New Project Wizard', engineers can either select the predecessor IPC427C bundle (6ES7654-0UE13-0XX0) and replace the CP 5611 with the onboard CP 5622 in HW Config, or construct the SIMATIC PC Station manually by inserting WinAC RTX 2010, WinCC Application, and CP 5622 modules directly from the hardware catalog.

IPC427D Embedded RTX Bundle Architecture in PCS 7

The SIMATIC IPC427D Microbox is a compact, fanless industrial PC frequently utilized as an embedded automation station (PCS 7 AS RTX) or combined single-station automation and visualization node (AS/OS Single Station).

In PCS 7 v8.2, the IPC427D PROFIBUS bundle (6ES7654-0UE23-0XX1) integrates:
* Operating System: Windows Embedded Standard 7 (WES7) 64-bit.
* Software Controller: SIMATIC WinAC RTX 2010 (real-time sub-system running parallel to Windows).
* Fieldbus Communications: Onboard PROFIBUS interface powered by the CP 5622 communications processor chip (6GK1562-2AA00), replacing the legacy CP 5611 used in the predecessor IPC427C.

Why GSD Files Are Not Used for PC-Based Controllers

A frequent point of confusion during project creation is searching for a "GSD file" for the IPC427D:
* GSD / GSDML Purpose: GSD files define fieldbus slave or PROFINET device parameters for distributed I/O modules, drives, and valve manifolds connected downstream of a controller.
* Controller Integration: As a master controller running WinAC RTX, the IPC427D is an active SIMATIC PC Station. PC Stations are configured natively in STEP 7 HW Config using internal catalog components rather than imported GSD files.

Method 1 - Predecessor Bundle Adaptation (IPC427C to IPC427D)

If using the PCS 7 'New Project' wizard and the IPC427D bundle MLFB is absent from the drop-down list:

[PCS 7 'New Project Wizard']
   │
   ├─► Select Predecessor Bundle: 6ES7654-0UE13-0XX0 (IPC427C)
   ├─► Complete wizard setup -> Generates project with pre-configured PC Station
   │
   ▼
[Open HW Config of the Generated PC Station]
   │
   ├─► Observe: Slot 2 contains WinAC RTX 2010; Slot 4 contains CP 5611
   ├─► In Catalog, navigate to: SIMATIC PC Station -> CP-PROFIBUS -> CP 5622
   ├─► Drag & drop CP 5622 directly onto Slot 4 to replace the CP 5611
   │     • Retain existing PROFIBUS DP network address and baud rate
   └─► Save and Compile HW Config

Because WinAC RTX 2010 treats the CP 5611 and CP 5622 communication drivers identically at the software interface layer, this transition is 100% transparent to the CFC user program.

Method 2 - Manual SIMATIC PC Station Assembly in HW Config

Alternatively, engineers can configure the station manually from scratch without wizard dependencies:

Virtual Rack SlotComponent NameCatalog PathHardware / Software FunctionSlot 1Station ConfigurationAuto-insertedRepresents the physical IPC427D PC housing.Slot 2WinAC RTX 2010SIMATIC PC Station -> Controller -> WinAC RTX -> WinAC RTX 2010Real-time S7 controller executing CFC/SFC logic.Slot 3WinCC Application (Optional)SIMATIC PC Station -> HMI -> WinCC ApplicationRequired if the IPC acts as a combined AS/OS single station.Slot 4CP 5622SIMATIC PC Station -> CP-PROFIBUS -> CP 5622Master PROFIBUS DP interface connecting ET 200M racks.Slot 5IE GeneralSIMATIC PC Station -> CP-Industrial Ethernet -> IE GeneralEthernet port for engineering access and plant bus sync.

Verification

To confirm that the IPC427D RTX station is configured and operational:
1. On the physical IPC427D, open the Station Configuration Editor and confirm that Slot 2 displays WinAC RTX and Slot 4 displays CP 5622 with "RUN" status.
2. In SIMATIC Manager on the ES, download the Hardware Configuration to the IPC427D PC Station.
3. Open NetPro and download the configured network connections.
4. Download the CFC chart program to WinAC RTX; verify that the WinAC control panel displays the green RUN indicator.
5. In HW Config, switch to online mode and verify that all connected PROFIBUS DP slaves (ET 200M racks) show healthy green status without bus faults.

Limitations and Operational Precautions

Ensure that the Windows Enhanced Write Filter (EWF) or File-Based Write Filter (FBWF) on the IPC427D is disabled prior to performing initial hardware downloads or network configuration changes. If write filters are active, any downloaded configuration changes will be completely discarded upon the next IPC reboot. Re-enable write filters only after commissioning is fully validated.

Engineer FAQ

What is the difference between bundle 6ES7654-0UE13-0XX0 and 6ES7654-0UE23-0XX1?

6ES7654-0UE13-0XX0 corresponds to the older IPC427C with PCI CP 5611. 6ES7654-0UE23-0XX1 corresponds to the IPC427D with PCIe CP 5622 onboard. Both execute WinAC RTX 2010.

Why does WinAC RTX fail to enter RUN mode after downloading?

Check the memory allocation settings in WinAC RTX properties. Ensure that the NVRAM/SRAM partition on the IPC427D is configured correctly for retentive data storage.

Can I use PROFINET distributed I/O with IPC427D RTX?

Yes. WinAC RTX 2010 can use the IPC427D's onboard Intel PROFINET interface (configured as an internal PROFINET IO Controller) to control ET 200SP or ET 200M stations.

Is a separate SIMATIC NET license required for CP 5622?

When purchased as part of the pre-configured PCS 7 AS RTX Microbox bundle, all required runtime licenses (WinAC RTX and CP 5622 driver) are pre-installed on the IPC.