Configuring SIMATIC PDM HART Communication via S7 Data Record Routing across Industrial Ethernet and S7-400H

To establish SIMATIC PDM HART communication with field transmitters connected to ET 200M HART modules via S7 Data Record Routing (Ethernet -> CP 443-1 -> S7-400H -> PROFIBUS DP -> IM 153-2 -> AI 8x12Bit HART), every intermediary transit node must support Data Record Routing (DS-Routing). The failure to connect is caused by an uncompiled routing path in NetPro, a missing PG/PC assignment, or an incompatible IM 153-2 interface module. In NetPro, assign the PG/PC station to the Ethernet subnet, compile and download the network connections to all CPUs and CPs, and verify the IM 153-2 is a High Feature module (6ES7153-2BA02-0XB0 or higher).

S7 Data Record Routing (DS-Routing) Architecture for HART Field Devices

In modern process automation, field instruments are parameterized and diagnosed digitally from a centralized Engineering Station (ES) using SIMATIC Process Device Manager (PDM). In architectures with redundant S7-400H controllers, the ES connects via Industrial Ethernet, while field devices communicate via 4-20 mA with superimposed HART modulation connected to distributed I/O modules on PROFIBUS DP.

To communicate with a HART transmitter across multiple network tiers, the engineering system utilizes S7 Data Record Routing (DS-Routing). PDM packages HART commands into S7 data records (SFB52/53 RDREC/WRREC), transports them over Industrial Ethernet to the CP 443-1, routes them through the S7-400H backplane, transmits them across PROFIBUS DP to the ET 200M IM 153-2, and delivers them to the HART AI module.

Hardware Prerequisites: S7-400H, CP 443-1, and ET 200M IM 153-2

For seamless data record routing, every participating hardware node must support DS-Routing in its firmware:

S7-400H CPU: E.g., 6ES7417-4HL04-0AB0 (Firmware V4.0 or higher supports DS-Routing natively).
Ethernet CP: E.g., 6GK7443-1EX11-0XE0 / 6GK7443-1EX20-0XE0 (Supports data record routing over S7 protocol).
ET 200M Interface Module: Must be an IM 153-2 High Feature module (6ES7153-2BA02-0XB0 or higher). Standard IM 153-1 modules do not support HART data record routing!
Analog Input Module: E.g., 6ES7331-7TF01-0AB0 (SM 331, AI 8x0/4...20mA HART), with HART protocol enabled in HW Config channel parameters.

Why NetPro Network Compilation and Download Are Mandatory

A frequent stumbling block is configuring hardware in HW Config but omitting network routing compilation:

The S7-400 CPU does not dynamically discover network routes; it relies on internal Routing Tables generated by NetPro.
The Engineering Station must be declared as a PG/PC Station in STEP 7 and assigned to the identical Industrial Ethernet subnet as the CP 443-1.
In NetPro, executing Network -> Save and Compile builds the sub-network routing database.
This routing information must be downloaded to the S7-400H CPUs and CP 443-1 communication processors. Without this download, the CP severs incoming PDM routing telegrams with an 'Address unreachable' error.

Configuring Set PG/PC Interface and PDM Communication Path

On the Engineering Station operating system:

Open Set PG/PC Interface in Windows Control Panel.
Ensure the Access Point S7ONLINE (STEP 7) is assigned to the physical network card communicating with the CP 443-1 (e.g. TCP/IP -> Intel Gigabit... or ISO Ind. Ethernet).
In the STEP 7 project, open the PG/PC object properties -> Interfaces. Assign the network adapter to the Industrial Ethernet subnet and click Assign.
In SIMATIC PDM, open the field instrument's Object Properties -> Communication. Verify the connection type is configured as S7 Routing.

Hardware Compatibility and Firmware Prerequisite Matrix

The following table details compatibility requirements for HART data record routing in S7-400H architectures:

Hardware ComponentOrder Number (MLFB)Minimum Required FirmwareData Record Routing CapabilityS7-400H Central Processing Unit6ES7417-4HL04-0AB0V4.0.0Supported across backplane busIndustrial Ethernet CP6GK7443-1EX11-0XE0V2.0.0Supported via S7 communicationET 200M Interface Module6ES7153-2BA02-0XB0V4.0.0Supported (High Feature required)ET 200M Standard Interface6ES7153-1AA03-0XB0AnyNOT Supported (Cannot route HART records)HART Analog Input Module6ES7331-7TF01-0AB0V1.0.0Supported (8 channels HART)SIMATIC PDM Software6ES7658-3...V6.1 / V8.0 / V9.0Requires PDM Routing Option license

Step-by-Step Configuration Workflow for PDM S7 Routing

Follow this sequence to establish end-to-end PDM communication:

Audit HW Config: In STEP 7, open HW Config for the ET 200M station. Confirm 6ES7153-2BA02-0XB0 is selected. In the properties of the 6ES7331-7TF01-0AB0 module, open the HART tab and enable HART protocol on the specific channel.
Configure PG/PC in NetPro: Open NetPro. If missing, insert a PG/PC station. Open its properties, add an Ethernet interface, and link it to the same Ethernet subnet as CP 443-1.
Compile NetPro: In NetPro, click Network -> Save and Compile (select Compile and check everything). Ensure 0 errors.
Download Network to S7-400H: Select the CPU and CP 443-1 objects in NetPro and perform Target System -> Download to Current Project -> Selected Objects.
Assign S7ONLINE: Open Set PG/PC Interface. Assign S7ONLINE to your active network adapter.
Launch PDM: In SIMATIC Manager Process Device Plant View, right-click the transmitter -> Open Object. Confirm online communication initiates.

Verification

Confirm successful HART routing through these diagnostic steps:

PDM Online Identification: In PDM, execute Device -> Upload to PG/PC. Confirm the device tag, manufacturer, and firmware version upload.
Measured Value Live View: Open the PDM Online View. Confirm process variables (PV, SV, TV, QV) and loop current (mA) update dynamically.
LED Diagnostic on Module: Verify the green RUN LED on the 6ES7331-7TF01-0AB0 is solid and channel fault LEDs are unlit.
Module Diagnostic Buffer: In HW Config, select the AI module and click Module Information. Confirm zero channel parameterization faults.

Limitations and Operational Precautions

Keep these operational precautions in mind:

PDM Bandwidth Restrictions: HART over PROFIBUS uses low-speed FSK modulation (1200 baud at the instrument level). Reading complex calibration matrices can take several minutes per instrument; do not poll multiple devices simultaneously during critical production phases.
Redundant PROFIBUS Line Switching: During an S7-400H master-reserve failover, active PDM communication sessions may momentarily disconnect and require a retry.
Commercial Accuracy Disclaimer: Software order numbers (MLFBs), package structures, and hardware capacity prerequisites vary across PCS 7 versions and hardware platforms. System integrators must confirm exact software entitlements and licensing requirements against the official Siemens Catalog CA 01 and obtain an authorized Siemens distributor quotation prior to purchasing.

Engineer FAQ

Does S7 Data Record Routing require programming in CFC or user logic?

No. S7 Data Record Routing is handled entirely at the system firmware level by the CPU, CP, and IM modules without requiring CFC blocks or user code.

What PDM license is necessary for S7 routing?

In addition to base SIMATIC PDM, the engineering station must have the 'SIMATIC PDM Routing' software option license installed in Automation License Manager.