Exporting Hardware Configurations to SIMIT Using HWCNExport in PCS 7 and TIA Portal

In SIMATIC virtual commissioning, exporting controller hardware configurations into the SIMIT Simulation Platform is executed using the HWCNExport utility. When working with newer engineering frameworks such as TIA Portal V15.1 or modernized PCS 7 installations, the legacy standalone HWCNExport V1.03 utility encounters compatibility errors or cannot locate newer CPU types. To export hardware models for SIMIT, engineers must install SIMIT V10.0 (or SIMIT V9.1 Update 1) which provides the updated HWCNExport V2.x tool and the native TIA Portal Openness Export Add-In. This utility generates an XML hardware description that imports into SIMIT Couplings to automatically map virtual I/O signals, memory addresses, and fieldbus nodes.

HWCNExport Architectural Role in the SIMIT Simulation Ecosystem

The SIMIT Simulation Platform (6ES7910-0AA00-0YA0) is Siemens' comprehensive simulation software used for virtual commissioning, operator training systems (OTS), and hardware-in-the-loop (HIL) plant testing. SIMIT mirrors the physical behavior of plant sensors, actuators, and processes, communicating with software emulators (S7-PLCSIM, S7-PLCSIM Advanced) or physical controllers.

Before process simulation can begin, SIMIT requires a complete signal dictionary matching the automation controller's hardware address map (process image inputs, outputs, diagnostic addresses, and symbol names). Creating thousands of I/O tags manually is error-prone. The HWCNExport (Hardware Configuration Export) utility automates this interface. It extracts the entire distributed I/O topology from STEP 7 / PCS 7 HW Config or TIA Portal and compiles it into a standardized .xml file that SIMIT imports to build the simulation coupling automatically.

Version Evolution and Compatibility Constraints: V1.03 vs. V2.x

When engineers attempt to utilize older versions of HWCNExport.exe with modern engineering software, compatibility breaks down due to software architectural shifts:

HWCNExport V1.03 Limitations: Version 1.03 was engineered specifically for classic STEP 7 V5.5 and early TIA Portal V13/V14. It lacks schema definitions for newer controller hardware—such as SIMATIC ET 200SP Open Controllers, S7-1500R/H redundant CPUs, and PCS 7 V9.0 Compact Field Units (CFU). Attempting to parse modern hardware configurations throws unhandled object reference exceptions.
Transition to TIA Portal Openness Add-Ins: Starting with TIA Portal V15 and V15.1, Siemens replaced standalone executable parsing with TIA Portal Openness Add-Ins. The modern SIMIT exporter integrates directly into the TIA Portal menu (Tools -> Export to SIMIT), interacting directly with the project object model.
SIMIT Update Prerequisites: Deploying SIMIT V9.1 Upd1 or SIMIT V10.x includes the updated HWCNExport package compatible with TIA Portal V15.1, allowing seamless XML generation.

Hardware Exporter Utility and SIMIT Version Compatibility Matrix

The following table summarizes the compatibility between engineering software, exporter tools, and SIMIT platforms:

| Engineering Platform | Compatible Exporter Utility | SIMIT Platform Version | Primary Output File Format |
|---|---|---|---|---|
| PCS 7 V8.1 / V8.2 (STEP 7 V5.5) | HWCNExport.exe V1.03 / V1.04 | SIMIT V8.1 / V9.0 / V9.1 | .xml (Classic STEP 7 Schema) |
| PCS 7 V9.0 SP1 (STEP 7 V5.6) | HWCNExport.exe V2.0+ | SIMIT V9.1 Upd1 / V10.0 | .xml (Extended PROFINET Schema) |
| TIA Portal V14 SP1 | HWCNExport.exe V1.04 | SIMIT V9.1 | .xml via Openness V14 |
| TIA Portal V15.1 | SIMIT TIA Add-In / HWCNExport V2.1 | SIMIT V10.0 / V10.1 | Native XML via TIA Openness V15.1 |
| TIA Portal V16 / V17 | SIMIT TIA Export Tool V3.0 | SIMIT V10.2 / V10.3 | Modernized Multi-Controller Schema |

Step-by-Step Procedure to Export HW Config and Import into SIMIT

To export hardware configurations and instantiate them within SIMIT:

Obtain and Install the Correct Exporter Package:
- For classic PCS 7 / STEP 7 V5.5/V5.6: Ensure HWCNExport.exe is located in the SIMIT installation directory (...\Siemens\Automation\SIMIT\SIMIT Engineering\data\tools\HWCNExport\).
- For TIA Portal V15.1: Install SIMIT V10.0 / V10.1 (or download the 'SIMIT TIA Portal Add-In' from SIOS Entry ID: 109746429).
- In TIA Portal, enable the Add-In under the Add-Ins task card.
Export Hardware Configuration from the Engineering Project:
- In STEP 7 / PCS 7: Open HW Config, ensure the station compiles cleanly (Station -> Save and Compile). Close HW Config. Open Command Prompt, run HWCNExport.exe -p "C:\Path\To\Project.s7p" -s "AS01" -o "C:\Export\AS01_HW.xml".
- In TIA Portal V15.1: Right-click the PLC station in the project tree, select Export to SIMIT, choose output directory, and click Export.
- Confirm that the resulting .xml file contains all distributed I/O racks and submodules.
Import Hardware Configuration into SIMIT:
- Launch SIMIT Simulation Platform and open your simulation project.
- In the project navigation tree, expand Couplings.
- Right-click Couplings and select New Coupling; select PLCSIM, PLCSIM Advanced, or Virtual Controller.
- In the coupling configuration dialog, click the Import from HW Config icon.
- Browse to the exported AS01_HW.xml file and select Open.
- SIMIT automatically populates the I/O signal table with all physical input/output bytes, bit addresses, and tag names.
Compile and Start Simulation:
- Interconnect the imported SIMIT signals to your technological process models (valves, pumps, tanks).
- Start the simulation; verify bidirectional signal exchange with the controller.

Verification

Verify signal mapping and coupling integrity:
1. In SIMIT, open the coupling signal editor; confirm that input words (e.g., IW256) and output words (e.g., QW512) match the HW Config addresses exactly.
2. Start S7-PLCSIM (or PLCSIM Advanced) and download the controller code.
3. In SIMIT, toggle a virtual limit switch input; verify in CFC online that the channel block immediately reflects the state change.
4. In CFC, command a valve output; verify that the SIMIT actuator model receives the signal and updates the simulated position.

Limitations and Operational Precautions

Module Firmware Revisions: Ensure the firmware versions declared in HW Config match the profiles supported by the SIMIT Virtual Controller.
Specialized Module Limitations: Specialized communication cards (e.g., CP 443-5 Basic) or third-party serial cards may not generate simulated I/O signals automatically and require manual SIMIT tag creation.
Commercial Accuracy Notice: Ensure that SIMIT Simulation Platform licensing (6ES7910-0AA00-0YA0) matches the required simulated I/O channel capacity (SIMIT S, M, L, or XL).

Engineer FAQ

Where do I find the updated HWCNExport tool for modern software?

The updated exporter is bundled inside SIMIT V10.x installation packages under the tools directory and available as an official download on the Siemens support portal.

Can HWCNExport V1.03 export from TIA Portal V15.1?

No. V1.03 lacks TIA Openness V15.1 interfaces and fails when parsing modern S7-1500 or ET 200SP hardware structures.

Does SIMIT require an active PLC hardware connection to import hardware?

No. The import relies strictly on the offline XML file generated by HWCNExport from the engineering project database.

What should I do if an ET 200SP CPU fails to simulate in SIMIT?

Verify that SIMIT is updated to the latest service pack (SIMIT V10.1+) and ensure that S7-PLCSIM Advanced V2.0 SP1 or higher is selected as the coupling engine.