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How to Add and Configure Additional ET 200M Remote I/O Stations on PROFIBUS DP in SIMATIC PCS 7

How to Add and Configure Additional ET 200M Remote I/O Stations on PROFIBUS DP in SIMATIC PCS 7

In SIMATIC PCS 7 V7.1, adding an additional ET 200M remote I/O station to an existing S7-400 PROFIBUS DP master line requires setting the hardware address on the IM 153-2 interface module DIP switches and configuring the station in STEP 7 HW Config. Rather than building the station from scratch, engineers can copy an existing healthy ET 200M station in HW Config and paste it onto the PROFIBUS master line. Once pasted, adjust the PROFIBUS DP address to match the DIP switches, configure active bus modules for hot swapping, assign contiguous I/O peripheral addresses, and execute a CFC compilation with 'Generate Module Drivers' checked.

Table of Contents

ET 200M Remote I/O Architecture and IM 153-2 Module Features

The SIMATIC ET 200M distributed I/O system is the foundational remote I/O platform for PCS 7 V7.1:
* The Interface Module: Powered by the IM 153-2 High Feature (6ES7153-2BA02-0XB0 / 6ES7153-2BA10-0XB0).
* Modular Capacity: Accommodates up to 8 S7-300 I/O signal modules per single IM, or up to 12 modules with extended active backplane rails.
* Process Automation Features:
* Supports Hot Swapping in RUN (Module exchange under voltage without tripping controller).
* High-precision time stamping of digital inputs (1 ms accuracy for sequence of events SOE).
* Compatible with standard and intrinsically safe (Ex) signal modules.

Setting Physical PROFIBUS DP Addresses via Hardware DIP Switches

Before mounting the IM 153-2 on the DIN rail:

  1. Locate Address Switch:
    * Open the front door of the IM 153-2.
    * Locate the 8-position DIP switch labeled DIP / ADDRESS.
  2. Binary Addressing Rules:
    * The switches represent binary values: 1, 2, 4, 8, 16, 32, 64.
    * Switch 8 is reserved or used for diagnostic modes.
    * Example: To set PROFIBUS address 14:
    • Turn ON switch 2, switch 4, and switch 8 (2 + 4 + 8 = 14).
  3. Power Cycle Requirement:
    * DIP switch changes are read only during initial power-up; if the switch is adjusted while powered, cycle the DC 24V supply to register the new address.

HW Config Station Insertion: Copy-Paste vs Catalog Workflow

To integrate the new station into the PCS 7 project:

  1. The Fast Copy-Paste Method:
    * In HW Config, select an existing, functioning ET 200M station on the PROFIBUS line.
    * Press Ctrl + C (Copy).
    * Click on the PROFIBUS DP master line: press Ctrl + V (Paste).
    * Double-click the pasted station: assign the new PROFIBUS DP address (e.g., 14).
  2. Adjust Module Configuration:
    * In the lower rack configuration table, replace, delete, or add specific analog (SM 331) and digital (SM 321, SM 322) I/O modules matching the physical installation.
    * Verify that I/O start addresses do not overlap with existing hardware.
  3. Save and Compile HW Config:
    * Execute Station > Save and Compile. Confirm System Data Blocks (SDBs) update without errors.

Active Bus Module Configuration and Hot Swapping in RUN

To enable modules to be removed and inserted while the plant is live in RUN:

  • Hardware Prerequisite:
  • The physical rack must use Active Bus Modules (6ES7195-7HB00-0XA0 for single IM / 6ES7195-7HD10-0XA0 for I/O modules) mounted on an active DIN rail.
  • HW Config Setting:
  • Double-click the IM 153-2 in HW Config: open the Operating Parameters tab.
  • Ensure the checkbox Replace modules during operation (Hot Swapping) is checked.
  • CFC Driver Compilation:
  • In SIMATIC Manager, open CFC: execute Chart > Compile > Changes Only with Generate Module Drivers checked.
  • The compiler automatically creates diagnostic blocks (MOD_D1) for the new station.

Comparison of ET 200M Expansion Methods in PCS 7

The table below compares engineering techniques for adding remote I/O stations in PCS 7.

Engineering TechniqueConfiguration SpeedRisk of Address CollisionModule Driver AutomationRecommended Use CaseCopy-Paste Existing StationVery Fast (2 minutes)Low (HW Config auto-increments)Full automated generationStandard Best PracticeManual Catalog Drag-and-DropModerate (10 minutes)LowFull automated generationGreenfield unique layoutsGSD File ImportSlowModerateNo driver generator supportNon-Siemens third-party slavesH-CiR (Configuration in RUN)Requires H-SystemLowFull automated generationLive plant expansions without stop

Verification

To confirm that the new ET 200M station is communicating properly:
1. Power up the physical ET 200M station.
2. Verify that the IM 153-2 BF (Bus Fault) and SF (System Fault) LEDs extinguish, and ON remains steady green.
3. In HW Config, select PLC > Monitor/Modify: verify that peripheral input channels read live field voltages.
4. In CFC, interconnect a channel address (e.g., IW 600) to Pcs7AnIn: compile and download changes.
5. In CFC Test Mode, confirm that Pcs7AnIn.Out.Value reports live field telemetry with signal status 16#80 (Good).

Limitations and Operational Precautions

  • Never download a full hardware configuration to a standard single S7-400 CPU while the plant is running; downloading HW Config requires stopping the CPU unless using an S7-400H redundant system with H-CiR.
  • Ensure the PROFIBUS bus cable is properly terminated with active bus terminators at both physical ends of the segment.
  • Do not exceed the maximum allowable PROFIBUS DP cable length for the configured baud rate (e.g., max 100 meters at 12 Mbps without RS-485 repeaters).
  • Always validate final hardware ordering numbers, active bus modules, and software licensing against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Why does the IM 153-2 have a steady red BF LED after setting the DIP switch?

The controller cannot find the station. Verify that the DIP switch binary calculation matches the address in HW Config, check that the DC 24V supply was power-cycled after changing the DIP switch, and inspect PROFIBUS connectors.

Can I add an ET 200M station without stopping an S7-400H controller?

Yes. On redundant S7-400H systems, hardware can be added dynamically in RUN mode using the Hardware Configuration in RUN (H-CiR) workflow.

What happens if 'Replace modules during operation' is unchecked?

If an I/O module is pulled out while hot swapping is disabled, the entire ET 200M backplane communication halts, dropping all 8 modules on the rack.

Technical References

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Related Tags

  • ET 200M
  • IM 153-2
  • PROFIBUS DP
  • HW Config
  • Hot Swapping
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