Implementing Configuration in RUN (CiR) with Third-Party Field Devices in SIMATIC PCS 7

In SIMATIC PCS 7, Configuration in RUN (CiR) supports third-party PROFIBUS-DP and PROFINET devices (such as SEW Eurodrive, Danfoss, or Festo valve terminals) provided the devices use standard-compliant GSD/GSDML files and do not alter master bus timing parameters. To deploy third-party hardware without stopping the controller, pre-allocate a CiR object on the master system in HW Config with ample slave and I/O address reserves, insert the third-party slave into the reserved address band, and execute Download in RUN.

Principles of Configuration in RUN (CiR) in PCS 7

In continuous process industries (chemicals, pharmaceuticals, oil & gas), stopping an S7-400 or S7-410 automation station to add an actuator, drive, or remote I/O station incurs severe financial and operational penalties. SIMATIC PCS 7 provides Configuration in RUN (CiR), allowing hardware configuration changes while the controller continues executing user logic without interrupting process control.

CiR functions at the master communication processor layer (e.g., CPU internal DP port or CP 443-5 Extended). When an engineer activates CiR, the system creates a virtual placeholder—the CiR Object—which pre-allocates:
1. A pool of unassigned PROFIBUS-DP station addresses (e.g., reserving addresses 20 to 60).
2. A reserved memory block of logical input and output addresses (e.g., reserving 2048 input and 2048 output bytes).
3. A worst-case bus cycle calculation based on token rotation time (Ttr).

Because CiR operates at the standard PROFIBUS (IEC 61158) protocol level, it is vendor-agnostic. Any third-party field device (e.g., an SEW Eurodrive Movidrive frequency inverter or Festo CPX valve manifold) can be introduced via CiR, provided it integrates via standard GSD files without modifying the master bus parameters.

Third-Party Device Compatibility and CiR Boundary Matrix

Evaluate device eligibility and technical constraints before attempting online hardware additions:

Device Category / ManufacturerIntegration MechanismPermissible via CiR?Constraints and Boundary ConditionsStandard Third-Party VFD (e.g., SEW, Danfoss)Standard PROFIBUS DP-V0/V1 GSD fileYesSlave address and PZD I/O bytes must fit within pre-allocated CiR reservesThird-Party Valve Manifold (e.g., Festo CPX)Modular GSD fileYesModule sub-slots must be configured cleanly within the reserved I/O spaceIntelligent DP Slave (I-Slave, S7-300 / S7-1200)GSD / Coupling blockYesPartner CPU must be powered and initialized before activating cyclic exchangeHardware Requiring Master Bus Parameter ChangesNon-standard baud rates or custom TslotProhibitedAltering master timing parameters requires a CPU STOP; halts entire busNon-Redundant Device on Fault-Tolerant BusDirect single DP line to H-systemConditionalRequires Y-Link gateway (6ES7197-1LA12-0XA0) to maintain H-redundancy

Procurement notice: Always confirm device GSD certification with authorized equipment vendors before engineering CiR expansions.

Configuring the CiR Object and Address Reserves in HW Config

CiR capability must be pre-planned during initial engineering before the plant enters RUN:

Enable CiR on the Master System:
* Open HW Config on the PCS 7 Engineering Station.
* Right-click the PROFIBUS-DP master system line and select Properties - PROFIBUS.
* Under the Network Settings tab, click Options.
* Check the box: Activate Configuration in RUN (CiR).
Configure CiR Reserves:
* Specify the number of reserved DP slave addresses (e.g., Reserved station addresses: 15).
* Specify the memory reserve:
- Input bytes reserve: 1024 bytes.
- Output bytes reserve: 1024 bytes.
- Verify the maximum permissible bus interruption time (typically < 100 ms to prevent trips on field watchdogs).
Save, Compile, and Execute Initial Download:
* Compile and download the initial project with the CPU in STOP. The master system is now CiR-ready for all future online expansions.

Step-by-Step Procedure to Add Third-Party Slaves While in RUN

To add a third-party device (e.g., an SEW inverter) to an operating plant:

Install Certified GSD File:
* In HW Config, select Options > Install GSD File.
* Browse to the verified GSD file supplied by the manufacturer (e.g., SEW_000B.GSD).
* Update the hardware catalog.
Insert and Parameterize Device:
* Locate the third-party device under PROFIBUS-DP > Additional Field Devices.
* Drag the slave onto the CiR-enabled DP master system.
* Assign an address from the pre-allocated CiR address reserve band.
* Parameterize the required cyclic process data modules (e.g., 3 PZD words in / 3 PZD words out).
Verify CiR Consistency:
* In HW Config, select Station > Check CiR Compatibility.
* The compiler verifies that the added slave consumes only available CiR reserves and does not violate bus timing.
* A prompt confirms: The configuration can be downloaded in RUN.
Execute Download in RUN:
* Select PLC > Download.
* Confirm the download prompt: The controller freezes I/O briefly (< 100 ms), updates system data blocks, activates the new slave, and resumes normal execution.

Verification

Verify that the third-party device is active:
1. In HW Config Online, confirm that the newly added third-party slave shows a green checkmark with zero bus fault (BF) indicators.
2. In CFC Editor, connect technological blocks (e.g., FbDrive or PZD_In/Out) to the new peripheral addresses (PIW / PQW).
3. Download CFC changes only: Confirm that cyclic data exchange (speed setpoint and actual status) commences immediately.

Limitations and Operational Precautions

Once all pre-allocated CiR slave addresses or I/O bytes are consumed, no further devices can be added without expanding the CiR object, which requires an offline recompilation and controller STOP.
If a third-party slave is powered off or miswired when downloaded in RUN, the CPU triggers OB 86 (Rack Failure). Ensure the field device is physically powered and terminated before downloading.
Never modify the PROFIBUS transmission rate (baud rate) via CiR; changing baud rate interrupts the entire plant bus.

Engineer FAQ

Can I delete an existing third-party device using CiR?

Yes. You can delete an unused slave or remove I/O modules in RUN. The freed address space returns to the available CiR memory pool.

What happens if the third-party GSD file contains invalid parameters?

The HW Config consistency check will catch syntax errors. However, if the device rejects parameters during online startup, the controller flags an OB 82 diagnostic event while remaining in RUN.

Does PROFINET support CiR for third-party devices?

Yes. In PCS 7 V8.1 and higher, PROFINET IO supports CiR (Configuration in RUN), allowing third-party GSDML devices to be added dynamically over Industrial Ethernet.