Integrating S7-1500 PLCs into PCS 7 V8.1 Hardware Architectures and Communication Methods

In SIMATIC PCS 7 V8.1, SIMATIC S7-1500 controllers cannot be added to the STEP 7 HW Config catalog or programmed using PCS 7 CFC and the Advanced Process Library (APL). SIMATIC PCS 7 is exclusively architected around the S7-400 and AS 410 controller families. However, an S7-1500 PLC (programmed in TIA Portal) can be integrated into a PCS 7 facility as an autonomous package unit or third-party subsystem using four standardized communication paths: Industrial Ethernet S7 Communication (PUT/GET or BSEND/BRECV) between S7-400 and S7-1500, Open User Communication (Modbus TCP or raw TCP/IP), direct WinCC OS visualization via the SIMATIC S7-1200/S7-1500 Channel driver, or hardware coupling via a PN/PN Coupler (6ES7158-3AD10-0XA0).

Executive Summary

Process automation engineers modernizing facilities often seek to integrate modern modular equipment—such as skids, centrifuges, or water treatment packages controlled by SIMATIC S7-1500 PLCs—into existing SIMATIC PCS 7 V8.1 distributed control systems. Beginners frequently attempt to locate S7-1500 hardware support packages (HSPs) or GSD files to insert the S7-1500 CPU directly into the PCS 7 STEP 7 HW Config catalog. This technical guide clarifies the foundational architectural boundaries of PCS 7, explains why S7-1500 CPUs cannot be native PCS 7 automation stations, and details the four certified communication architectures used to exchange data between S7-1500 package units and PCS 7.

Architecture and Fundamental Mechanics

The architectural boundary between SIMATIC PCS 7 and SIMATIC S7-1500 encompasses fundamental engineering differences:
1. PCS 7 Controller Exclusivity:
- SIMATIC PCS 7 is built upon the classic STEP 7 S7-400 / CPU 410 operating system kernel.
- System features—including Advanced Process Library (APL), automatic module driver generation (GenModDrv), Configuration in RUN (CiR), and Plant Hierarchy (TH)—are strictly compiled for S7-400 microcode. S7-1500 controllers operate on modern TIA Portal firmware and cannot execute PCS 7 CFC execution tasks.
2. Four Certified Integration Architectures:
- Architecture A: AS-to-AS S7 Communication (Controller Level):
An S7-400 controller exchanges data blocks with an S7-1500 over Industrial Ethernet using configured S7 connections with PUT (FB15) / GET (FB14) or BSEND (FB12) / BRECV (FB13). In TIA Portal, 'Permit access with PUT/GET communication from remote partner' must be enabled in the S7-1500 CPU protection settings.
- Architecture B: Direct WinCC OS Integration (HMI Level):
The PCS 7 WinCC OS Server communicates directly with the S7-1500 over Industrial Ethernet using the dedicated SIMATIC S7-1200, S7-1500 Channel in WinCC Tag Management, bypassing the S7-400 AS entirely.
- Architecture C: Hardware Coupling via PN/PN Coupler:
A physical PN/PN Coupler (6ES7158-3AD10-0XA0) links the PROFINET IO network of the S7-1500 with the PROFINET network of the AS 410, exchanging high-speed deterministic I/O bytes.
- Architecture D: Open User Communication / Modbus TCP:
Controllers exchange data using standard industrial Modbus TCP blocks (MB_RED_CL or TSEND/TRCV).

Step-by-Step Implementation Procedure

Configure S7-1500 in TIA Portal for S7 Communication:
a. Open the S7-1500 project in TIA Portal.
b. In CPU Properties, navigate to Protection & Security -> Connection mechanisms.
c. Check the box: 'Permit access with PUT/GET communication from remote partner'.
d. In the DB holding data for PCS 7, open DB Properties: uncheck 'Optimized block access' to ensure standard byte/word offsets (e.g., DB100.DBW0).
e. Compile and download to the S7-1500 CPU.
Configure Unspecified S7 Connection in PCS 7 NetPro:
a. Open SIMATIC Manager on the PCS 7 Engineering Station and open NetPro.
b. Select the S7-400 CPU.
c. Insert a new connection: select 'Partner: Unspecified', Type: S7 connection.
d. In connection properties, enter the physical IP address of the S7-1500 CPU.
e. Under 'Address Details', set Partner Rack = 0, Partner Slot = 1 (standard for S7-1500 CPUs).
f. Save and compile NetPro and download connection tables to the S7-400 AS.
Program PUT/GET Logic in PCS 7 CFC:
a. Open a CFC chart in the S7-400 program.
b. Instantiate GET (FB14) and PUT (FB15) from the S7 Communication Library.
c. Connect the NetPro Local ID to parameter ID.
d. Configure data pointer strings: e.g., ADDR_1 := P#DB100.DBX0.0 BYTE 40.
e. Trigger cyclic polling using a pulse generator (TimerP or clock memory bit).
Alternative: Add S7-1500 Channel Directly to WinCC OS:
a. Open WinCC Explorer on the ES for the target OS project.
b. In Tag Management, right-click and select Add new driver -> SIMATIC S7-1200, S7-1500 Channel.
c. Right-click the channel unit (OMS+), select New Connection, and enter the S7-1500 IP address.
d. Create WinCC tags mapped to the S7-1500 data blocks for direct operator faceplate visualization.

Verification

In CFC online, monitor the GET block: confirm DONE pulses true and ERROR = 0.
Modify a test variable in the S7-1500 DB via TIA Portal watch table: verify the value appears instantly in the S7-400 receiving DB in SIMATIC Manager.
In WinCC Runtime, confirm that tags assigned to the S7-1500 update with healthy signal quality (16#80).

Limitations and Operational Precautions

S7-1500 tags cannot generate automatic PCS 7 APL block icons or OS messages via the standard OS Compile Wizard; alarms and faceplates for S7-1500 data must be engineered as standard WinCC tags.

Engineer FAQ

Can I add an S7-1500 CPU directly to the PCS 7 HW Config catalog?

No. SIMATIC PCS 7 exclusively supports S7-400 and AS 410 controllers; S7-1500 hardware cannot be inserted into the PCS 7 AS catalog.

What setting in TIA Portal is required for S7-400 PUT/GET communication?

You must enable 'Permit access with PUT/GET communication from remote partner' in the S7-1500 CPU protection settings.

Why must 'Optimized block access' be disabled on the S7-1500 DB?

S7-400 PUT/GET blocks require fixed byte/word offset addresses, which are only available when optimized block access is disabled in TIA Portal.

Can WinCC in PCS 7 read tags directly from S7-1500?

Yes. WinCC supports the 'SIMATIC S7-1200, S7-1500 Channel' driver to read tags directly over Industrial Ethernet.

What hardware rack and slot settings are used for S7-1500 in NetPro?

In NetPro, configure Partner Rack = 0 and Partner Slot = 1 for S7-1500 controllers.

Technical References

Related Tags

S7-1500
PCS 7 V8.1
S7 Communication
PUT GET
TIA Portal
Package Units

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Integrating S7-1500 PLCs into PCS 7 V8.1 Hardware Architectures and Communication Methods