Configuring PCS7 Communication with Redundant S7-1500R/H via PROFINET

Integrating a SIMATIC PCS 7 AS410 (S7-400H) process automation system with a redundant S7-1500R/H controller over PROFINET requires coordinated engineering across two tool environments: SIMATIC Manager / PCS 7 for the H-station side and TIA Portal for the S7-1500R side. The integration pattern is well-supported in PCS 7 V9.0 SP2 and later with TIA Portal V16/V17, but several engineering constraints must be respected: the redundant CPU is addressed through its System IP, the PROFINET ring must use MRP with a SCALANCE redundancy manager, and the S7 connection type must be configured as a Fault-tolerant S7 connection on the AS410 side.

1. Architecture Overview

The reference architecture pairs the high-availability PCS 7 controller (AS410 / S7-400H) with a redundant S7-1500R or S7-1500H station over a single PROFINET ring. Both CPU pairs present a single logical interface to the upper-level system by means of a shared System IP address, which is moved from the active primary CPU to the backup CPU when a redundancy event occurs. The AS410 sends and receives process data through two independent PROFINET interfaces on the S7-400H side and a single System IP on the S7-1500R side.

1.1 Logical Topology

• AS410 pair: S7-400H with two CP443-1 modules (PROFINET IO) and one or two Sync modules for redundancy. Two PROFINET interfaces connect to ring A and ring B.
• S7-1500R/H pair: Two CPUs (e.g., 1515R-2 PN or 1517H-4 PN) connected via PROFINET ring. The System IP is bound to the active CPU. Each CPU has its own PROFINET interface and a separate MRP-capable switch port.
• SCALANCE XC/XB/XR switch: Acts as the MRP redundancy manager in the PROFINET ring. Connect one device as the MRP manager, all others as MRP clients.
• Optional OS server / Engineering station: Used for PCS 7 Operator Station and WinCC communication.

1.2 Connection Model

The PCS 7 side terminates the S7 fault-tolerant connection on a CP443-1 EX30 or higher. The S7-1500R side terminates the connection on the PROFINET interface of either CPU, but from the AS410 perspective it appears as a single partner identified by the System IP. Fault tolerance is implemented at the S7 application layer (S7 fault-tolerant connection), not at the PROFINET ring level.

2. System Components and Prerequisites

3. PROFINET Ring Topology with MRP

The PROFINET ring is the physical foundation of S7-1500R/H redundancy. Configure a closed PROFINET ring with the SCALANCE switch as the MRP manager.

3.1 Ring Construction

1. Connect Port 1 of CPU 0 to Port 1 of the SCALANCE switch.
2. Connect Port 1 of CPU 1 to the next SCALANCE port.
3. Connect the CP443-1 modules of the AS410 to two additional ports of the SCALANCE switch.
4. Close the ring by wiring back to an unused SCALANCE port (not required if star topology is used, but a closed ring is required for MRP).

3.2 MRP Configuration

Inside TIA Portal, navigate to Devices & Networks > Topology view. Define the ring ports on each device. For the SCALANCE manager, set MRP role = Manager; for both CPUs and the CP443-1 set MRP role = Client. The MRP manager must support MRP-Rev1 or higher; do not enable MRPD or MRP-Auto Manager on the manager port that is connected to a CPU ring port.

4. S7-1500R/H System IP Configuration (TIA Portal)

The System IP is the single IP address visible to external partners. When the primary CPU fails, the System IP moves to the backup CPU. This is what AS410 will use to reach the redundant station.

4.1 Enable System IP in TIA Portal

1. Open the S7-1500R device configuration in TIA Portal.
2. Select the PROFINET interface X1 (or X2, depending on which is the PROFINET ring port).
3. Open Properties > PROFINET interface > Ethernet addresses.
4. Tick the box "Activate system IP" and enter the IP address and subnet mask that will be visible to the AS410. Example: 192.168.0.10 / 255.255.255.0.
5. Each CPU still receives its own IP address under IP protocol > Set IP address in the project for diagnostic access (e.g., CPU0 = 192.168.0.11, CPU1 = 192.168.0.12).

4.2 Hardware Configuration Parameters

The official Siemens Function Manual describes this procedure under "Configuring PROFINET IO on a redundant S7-1500R/H system" (see Siemens PROFINET with redundant S7-1500R/H). The same document states that additional PROFINET IO devices should be attached through a switch in the ring rather than chained.

5. AS410 H-System Configuration (SIMATIC Manager)

The PCS 7 side uses SIMATIC Manager (STEP 7 V5.6) for hardware configuration of the AS410. The CP443-1 modules must have PROFINET IO mode activated and the partner network must include the System IP of the S7-1500R.

5.1 CP443-1 Configuration

1. Open the AS410 hardware configuration (HW Config) in SIMATIC Manager.
2. Open the properties of the CP443-1 EX30 module in slot 4 (PROFINET IO side).
3. Set the IP address (e.g., 192.168.0.20), subnet mask, and PROFINET device name.
4. Select the Ethernet tab and verify that the S7 protocol is enabled.
5. In Time-of-day synchronization, configure the synchronization mode if needed for time stamping in PCS 7.

5.2 Network Entry in NET PRO

Open NET PRO from SIMATIC Manager (Options > Configure Network). The S7-1500R is inserted as a SIMATIC S7 Station with a generic S7 CPU placeholder, then connected to the AS410 subnet.

1. Right-click the AS410 station > Insert New Object > SIMATIC S7 Station.
2. Select the S7-1500R placeholder type. NET PRO will list "S7-1500R/H" only after the matching PCS 7 HSP is installed.
3. Set the partner IP address to the System IP 192.168.0.10 (NOT the individual CPU IPs).
4. Set the partner rack/slot to 0 / 0 (rack 0, slot 0 of the System IP).

6. Establishing the Fault-Tolerant S7 Connection

The fault-tolerant S7 connection is configured in NET PRO. Both endpoints are required.

6.1 Insert the Connection in NET PRO

1. In NET PRO, select the CP443-1 of the AS410.
2. Right-click and choose Insert New Connection > S7 Connection.
3. Choose the S7-1500R placeholder as the partner.
4. In the connection properties, set:
   • Connection type: S7 connection fault-tolerant.
   • Connection name: e.g., AS410_to_1500R_FT1.
   • Local ID: assigned by NET PRO, used in the CFC block.
   • Partner IP: 192.168.0.10 (System IP).
   • Rack / Slot partner: 0 / 0.
5. Compile and download the NET PRO data to the AS410.

6.2 Connection Properties Cross-Check

7. CFC Communication Blocks for the Process Data Exchange

The communication blocks are inserted on the PCS 7 side (AS410) only. The S7-1500R exposes the data through standard DBs and operates as the S7 server.

7.1 Block Selection

7.2 Example: PUT Block to Write a Setpoint

The PUT block writes one or more DB areas to the S7-1500R. Configure the inputs as follows in CFC:

• REQ: 1 (start trigger)
• ID: Local ID from NET PRO (e.g., W#16#0001).
• DONE, ERROR, STATUS: Output status words.
• SD_1: P#DB200.DBX0.0 BYTE 32 – local source area on AS410.
• ADDR_1: P#DB100.DBX0.0 BYTE 32 – partner destination on S7-1500R.
• LEN: 32 (bytes)

For a fault-tolerant connection the block automatically retries over the redundant CP443-1 if the active path fails. No additional block parameters are required.

7.3 Example: GET Block to Read Process Variables

• ID: same connection ID as the PUT block.
• SD_1: local destination area on the AS410 side (e.g., DB300).
• ADDR_1: source area on S7-1500R (e.g., DB100, offset 0, length 32 bytes).

Pair GET with PUT to maintain a 2-way handshake: GET reads the acknowledgment word written by the S7-1500R program, PUT writes new setpoints each cycle. Trigger both blocks every 250–500 ms depending on the OS update cycle.

8. Compilation, Download, and Verification

8.1 Download Sequence

1. Download the S7-1500R hardware configuration (with System IP) to both CPUs from TIA Portal. Ensure Online > S7-1500R/H Diagnostic > Redundancy Status shows RUN/standby.
2. Download the S7-1500R program (DBs and any OB1 logic) to both CPUs.
3. From SIMATIC Manager, download the AS410 hardware configuration including the CP443-1 and NET PRO data.
4. Compile the AS410 CFC chart and download only the chart (not the program) to keep the running program intact.

8.2 Verification Matrix

8.3 Diagnostic Information

• TIA Portal: Online & Diagnostics > S7-1500R/H Redundancy shows the current primary, standby status, and last sync age.
• AS410: CFC online > block STATUS returns W#16#0000 (no error) or W#16#80XX (transport-level issue).
• SCALANCE: Information > MRP page shows whether a ring port is currently blocked (normal behavior with one manager).

9. Troubleshooting Matrix

10. Field-Proven Engineering Notes

• System IP requirement: Without a System IP the AS410 will address the active CPU only. After a switchover the S7 connection breaks until it times out. With a System IP the S7 layer follows the active CPU within ~200 ms.
• CFC block placement: Place the SEND/PUT block on the master AS410 only; the partner AS410 (backup AS410) does not need the same chart. The fault-tolerant connection handles redundancy transparently.
• MRP ring vs. star: A pure star with SCALANCE works, but the redundant ring protects against a single switch failure. Siemens explicitly recommends a ring for S7-1500R/H (see Siemens PROFINET function manual).
• Firewall / routing: If a router separates the AS410 and S7-1500R, route the System IP through the same subnet or open the ISO-on-TCP port (TCP port 102). The default S7 communication uses port 102.
• Time stamping: For PCS 7 sub-second time stamping, synchronize both the AS410 and S7-1500R through the same NTP server or use SIMATIC Time; mismatched time stamps will degrade the audit trail.
• CPU 1518H-4 PN (firmware V2.9) and PCS 7 V9.0 SP2: official Siemens product compatibility matrix confirms the combination works with TIA Portal V17 and the matching HSP.

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