Configuring Siemens ET 200SP as Remote I/O for PCS 7 Systems

Configuring Siemens ET 200SP as Remote I/O for PCS 7 Systems

SIMATIC ET 200SP is officially released as a distributed I/O subsystem for the SIMATIC PCS 7 process control system. This reference documents the released interface modules, the I/O module families, the ET 200SP motor starter variant, and the configuration path used inside the PCS 7 / TIA Portal engineering toolchain. The focus is on the PROFINET-only release scope that applies when an ET 200SP station is integrated as a process I/O island under an AS 410, AS 410E, or AS 410 (H/F) automation system, together with the module-count, BusAdapter, firmware, and diagnostics constraints that matter on a large-scale plant.

1. ET 200SP Release Status Inside PCS 7

The acceptance of ET 200SP in a PCS 7 system is governed by the manual SIMATIC Process Control System PCS 7 - Released Modules. Chapter 8 of that document lists the distributed I/O subsystems approved for operation under a PCS 7 automation station. ET 200SP is present in this matrix as a released PROFINET-based remote I/O.

Three release-scoped facts must be respected when planning a PCS 7 architecture around ET 200SP:

• Only PROFINET interface modules (IM155-6PN) are released for use under PCS 7. The PROFIBUS variant IM155-6DP High Feature is supported by ET 200SP as a product, but is not approved as a PCS 7 remote-I/O interface.
• The PROFINET interface module must be integrated with a BusAdapter (BA) or, for the Basic variant, with the two integrated RJ45 sockets.
• The release matrix is updated by Siemens on a per-firmware basis. The PCS 7 V9.x and V10.x releases cover ET 200SP IM and I/O module firmware that is listed in the Released Modules document referenced from the Siemens support entry 6ES7155-6xxx entry collection. Always cross-check the active matrix before committing to a module variant.

2. ET 200SP Architecture Overview

ET 200SP is a finely scalable distributed I/O system designed for compact control cabinets. The system is built from three mechanical / logical layers:

1. Interface module (IM) - the head of the station; exchanges process and diagnostic data with the higher-level PROFINET IO controller (PCS 7 AS).
2. BusAdapter (BA) - interchangeable media converter on PROFINET IM modules; defines the physical connector type (RJ45, FC, SCRJ, POF).
3. I/O modules and motor starters - plugged into the base units on the backplane; up to 32 or 64 modules per station depending on IM variant.

Compared with the ET 200S predecessor, ET 200SP reduces the footprint by approximately 50%, replaces screw / spring terminals with removable BaseUnit wiring terminals, and introduces color-coded potential groups (light gray for supply, dark gray for non-supply, blue for AI- / AO- reference, red for F- and motor-starter potentials).

3. PROFINET Interface Modules for PCS 7

The PROFINET interface module family is the only IM family that is released for PCS 7. Four variants exist; selection depends on station size, redundancy requirement, and connector strategy.

Selection guidance for PCS 7:

• Use IM155-6PN Standard (6ES7155-6AU00-0BN0) for typical process stations of up to 32 modules. This is the workhorse variant for ET 200SP under PCS 7.
• Use IM155-6PN High Feature (6ES7155-6AU00-0CN0) when the station grows past 32 modules, when isochronous PROFINET is required, or when extensive diagnostic data is to be pushed to the PCS 7 Maintenance Station.
• Use IM155-6PN Basic (6ES7155-6AR00-0AN0) only for non-redundant, low-cost process stations where the two integrated RJ45 ports are sufficient and BusAdapter flexibility is not required.
• Use IM155-6PN Standard with mounted BA 2xRJ45 (6ES7155-6AA00-0BN0) when the engineering team wants preconfigured copper ports but reserves the option to swap to a fiber-optic BA later.

3.1 BusAdapter Selection

BusAdapters convert the IM's internal PROFINET interface to the physical medium used in the field. Common BusAdapter types referenced in PCS 7 ET 200SP applications:

4. PROFIBUS Interface Module (IM155-6DP) and the PCS 7 Restriction

ET 200SP supports one PROFIBUS interface module, the IM155-6DP High Feature (6ES7155-6BA00-0CN0). This module accepts up to 32 I/O modules and terminates the station on a PROFIBUS DP network via a 9-pin sub-D socket.

Even though IM155-6DP is a valid member of the ET 200SP family, the PCS 7 Released Modules manual does not list it as a released I/O interface for a PCS 7 AS. The restriction exists because PCS 7 PROFINET-only I/O is the canonical, released path for ET 200SP. If a plant site still has brownfield PROFIBUS segments, the project must use ET 200M, ET 200iSP, or ET 200PA SMART as a PROFIBUS alternative - not ET 200SP.

Summary table:

5. I/O Module Families

ET 200SP modules are split into the following families. Every family is available as BaseUnit-based modules that plug into the same backplane bus.

The HART-capable AI and AO modules are particularly relevant for PCS 7 because they expose the HART variables to the Maintenance Station, allowing diagnostics on smart field devices (valve positioner, flow transmitter) to be displayed in the Asset Management faceplates.

5.1 HART and Diagnostics

HART modules in ET 200SP are typically 4-channel, 2-/4-wire AI or AO modules. When integrated under a PCS 7 AS, configure the HART secondary variables in HW Config / TIA Portal and ensure that the corresponding EDD is installed on the engineering station. The Maintenance Station then displays the additional HART variables (PV, SV, TV, QV) inside the standard PCS 7 asset faceplate.

6. ET 200SP Motor Starter

ET 200SP introduces a motor-starter form factor that did not exist in the older ET 200S product line in the same integrated way. Motor starters are available as direct-on-line, reversing, and electronic (soft starter) variants; they plug into the same BaseUnit backplane as I/O modules and are controlled through PROFINET like any other ET 200SP module.

For PCS 7 integration, motor starters are typically used for:

• Direct-driven pump and fan starters where the ET 200SP station replaces a motor control center (MCC) bucket.
• Reversing starters for small actuators and dampers.
• Soft starters for pumps and conveyors where reduced starting current is required.

7. Configuring ET 200SP as Remote I/O in TIA Portal / PCS 7 Engineering

Although PCS 7 historically relied on STEP 7 V5 / SIMATIC Manager for AS engineering, modern PCS 7 versions integrate with TIA Portal for ET 200SP configuration. The PROFINET subnet creation is described in the S7-1500 / ET 200MP Manual Collection configuration chapter "Step 2: Configuring an ET 200SP distributed I/O system on a PROFINET subnet". The procedure is reproduced below with PCS 7 specifics.

7.1 Prerequisites

• TIA Portal with the active PCS 7 engineering package installed (e.g. PCS 7 V9.1 SP2 or later, or PCS 7 V10).
• ET 200SP HSP (Hardware Support Package) installed so that all IM, BaseUnit, and module GSDML versions are recognized.
• PROFINET topology defined (network view) with the AS as PROFINET IO controller and the ET 200SP IM as PROFINET IO device.
• BusAdapter chosen (see section 3.1) and physically fitted on the IM.
• Module list with module types, slot numbers, and channel assignments aligned with the PCS 7 signal list (CFC / SFC chart).

7.2 Step-by-Step Configuration

1. In the TIA Portal project view, open Devices & networks and select the PROFINET subnet that the ET 200SP IM will sit on. The PROFINET subnet must already be created under the AS.
2. Insert a new device. Choose ET 200SP from the catalog and select the precise IM article number (for example, 6ES7155-6AU00-0BN0 for the Standard variant, or 6ES7155-6AU00-0CN0 for High Feature).
3. Assign the ET 200SP IM to the AS as a PROFINET IO device. Configure the PROFINET device name on the IM. This device name must match the value stored in the IM's non-volatile memory; use the Assign PROFINET device name function with the IM's MAC address.
4. Select the BusAdapter slot on the IM and assign the correct BusAdapter (BA 2xRJ45, BA 2xSCRJ, BA 2xLC, etc.). The BusAdapter determines the available PROFINET ports and the medium.
5. Insert the I/O modules into the slots of the station. Maximum 32 modules for Standard / Basic / DP, maximum 64 modules for High Feature. Verify that potential groups are consistent across BaseUnits (e.g. light gray for 24 VDC supply, dark gray for non-supply, blue for analog reference, red for motor-starter and F-modules).
6. For each module, configure channel diagnostics, value status, isochronous mode, and HART secondary variables where applicable. In PCS 7, set Value status (QI) = "enabled" for diagnostics-capable modules; this is required for the PCS 7 Maintenance Station to surface channel-level faults.
7. Compile the AS, then download HW Config to the AS. The PCS 7 AS will start the PROFINET AR (Application Relationship) to the ET 200SP IM and discover all modules.
8. In the PCS 7 plant view, assign the IO signals to the CFC / SFC charts. Open the PCS 7 signal list editor and ensure that the symbolic addresses generated by TIA Portal match the CFC interconnection.

7.3 Verification

After download, verify the station with the following checklist:

1. The ET 200SP IM's PROFINET device name is reachable via the AS's online diagnostics.
2. The station shows the expected number of configured modules in the IM's web server (http://<IM-IP> in a browser).
3. All DI channels transition between 0 and 1 in the IM's online module view (force / observe).
4. All AI channels display the correct raw value when a calibration source is applied.
5. The PCS 7 Maintenance Station reports no ET 200SP IM- or module-level diagnostics after a 1-hour soak.
6. If HART modules are used, the PCS 7 faceplates show PV, SV, TV, QV.
7. If F-modules are used, the PROFIsafe address matches the configuration and the AS reports the F-module as "safety mode active".

8. ET 200SP vs ET 200MP vs ET 200M: Positioning in PCS 7

ET 200SP, ET 200MP, and ET 200M are three distinct distributed I/O families that all appear in the PCS 7 release matrix. They are not interchangeable; each targets a different station size and control-class.

Engineering rule of thumb:

• For new PCS 7 plants on PROFINET, default to ET 200SP. It is the most compact, most scalable, and the only one with motor-starter integration at this footprint.
• For very large centralized I/O islands (60+ modules per station), use ET 200MP with S7-1500-class CPUs or ET 200M with S7-300 / S7-400 IM modules.
• For brownfield PCS 7 plants with PROFIBUS segments, retain ET 200M or ET 200iSP; do not attempt to integrate ET 200SP via IM155-6DP.

9. Specifications, Limits, and Module Counts

The following limits apply to an ET 200SP station under PCS 7:

Power and footprint:

• Station width: 1 slot = 15 mm, so a 32-module station is approximately 480 mm wide, excluding BusAdapter and end terminator.
• Power feed: 24 VDC nominal, 20.4 VDC to 28.8 VDC tolerance.
• Maximum load current on the system power rail depends on BaseUnit selection (BU15-P16+A0+2D, BU15-P16+A0+2B, etc.); the manual collection lists per-BaseUnit ratings.

10. Field Commissioning Notes and Diagnostics

Common field issues when integrating ET 200SP into a PCS 7 system, and how to verify each:

11. Frequently Asked Questions