Configuring WinCC as Profibus DP Master Without PLC Using CP5611
Reading data from Profibus DP field devices directly inside a WinCC HMI/SCADA station, without an intermediate SIMATIC S7 PLC, is a supported configuration provided the PC is equipped with a Class 1 master-capable Profibus interface (CP 5611, CP 5612, CP 5613, CP 5622, or a CP 5512 PCMCIA equivalent). This article documents the architecture, hardware prerequisites, WinCC PROFIBUS DP driver commissioning, GSD handling for the Endress+Hauser Massflo/Promass Profibus DP module order code FDK:085U0237, and the SOFTNET DP + OPC alternative path when the application needs to share data with third-party clients.
1. Profibus DP Master Classes and the PLC-Less Architecture
Profibus DP (IEC 61158/61784) defines two master roles that govern who owns the token and who polls cyclic I/O:
| Class | Role | Token handling | Cyclic I/O | Typical device |
|---|---|---|---|---|
| DPM1 (Class 1) | Active master, owns bus parameter set | Holds the token, polls slaves | Yes — mandatory | SIMATIC S7 CPU, WinCC station with CP 56x1 set to DP Master |
| DPM2 (Class 2) | Engineering/diagnostics master | Acquires token between Class 1 cycles | Optional (read only) | PG/PC with STEP 7, WinCC acting as monitor |
WinCC is normally a Class 2 client that talks to a SIMATIC PLC through the PLC's own DP interface or through Industrial Ethernet. The PLC-less configuration works because the WinCC PROFIBUS DP channel driver elevates the CP 5611 to Class 1 master status and runs the cyclic DP data exchange locally on the PC. From the slave's perspective the bus behaves identically to a PLC-controlled segment: the master sends configuration/parameterization telegrams during startup, then enters Data_Exchange with each slave.
2. Prerequisites and Hardware Selection
The application environment described in the source question (WinCC + CP 5611 + 3× Massflo FDK:085U0237) requires the following stack:
| Layer | Component | Required version / spec | Notes |
|---|---|---|---|
| Hardware | Siemens CP 5611 | PCI 2.1, 5 V, order code 6GK1 561-1AA00 or 6GK1 561-1AA01 | DP master & MPI; max 12 Mbit/s; 9-pin Sub-D female |
| Hardware | Massflo flowmeter + Profibus DP module | FDK:085U0237 (Promass 80/83 slot module) | 3 slaves → confirm address plan (3, 4, 5) |
| Software | SIMATIC NET PC Software | 2008 SP2 or later, includes CP 5611 driver | Installs the "PROFIBUS" access point |
| Software | WinCC | V6.2 SP3 / V7.0 SP3 / V7.2 with option "PROFIBUS DP" | Channel driver "PROFIBUS DP" must be licensed |
| Software | GSD file | E+H EH_PMx80.gsd or vendor-named file for the FDK:085U0237 module | Download from Endress+Hauser product page |
| License | WinCC DP Powerpack or unlimited tags | 128 tags + DP channel key | 128 tag limit refers to the WinCC tag count, not the slave count |
3. CP 5611 Installation and PC Adapter Configuration
- Power down the PC and seat the CP 5611 in an available 32-bit PCI 2.1 slot. The 5 V keying must match — CP 5611 is keyed for 5 V only; the later CP 5611 A2 (6GK1 561-1AA01) is universal-voltage keyed and is a drop-in replacement.
- Boot into Windows; the SIMATIC NET installer should detect the card and assign the "PROFIBUS" access point to the CP 5611.
- Open SIMATIC NET > Communication Settings and confirm:
| Field | Recommended value |
|---|---|
| Access point | PROFIBUS |
| Interface assignment | CP 5611 (PROFIBUS) |
| S7 / DP / FDL protocol selection | DP master |
| Baud rate | 1.5 Mbit/s (default for 3 slaves < 50 m). Reduce to 500 kbit/s or 187.5 kbit/s if cable length exceeds 100 m. |
| Bus profile | DP, monomaster (Class 1) |
| Highest station address (HSA) | 126 |
| Slot time (Tslot) | Auto, or 4096 tbit at 1.5 Mbit/s |
- Click Test → Read diagnostic buffer to confirm the card enumerates and the Profibus connector LED shows steady green.
- Terminate the segment: bus terminator ON at the CP 5611 end, OFF in the middle, ON at the farthest slave. Each Massflo DP module ships with a switchable terminator on the bus connector.
MPI protocol selection active, WinCC will only see the card as an MPI passive node and the PROFIBUS DP channel will refuse to start. Re-select DP master in Communication Settings and restart the "SIMATIC NET Configuration" service.
4. Installing the WinCC PROFIBUS DP Communication Driver
- In the WinCC Explorer, right-click Tag Management → Add New Driver.
- Select
PROFIBUS DPfrom the list (driver DLLPDPCS7.dllorPDPN.dlldepending on WinCC version). - Open Tag Management > PROFIBUS DP > System Parameters:
| Parameter | Value |
|---|---|
| Device name |
CP5611 (must match SIMATIC NET access point binding) |
| Bus profile | DP |
| Master class | Class 1 |
| Watchdog time | Default 10 s; reduce to 1–2 s for tighter failure detection |
| Auto-restart on bus fault | Enabled (checkbox) |
- Save. The PROFIBUS DP icon in Tag Management should now show the connection as "Connected" once a slave is configured.
5. GSD File Registration for the Massflo FDK:085U0237 Module
The FDK:085U0237 is the Endress+Hauser Profibus DP slot module used in Promass 80 / Promass 83 / older Massflo coriolis mass flowmeters. The accompanying GSD file (typically EHEH0xxx.gsd) must be registered in WinCC so the DP configuration tool knows the slave's slot map and module list.
- Obtain the GSD file from the Endress+Hauser W@M portal or product CD for the device. The matching bitmap is
EHEH0xxx.bmp. - Copy both files into the WinCC GSD directory:
C:\Program Files\Siemens\Automation\WinCC\GSD\(V6) orC:\Program Files (x86)\Siemens\Automation\WinCC\GSD\(V7). - Restart the WinCC Explorer so it rescans the GSD directory.
- Open PROFIBUS DP > DP Master System > Right-click → Add Slave. The Massflo device should now appear in the catalog under the Endress+Hauser vendor tree.
dpconfig.exe /rescan or via SIMATIC NET → Configuration Console → PROFIBUS DP → GSD Import. Ensure the GSD file's revision keyword (e.g., Revision_Number = 5) is at least as high as the device's actual firmware; older Rev3 GSDs will load against newer Promass firmware but limit profile features.
6. Building the DP Network Topology in WinCC
- In PROFIBUS DP, right-click the master system and select Add Slave.
- Pick the Endress+Hauser Massflo/Promass entry, drag-drop three instances onto the bus.
- Assign Profibus station addresses 3, 4, 5 to the three slaves (addresses 0, 1, 2 are reserved; address 126 is reserved for service tools).
- Open each slave and assign module slots. Typical Massflo default mapping:
| Slot | Module | I/O length | Cyclic data |
|---|---|---|---|
| 0 | AI 1 (Mass flow) | 5 bytes input | Float + status |
| 1 | AI 2 (Density) | 5 bytes input | Float + status |
| 2 | AI 3 (Temperature) | 5 bytes input | Float + status |
| 3 | Totalizer 1 | 5 bytes input | Float + status |
| 4 | Totalizer 2 | 5 bytes input | Float + status |
| 5 | Display value | 5 bytes input | Float + status |
| 6 | Output (Set point / batch) | 5 bytes output | Float + status |
7. Tag Configuration and Slot Mapping
For each slave, create WinCC tags under PROFIBUS DP → Slave → Slot N. The tag address format is:
[Slave address]:[Slot].[Channel offset].[Data type]
e.g., "3:0.0" for Massflo address 3, slot 0, input byte 0Example tag list for one Massflo:
| Tag name | Address | Type | Update | Scale |
|---|---|---|---|---|
| MassFlow_1 | 3:0.1 REAL | Float 32 | 500 ms | kg/h |
| Density_1 | 3:1.1 REAL | Float 32 | 1 s | g/cm³ |
| Temperature_1 | 3:2.1 REAL | Float 32 | 2 s | °C |
| Totalizer_1 | 3:3.1 REAL | Float 32 | 2 s | kg |
| Status_1 | 3:0.0 BYTE | Unsigned 8 | 500 ms | — |
With three slaves the project consumes approximately 30–45 process tags; the WinCC 128-tag license leaves more than 70 tags available for derived tags (engineering units, totals, alarm tags). For 1.5 Mbit/s DP and three slaves the cyclic update period measured on a CP 5611 typically settles near 10–30 ms — well below any HMI refresh need.
8. SOFTNET DP Alternative with OPC Interface
If a third-party OPC client (Excel, Python opcua, an external historian) must consume the data, or if the HMI software is not WinCC, use SIMATIC NET SOFTNET DP instead of the WinCC PROFIBUS DP channel:
- Install SIMATIC NET SOFTNET-DP on the PC (it is licensed separately from WinCC; SOFTNET-DP is included with WinCC V6/V7 but is a single-CP license).
- Configure the DP master in the SIMATIC NET Configuration Console — the same procedure as section 3.
- Open OPC Scout (V6) or OPC UA Configurator (V7+). Browse to
DP:[Slave address]→Slot Nand add the items. The DA server runs atopcda://localhost/SIMATIC NET. - From the third-party client, connect to the local DA 2.0/3.0 server or (on V14+) the OPC UA endpoint
opc.tcp://localhost:4840.
9. Diagnostics, Bus Monitor, and Verification
Verify the master-slave handshake with these tools:
-
SIMATIC NET → PROFIBUS Diagnostics — live list of stations and their diag bytes. All three Massflo addresses should appear with
Diag.State = 00h(no fault). - Bus Monitor (BT 200 trace) — capture the startup sequence; expected order is Request_FDL_Status → Token → Parameterization → Configuration → Data_Exchange.
-
WinCC Online tag table — bring up Graphics Designer, insert an I/O field bound to
MassFlow_1, set update to 250 ms, and confirm the value tracks the local Massflo display. - CP 5611 LEDs: green = token held, yellow flashing = bus activity, red = configuration or physical-layer fault.
CP 5611 LED Interpretation
| LED | Color | State | Meaning |
|---|---|---|---|
| RUN | Green | Steady | Card ready, firmware OK |
| RUN | Off | — | Card not initialized (PCI issue or driver not loaded) |
| DP | Green flashing | 1 Hz | Token held, cyclic I/O running |
| DP | Red | Steady | No slave responded to parameterization |
| DP | Yellow | Steady | Bus short-circuit or termination missing |
10. Troubleshooting Matrix
| Symptom | Likely root cause | Fix |
|---|---|---|
| Slave does not appear in bus monitor | Wrong address or baud rate mismatch | Verify Massflo DIP switch / display shows 3, 4, 5; confirm all slaves share 1.5 Mbit/s; re-check termination |
| Diag.State = 0x05 (parameterization fault) | GSD mismatch or wrong module order | Reinstall the FDK:085U0237 GSD; rebuild the slot map; compare Module Ident_Number with the GSD entry |
| Cyclic data valid but values = 0x7F A0 00 00 (NaN) | Status byte reports "Uncertain / Substitute" | Check Massflo sensor health via local display; cyclically write "Out of Service" bit false from WinCC if the device is in simulation |
| Intermittent comm loss after a few minutes | Slot time too low for cable length | Lower baud to 500 kbit/s, raise Tslot in Station Configuration, or replace marginal Profibus connector |
| WinCC shows "PROFIBUS DP: Connection broken" | CP 5611 service not running or wrong access point bound | Verify "SIMATIC NET Configuration" service is Started; ensure the PROFIBUS PC station access point is bound to CP 5611 (not to a CP 5611 MPI profile) |
| Tag quality = "Bad - Configuration Error" | Slot referenced but no module assigned | Open Tag Management → PROFIBUS DP → Slave → Slot → right-click → Properties → confirm module type and address |
| One slave works, others do not | Duplicate station address or termination left enabled mid-segment | Walk the segment: only the two physical ends may carry termination; check Massflo address displays match the WinCC configuration |
11. Cable and Network Engineering Considerations
Profibus DP cable (Siemens 6XV1 830-0EH10 or equivalent, type A) imposes hard limits that the source question does not address explicitly. Use these rules of thumb:
| Baud rate | Max segment length (type A cable) |
|---|---|
| 12 Mbit/s | 100 m |
| 1.5 Mbit/s | 200 m |
| 500 kbit/s | 400 m |
| 187.5 kbit/s | 1 000 m |
| 93.75 kbit/s | 1 200 m |
With three Massflo slaves on a single segment the stub lines to each flowmeter should stay under 0.3 m. Shielding must be bonded to the control cabinet ground bar at one end, and the cable shield clamp on each connector must bite into the braided shield — not the foil only.
12. Verification Checklist Before Going Live
- All three Massflo stations visible in the SIMATIC NET diagnostic view, no Diag flags set.
- WinCC tag simulation table shows all 15–20 process tags with
quality = Good. - A forced value change at the Massflo (e.g., change mass-flow engineering unit) reflects inside one full update cycle in Graphics Designer.
- Pull one Profibus connector — the corresponding tags flip to
quality = Badwithin the configured watchdog (1–2 s). - Reconnect the slave — the master re-parameterizes automatically and tags return to
Good. - Alarm logging captures the loss and recovery with timestamps.
- Tag logging configured for at least mass flow, density, temperature, and totalizer on each of the three slaves.
Refer to the WinCC V7.4 Communication Manual — PROFIBUS DP channel for the official channel description, and to the Endress+Hauser flow measurement product overview for current Massflo/Promass Profibus DP module ordering data and GSD downloads. For SIMATIC NET PC Software installation details consult the SIMATIC NET PC Software Installation Manual, and for the master-class semantics see PI (Profibus & Profinet International).
Can WinCC really act as a Profibus DP Class 1 master without any PLC?
Yes. With the WinCC PROFIBUS DP channel driver installed and a CP 5611 / CP 5612 / CP 5622 bound to the PROFIBUS access point as DP master, WinCC runs the cyclic DP data exchange directly and the slaves see a standard Class 1 master — no SIMATIC PLC is required in the segment.
How many tags does each Massflo FDK:085U0237 module typically expose?
Three to six cyclic process variables per slave (mass flow, density, temperature, totalizer 1, totalizer 2, plus a 1-byte status). Plan 8–12 WinCC tags per flowmeter including status and engineering-unit tags; a 128-tag WinCC license easily covers three slaves.
What baud rate should I pick for three Massflo slaves?
Use 1.5 Mbit/s if the total cable length is under 100 m and stubs are below 0.3 m. Drop to 500 kbit/s for segments up to 400 m. Always set all slaves and the master to the same baud rate; auto-detect is not defined for Profibus DP and is the most common cause of "no station found" errors.
When should I choose SOFTNET DP + OPC instead of the WinCC channel?
Choose SOFTNET DP when a non-WinCC client (Excel, Python, third-party SCADA) must consume the data via OPC DA or OPC UA on the same PC. Choose the WinCC channel when WinCC is the only HMI/SCADA and you want native tag alarming, archiving, and Graphics Designer binding without an OPC layer.
What does the Massflo FDK:085U0237 GSD file actually contain?
The GSD describes the device identity (Vendor_ID = 0x10E2 for Endress+Hauser), the supported module list (AI blocks of 5 bytes input, totalizer blocks, display value), the maximum cyclic I/O length, and the diagnostic alarm behavior. Importing it into WinCC makes the device appear in the DP catalog so you can drag-drop it onto the master system and assign slot modules.
Why does WinCC show "PROFIBUS DP: Connection broken" even though CP 5611 LEDs are green?
The green LED only proves the card holds the token, not that the WinCC channel is bound to it. Open SIMATIC NET → Communication Settings and confirm the "PROFIBUS" PC station access point is bound to CP 5611 (PROFIBUS) with the DP master profile (not MPI). Then restart the SIMATIC NET Configuration service.