Resolving Siemens IM153-2 DP/PA Link HW Update Failure in Step7

Problem Overview

The Siemens ET 200M IM 153-2 interface module with catalog number 6ES7 153-2BA82-0XB0 is widely deployed as a Profibus DP/PA link bridging DP masters to PROFIBUS-PA segment instrumentation. Engineers frequently encounter a condition in which the Hardware Catalog in SIMATIC Manager (Step7) does not list the device under Profibus DP > DP/PA Link, or the entry is marked with a yellow "Hardware update not available" warning. The same problem surfaces when an existing project was migrated from an older Step7 version, or when a replacement unit is commissioned alongside an existing IM 157-0XA82 DP/PA Link.

This reference documents the root cause, the required Step7 environment, the Hardware Support Package (HSP) install path, the GSD-based fallback configuration, and a field-proven substitution procedure that allows the IM 153-2 (6ES7 153-2BA82-0XB0) to operate in place of the older IM 157 (6ES7 157-0XA82-0XA0) on the Profibus DP line.

Affected Products and Versions

The article assumes a SIMATIC S7-300 / S7-400 DP master (CPU 31x-2DP, CPU 41x, or CP 443-5) on PROFIBUS-DP, with at least one HART-capable PA field device (e.g. SITRANS P, SITRANS F, SIPART PS2) on the PA segment.

Root Cause Analysis

Three root causes are observed in the field:

1. Missing Hardware Support Package (HSP). Step7 ships with a baseline hardware catalog. The 6ES7 153-2BA82 module (and its PA-Link firmware feature) was added in HSP 0183 / 0190 / 0206 distributed for Step7 V5.4. Without installing the matching HSP on top of the installed Step7 version, the device appears as a placeholder entry or not at all under Profibus DP > DP/PA Link.
2. Step7 version mismatch. The IM 153-2 as a DP/PA Link was integrated into the SIMATIC Manager under HW Config only in Step7 V5.4 SP3 and later. On Step7 V5.3 or earlier the device is recognized only as a DPV1 slave, not as a DP/PA link. On Step7 V5.5 (TIA Portal precursor) the install path of the HSP changed and is restricted; the official Siemens statement is that the HW Update for the IM 153-2 as a DP/PA Link cannot be installed in versions later than Step7 V5.4. For projects running in TIA Portal, the module must be configured as a Profibus-DP slave with PA I/O mapped via a GSD file rather than the HSP.
3. GSD file not registered. When the project uses a third-party master, a non-Siemens tool, or an older Step7 install, the GSD file for the IM 153-2 (file name SIEM8153.GSD for the BA82 family) must be imported manually via HW Config > Options > Install GSD File.

Prerequisites

• SIMATIC Step7 V5.4 SP3 or SP5 installed, with administrator rights on Windows XP / Windows 7 / Windows 10 compatibility mode.
• Matching HSP file: S7HSPxxxxx.exe (typical revisions: HSP 0183 V5.0, HSP 0190 V5.0, HSP 0206 V2.0) - available from the Siemens Industry Online Support under entry ID 23183356.
• IM 153-2 module with article number 6ES7 153-2BA82-0XB0 (firmware V3.x or V4.x).
• ET 200M backplane with at least one SM 3xx signal module assigned after the IM 153-2.
• Profibus-DP master with diagnostic repeater or topology scanner recommended for first commissioning.
• GSD file SIEM8153.GSD plus bitmap files, downloadable from Siemens Industry Online Support if you are running a non-V5.4 environment.

Solution A - Install the HSP on Step7 V5.4

1. Close SIMATIC Manager and all Step7 components including the Automation License Manager.
2. Run the HSP executable with administrator rights. The installer detects the Step7 installation path automatically and updates the s7hsp catalog database.
3. Restart SIMATIC Manager and open the target project.
4. Open HW Config, right-click the Profibus-DP master system, and select Insert Object > DP/PA Link.
5. In the catalog, navigate to Profibus DP > DP/PA Link > Siemens AG > IM 153-2 (6ES7 153-2BA82-0XB0). The module is now selectable with full PA segment parameter set.
6. Drag the IM 153-2 onto the DP line and assign a Profibus address (default: 3, but a value between 3 and 124 is valid).
7. Open the PA master segment created by the link and add the PA slave devices (e.g. SITRANS P DS III, SIPART PS2). Set their addresses to 1..63 within the PA segment.
8. Save, compile, and download the configuration to the CPU.

Verification (Solution A)

• The SF LED on the IM 153-2 must be off; BF (Bus Fault) LED must be off after the master has parameterized it.
• In HW Config > Station > Online, the module should report OK for the IM and all PA slaves.
• Use the diagnostic buffer of the DP master (CPU > Module Information > Diagnostic Buffer) to confirm the IM 153-2 returned a DPV1 diagnostic frame with no configuration error code.

Solution B - GSD File Configuration (Step7 V5.5 or TIA Portal)

When you cannot use Step7 V5.4, the IM 153-2 can be added as a generic Profibus-DP slave using the GSD file.

1. Download SIEM8153.GSD (revision 2.0 or higher for the BA82 variant) and the associated .bmp bitmap from the Siemens support portal under the article number 6ES7 153-2BA82-0XB0.
2. In HW Config (Step7 V5.5) or in the device catalog of TIA Portal, choose Options > Install GSD File (Step7) or Options > Manage general station description files (GSD) (TIA Portal).
3. Restart the catalog update.
4. Insert the module as a DP Slave > Siemens AG > IM 153-2 onto the DP line.
5. Open the slot configuration and assign up to 12 slots with the modules that will physically follow the IM 153-2 in the ET 200M station (e.g. SM 321 DI32, SM 322 DO32, SM 331 AI8, SM 332 AO8, SM 335, FM 350, etc.).
6. For PA functionality, the GSD-based configuration exposes a transparent DP/PA coupling: the PA segment is mapped through the IM 153-2 in the same manner as in Solution A, but the engineer must manually load the device-specific GSD of each PA slave.
7. Compile and download. Note that on TIA Portal V13 SP1 and earlier, the DP/PA coupling menu may be greyed out; in that case use Step7 V5.4/5.5 to build the project and import the symbol table into TIA Portal.

Verification (Solution B)

• In the DP master diagnostic buffer, look for diagnostic event 0xE002 (configuration OK) following parameterization.
• Read at least one PA slave cyclically (e.g. process variable from a SIPART PS2) and verify the value in a VAT table.
• Compare the IM 153-2 firmware version reported in the diagnostic screen (Menu PLC > Module Information > IM 153-2 > Version) against the value listed on the type plate.

Solution C - Field Replacement of IM 157 with IM 153-2

A well-documented field substitution exists: an IM 157-0XA82-0XA0 that has failed can be replaced by an IM 153-2 (6ES7 153-2BA82-0XB0) because the two modules behave identically on the Profibus-DP line from the master's perspective.

1. Power down the ET 200M station. Replace the IM 157 with the IM 153-2 in slot 1 of the active backplane (or use a TB 153 / TB 153M backplane).
2. Reconnect the Profibus-DP cable to the IM 153-2 9-pin D-sub connector.
3. Connect the PA trunk cable to the same terminal block; the IM 153-2 has the same PA connector pinout as the IM 157.
4. Re-download the configuration if the GSD entries are present. If the original project used the IM 157 catalog entry, change the device type in HW Config to the IM 153-2 (BA82) and re-compile.
5. Power up and observe the LEDs: PWR (green) on, SF (red) off, BF (red) off once the master has completed parameter assignment.
6. Run a master diagnostic and verify all PA slaves report OK.

Configuration Parameters and Limits

LED Diagnostics and Fault Codes

Profibus Diagnostic Codes (Hex)

Hardware Update Procedure (FW Update)

Once the module is visible in the catalog and online to the CPU, a firmware update is performed as follows:

1. Open HW Config, right-click the IM 153-2 in the station, and select Object Properties > Firmware Update.
2. Browse to the .upd file (typical file: 6ES7153-2BA82-0XB0_V4_0_0.UPD) and select the desired target version.
3. Click Run Update. The module will automatically restart; the BF and SF LEDs will flash alternately for 30 s to 120 s during the write cycle.
4. After the update completes, the module restarts and enters data exchange. Verify the new firmware version under Module Information > IM 153-2 > Version.

Troubleshooting Matrix

Commissioning Checklist

• Confirm the IM 153-2 catalog number 6ES7 153-2BA82-0XB0 is on the type plate, and that the device is on the ET 200M compatibility list for the firmware version installed.
• Verify the Profibus-DP address is unique and within the range 3..124 to avoid reserved addresses used by diagnostic repeaters.
• Insert a Profibus terminator at the physical ends of the DP segment (typically at the master and at the last slave). Use an active RS-485 terminator if the bus is longer than 100 m at 12 Mbit/s.
• Validate the PA trunk with a PROFIBUS-PA tester (e.g. Softing PROFIbus Tester BC-700-PB) for signal level and current draw. Acceptable PA voltage at the coupler: 24 V DC (typical), 15 V DC minimum at the last device.
• Confirm each PA slave has a unique address 1..63 and that no master-class-2 tools (FieldCare, PDM, FDT/DTM) are connected during the first parameter assignment.
• Download the project, switch CPU to RUN, and verify all LEDs on the IM 153-2 transition from BF/SF red to green data-exchange state within 10 s.
• Read at least one cyclic value from each PA slave through a VAT and verify it matches the HART Communicator reading to within the configured error tolerance.

Standards and Reference Documentation

• IEC 61158-2 - Fieldbus standard for PROFIBUS-PA physical layer, Manchester 31.25 kbit/s.
• IEC 61784-1 - PROFIBUS CP 3/2 communication profile.
• PI (PROFIBUS & PROFINET International) installation guideline for PROFIBUS-DP/PA, edition 2021.
• Siemens HSP Installation Guide (entry 23183356)
• SIMATIC ET 200M IM 153-2 Manual (entry 13944404)

FAQ