1. System Overview
PROFIBUS DP networks routinely mix masters and slaves from different vendors. A common field configuration pairs an OMRON CJ1W-PRM21 PROFIBUS DP master (built on the Siemens ASPC2 ASIC) with SIMATIC ET 200M distributed I/O slaves, while also integrating Siemens PP17-I pushbutton panels and SIMODRIVE 611U drives on the same segment. The ASPC2 chipset used in the PRM21 is fully PROFIBUS-DP compliant and has been validated against SPC3-based slaves such as the IM 153-1AA03-0XB0.
Typical segment at the reported site:
| Role | Device | Order Number | GSD File | ASIC |
|---|---|---|---|---|
| Master (Class 1) | OMRON CJ1W-PRM21 | CJ1W-PRM21 | OMRON master config (CX-Profibus) | Siemens ASPC2 |
| Slave | PP17-I pushbutton panel | 6AV3 684-1AA00-0AX0 (typical) | siem8065.gse V1.1 | SPC3 |
| Slave | SIMODRIVE 611U | 6SN1118-xAA00 (typical) | si02808f.gsd V2.3 | SPC3 |
| Slave | ET 200M IM 153-1 | 6ES7 153-1AA03-0XB0 | siem801d.gsd V1.21 / V1.25 (DP) or si01801d.gse V1.6 (DPV1) | SPC3 |
The PP17-I and SIMODRIVE 611U both go into data exchange. The ET 200M IM 153-1AA03-0XB0 remains in failure state. The reported front-panel diagnostic on the IM 153-1 lists:
- Configuration fault
- Station not ready
- Reparameterization requested
These three items are the standard PROFIBUS diagnostic bits Fault_1, Stat_Diag, and PRM_Diag. The combination points to a host/master configuration mismatch — not a hardware failure of the IM 153-1 itself.
2. Problem Description
The IM 153-1 accepts parameter assignment, the BUSF (bus fault) LED on the IM 153-1 blinks red or is solid red, and the IM 153-1 does not enter the Data_Exchange state. The SM 321 (6ES7 321-1BL00-0AA0, 32 DI) signal-status LEDs never light in the running system because the host is in the failure state and is not being polled for I/O data.
Parameterization completes — the master writes its Set_Prm telegram to the slave — but the slave rejects the configuration. The PROFIBUS diagnostic telegram returned to the master contains PrmData error bits and the PRM_Diag flag, which is the cause of the reparameterization request and the configuration-fault diagnostic.
3. Root Cause Analysis
The IM 153-1AA03-0XB0 is a parameter-rich slave. The set of available GSD files for this single part number is the leading cause of mismatch faults. The relevant files are:
| GSD File | DP Profile | User Prm Length | Suitable for PRM21? |
|---|---|---|---|
| siem801d.gsd V1.21 | DP (basic) | Standard | Recommended baseline |
| siem801d.gse V1.25 | DP (extended user Prm) | Extended (with diagnostic enable, isochronous bits, etc.) | May fail if OMRON tool does not surface extended Prm slots |
| siem801d.gsg V1.25 (DE) | DP (extended user Prm) | Extended | Same as .gse; language only differs |
| si01801d.gse V1.6 | DPV1 | DPV1 record structure | Use only with DPV1 master |
| si01801d.gsg V1.6 (DE) | DPV1 | DPV1 record structure | Use only with DPV1 master |
Three independent causes must be ruled out in this order:
- GSD profile mismatch. Loading a DPV1 GSD (V1.6) into a DPV0-only master (PRM21) makes the master transmit a DPV1-formatted parameter telegram that the IM 153-1 either rejects or interprets as a different module layout.
- Extended user-parameter bytes. The V1.25 GSD exposes the User_Prm_Data byte at the slot level. If the CX-Profibus configuration tool does not pass those bytes through to the PRM21, the IM 153-1 sees a parameterization error and asserts Prm_Data fault.
- Slot/module mismatch. The IM 153-1 enumerates empty slots 1, 2, and 3 before the SM 321 in slot 4. If those empty slots are not declared as empty slots (slot 0 placeholder) in CX-Profibus, the slave will detect an unexpected module ID and raise CFG_Fault.
4. GSD File Selection Procedure
Follow this order when commissioning an IM 153-1AA03-0XB0 behind a PRM21 master:
- Open the official Siemens SIMATIC ET 200M product support page for order number 6ES7 153-1AA03-0XB0 and download the DP basic GSD (siem801d.gsd, file version V1.21 or V1.25, dated 06/2003 or later).
- Avoid the DPV1 GSD set (si01801d.gse/.gsg V1.6) unless the PRM21 firmware is upgraded to the DPV1-aware revision and CX-Profibus is configured for DPV1 parameterization.
- Place the GSD in the OMRON GSD library directory and re-index the catalogue in CX-Profibus. The vendor key (Siemens) and the model key (ET 200M IM 153-1) must be visible after re-indexing.
- Add the device to the bus at the configured PROFIBUS address (avoid duplicate addresses — the PRM21 will flag station failure on a duplicate address).
5. Hardware and Bus Check
Before touching the configuration tool, verify the physical layer of the segment because IM 153-1 configuration faults are sometimes caused by a slave that drops the bus long enough for the master to consider the slave to have failed parameterization.
| Check | Acceptable Value | Action on Failure |
|---|---|---|
| Segment termination | Active terminator ON at both ends only | Enable terminating resistor on the PRM21 and the last slave; turn off on all middle slaves |
| Shield continuity | 360° bonding at every connector | Re-clamp PROFIBUS connector shields to the backshell, not to a pigtail |
| Baud rate / segment length | 1.5 Mbps ≤ 200 m; 12 Mbps ≤ 100 m | Reduce baud rate or shorten cable |
| PROFIBUS address | Unique on the segment (1–125) | Re-address any duplicate |
| IM 153-1 rotary switches | Match software address | Cycle power after a hardware-address change |
| 24 V load supply at the IM 153-1 | DC 24 V (20.4–28.8 V) per module spec | Recheck the power module feeding the ET 200M backplane |
6. CX-Profibus Slot Configuration
This is the most common failure path with a third-party master. The IM 153-1AA03-0XB0 occupies slots as follows when fitted with a single SM 321 (6ES7 321-1BL00-0AA0):
| Slot | Module | Module ID (hex) |
|---|---|---|
| 0 | IM 153-1 (DP interface) | 0x00 (implicit) |
| 1 | Empty placeholder | 0x00 (per GSD) |
| 2 | Empty placeholder | 0x00 (per GSD) |
| 3 | Empty placeholder | 0x00 (per GSD) |
| 4 | SM 321 32 DI (6ES7 321-1BL00-0AA0) | Per GSD module list (e.g. 0x10 / 0x20 series ID) |
Step-by-step in CX-Profibus:
- Open the master project, right-click the IM 153-1AA03-0XB0 entry, and select Edit Slave Configuration.
- Insert three empty slot entries for slots 1, 2, and 3 before inserting the SM 321. Skipping the empty slots is the single most common cause of configuration fault on this hardware revision.
- Insert the SM 321 32 DI in slot 4, matching the exact order number (6ES7 321-1BL00-0AA0). Do not substitute a different order number — the module ID will not match the GSD entry.
- Open the Parameter Data tab. For the DP-basic GSD (V1.21), keep the default values. The diagnostic enable bit and watchdog-related parameters should be left at their default unless the application requires disabling them.
- If the V1.25 GSD is used, ensure that the
User_Prm_Dataoctet is fully populated in the CX-Profibus editor. Most early versions of CX-Profibus do not surface the user-parameter bytes; in that case drop back to V1.21. - Download the configuration to the PRM21. Cycle power on the IM 153-1 to force re-parameterization.
7. LED Diagnostics on the IM 153-1
Use the front-panel LEDs of the IM 153-1AA03-0XB0 to confirm whether the slave is in parameterization failure or in steady data exchange:
| SF (red) | BF (red) | ON (green) | State | Action |
|---|---|---|---|---|
| OFF | OFF | ON | Data exchange OK | None |
| ON | OFF | ON | Slave diagnostic pending (e.g. wire-break on a DI) | Read the diagnostic buffer via the master or STEP 7 |
| OFF | Flashing | ON | Parameterization error — slave rejected Set_Prm | Check GSD version, slot layout, and user-parameter bytes |
| OFF | Solid ON | ON | No bus communication / address conflict / wiring break | Check bus termination, baud rate, PROFIBUS address, cable |
| OFF | Flashing | OFF | No 24 V supply to the IM 153-1 or firmware in startup | Verify 24 V at the backplane and allow full boot |
| Flashing | Flashing | Flashing | Firmware update in progress | Do not power cycle |
8. Verification Procedure
After the new GSD and slot layout are downloaded, run the following checks in order:
- Inspect the IM 153-1 LEDs: SF OFF, BF OFF, ON green — confirms the slave is in data exchange.
- In CX-Profibus, monitor the bus and confirm the IM 153-1 shows Data_Exchange state (not Fault or Wait_Prm).
- Force a digital input on the SM 321 and confirm the corresponding input word in the PRM21 input area updates. The default mapping for a 32 DI module in slot 4 is 4 input bytes at the I/O address assigned by the master configuration.
- Disconnect the bus connector from the IM 153-1; the PRM21 should report station failure for that address within the configured watchdog time (default 10 s). Re-connect and confirm automatic recovery.
- Cycle the IM 153-1 power; the master should automatically re-parameterize the slave on next scan.
9. Field-Commissioning Notes for Mixed PROFIBUS Segments
- GSD stacking. Do not load two GSD files that resolve to the same order number. The catalogue indexer can pick either one when CX-Profibus re-indexes and the result is intermittent. The Siemens product support entry for the IM 153-1AA03-0XB0 lists both the DP and DPV1 GSDs in a single folder — keep the folder, but install only the variant you intend to use.
- Reserved PROFIBUS addresses. OMRON reserves address 0 for the master (PRM21). Slave addresses must be in 1–125. Do not set address 0 on the IM 153-1 rotary switch — the slave will be silent and the master will report no response.
- Watchdog. Keep the PROFIBUS watchdog enabled in the master. A slave that drops off-bus is detected within the watchdog window. The IM 153-1 stores the watchdog setting passed by the master; mismatches trigger the PRM_Diag flag.
- Address change on the fly. PROFIBUS address changes on the IM 153-1 take effect only after a power cycle. The slave does not re-enter the bus after a switch change without a reset.
- Identifying the ASIC at the master. The OMRON CJ1W-PRM21 module ID and revision are visible in CX-Profibus. If revision is below 2.0, certain DPV1 acyclic records are not supported. The DP basic GSD (V1.21) is the safest baseline.
- EMERGENCY STOP and Failsafe. The IM 153-1AA03-0XB0 (standard) does not handle PROFIsafe. For fail-safe I/O, replace the IM 153-1 with the IM 153-2 (6ES7 153-2BA00-0XB0 or later) and use the F-GSD. Mixing F-GSDs in a DPV0 segment will produce the same configuration-fault pattern documented here.
10. Quick-Reference Checklist
- [ ] Use the DP basic GSD (siem801d.gsd V1.21) for the IM 153-1AA03-0XB0 when the master is a PRM21.
- [ ] Reserve the DPV1 GSD (si01801d.gse V1.6) for DPV1-capable masters only.
- [ ] Declare slots 1, 2, 3 as empty slot placeholders before the SM 321 in slot 4.
- [ ] Match the module order number exactly when adding the SM 321.
- [ ] Confirm the PROFIBUS address is unique on the segment and is in the 1–125 range.
- [ ] Confirm bus termination is active at the two physical ends only.
- [ ] Verify 24 V load supply to the IM 153-1 backplane.
- [ ] Verify the SF/BF/ON LED pattern after download.
- [ ] Force an input and confirm the input area in the PRM21 updates.
11. Frequently Asked Questions
Which GSD file is correct for the IM 153-1AA03-0XB0 behind an OMRON CJ1W-PRM21?
Use the DP basic GSD siem801d.gsd at file version V1.21 (or V1.25 if CX-Profibus surfaces the User_Prm_Data bytes). Avoid the DPV1 GSD si01801d.gse V1.6 unless the PRM21 firmware is upgraded to a DPV1-aware revision and CX-Profibus is configured for DPV1 parameterization.
What does "configuration fault, station not ready, reparameterization requested" on the IM 153-1 mean?
It is the PROFIBUS standard diagnostic set CFG_Fault, Stat_Diag, and PRM_Diag. The slave rejected the master's Set_Prm telegram — typical causes are wrong GSD revision, missing empty-slot placeholders, or mismatched module order numbers in slots.
How many empty slots must be declared before the SM 321 in an IM 153-1AA03-0XB0 with one module?
Three empty slot placeholders (slots 1, 2, 3) followed by the SM 321 in slot 4. The IM 153-1 enumerates the backplane from slot 0 (itself); skipping the empty slots is the most common cause of configuration fault in mixed-vendor DP networks.
Is the IM 153-1AA03-0XB0 PROFIsafe-capable?
No. The IM 153-1AA03-0XB0 is a standard DP interface module. For PROFIsafe, replace it with the IM 153-2 (for example 6ES7 153-2BA00-0XB0) and install the F-GSD.
Can the ASPC2 master in the CJ1W-PRM21 talk to the SPC3 slave in the IM 153-1AA03-0XB0?
Yes. Both ASPC2 and SPC3 are Siemens PROFIBUS ASICs and are interoperable at the DP protocol level. The fault seen in the field is configuration-layer, not physical-layer — the master and slave speak the same protocol, but the master's configuration tool has not yet produced a configuration string that the slave accepts.