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Upgrade of ET200M to ET200SP in PCS7 (and PAA Software)

Created by: G_R_E_Y_31 at: 4/8/2025 3:27 AM (4 Replies)

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4/8/2025 3:27 AM	Rate (0)
G_R_E_Y_31 Bronze Member Joined: 5/26/2011 Last visit: 9/9/2025 Posts: 480 Rating: (7)	Hi experts, There is a PCS7 upgrade (v8 to v10) that will also upgrade the ET200M to ET200SP (not HA). I saw this document for upgrade of ET200M to ET200SP HA, which seems to recommend the use of another software called Process Automation Accelerator (PAA): Upgrade ET 200M to ET 200SP HA The document seems to suggest that the upgrade of ET200M to ET200SP HA will also necessitate some program adjustments (IO address? Channel drivers replacement?), and PAA will help on this. My question is would this also apply in ET200SP (not HA)? What exactly will be the program adjustments, am I right the IO address will move and will need new channel drivers? Are there more? We should be able to do these program adjustments without PAA right? Thanks you so much for any response.
	Last edited by: G_R_E_Y_31 at: 04/08/2025 03:49:46 Last edited by: Moderator_Lan at: 04/08/2025 07:44:36 link optimized
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4/9/2025 9:07 AM	Rate (1)
Techno_Taru Bronze-Expert Joined: 1/11/2019 Last visit: 8/14/2025 Posts: 899 Rating: (171)	1. Do the program adjustments apply for ET200SP (non-HA)? Yes, some program adjustments are needed even when migrating from ET 200M to ET 200SP (non-HA), although less complex than for HA systems. Here's why: Hardware differences: ET200M is based on S7-300 architecture and uses PROFIBUS. ET200SP is based on a newer platform, uses PROFINET, and has a different modular structure and addressing scheme. Because of these differences, the program and hardware configuration in the PCS 7 project will not be a direct drop-in replacement. 2. What program adjustments are typically needed? Here's what typically needs to be updated: a. IO Addresses Change ET200M uses a fixed addressing scheme. ET200SP allows flexible addressing depending on module placement in the base rack. This means IO addresses will most likely shift, especially if the channel counts or data types per module differ. As a result, your CFC/SFC blocks, especially those tied to IO (e.g., measuring/actuating blocks like AI, AQ, DI, DO), will need to be re-linked or re-addressed. b. Channel Driver Adjustments The channel drivers (CDs) used in CFC often have hardware-specific parameters tied to the exact module (e.g., 4AI, 2AO, etc.). If you're switching to a different module in the SP series (e.g., from a 4AI HART to a different model in SP), the CD block might need to be replaced to match the new module type or at least reconfigured. c. HW Config / Topology Adjustments You'll need to recreate the hardware configuration in HW Config or TIA Portal depending on the version. With ET200SP, you'll configure modules in a BaseUnit-oriented layout, and connections will now be PROFINET-based. d. Symbolic addressing may need updates If symbolic names (e.g., Tank_Level_AI) are used in connection to addresses, ensure they still point to the correct IOs. 3. Do we need Process Automation Accelerator (PAA)? PAA is a productivity tool introduced by Siemens to help automate the migration of IO configurations and logic blocks, especially useful for large or complex HA projects. But for your case: PAA is not required if you are doing a manual upgrade and you're confident in managing the hardware and addressing updates. However, it can save time and reduce human error if your project is large (e.g., 1000+ IOs). So yes, you can do these adjustments without PAA, especially in smaller systems. Recommended Approach Without PAA Backup the existing PCS 7 v8 project. In the upgraded PCS 7 v10 environment: Replace the hardware configuration: Add ET200SP instead of ET200M. Re-map the IO addresses based on the actual hardware module sequence. Review all channel drivers (CD blocks) in your CFCs and reconfigure or replace them as needed. Validate all connections in NetPro or TIA topology depending on your setup. Perform a cross-reference to see where IO addresses are used. Simulate or test run in a test environment (if possible) before deploying. https://sieportal.siemens.com/en-WW/support/forum/posts/pcs7-upgrade/327176 Upgrading to SIMATIC PCS 7 v10 - Pigler Automation

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4/16/2025 9:09 AM	Rate (0)
G_R_E_Y_31 Bronze Member Joined: 5/26/2011 Last visit: 9/9/2025 Posts: 480 Rating: (7)	Hi Techno_Taru, Thanks for that very detailed answer! It definitely helps. 1) I still plan on using the Profibus DP version of ET200SP IM, since the racks are not so many, and they are all installed indoor and just besides each other, I don't think there's much reason to make it Profinet. But I think even on Profibus DP version of ET200SP all your points still hold right? All those changes are due to ET200M to ET200SP change not the DP to Profinet right? 2) I can't seem to visualize the addressing on ET200SP not being "fixed".. Can you provide example? Because I believe it would still be Ix.x and IWx.x no? What I'm imagining the address change can come from is maybe a 16DI module that previously would just have 2 bytes of address on ET200M, would perhaps now have 4 bytes on ET200SP, maybe signal + status (or maybe on analog ones)? 3) You suggest that the addressing can be "flexible". But if the previous one is fixed, perhaps I can also just keep it fixed in ET200SP? 4) A question related to the Profibus vs Profinet IM. On the old ET200M the biggest rack they have is 12x modules of 8AI module. Converting this to ET200SP, PCS7 suggest using 4AI module, so it will now be 24x modules of 4AI rack. I read that Profibus IM limit is 244 bytes (please check attached), is that per rack? Anyway 24x 4AI is just 192byte of signal in ET200M, but I'm not sure if it will be larger in ET200SP? Does Profibus ET200SP IM have lower module limit per rack vs Profinet IM? 5) Maybe you can also support me on the specifics of the hardware migration. They only have 4 types of signal module on their ET200M, 1 type each DI, DO, AI and AO. I read the PCS7 supported hardware for ET200SP, so I came up on the conversion below: 6ES7 321-1BL00-0AA0 > 6ES7131-6BH01-0BA0 (32DI to 16DI so will be twice the quantity) 6ES7 322-1BL00-0AA0 > 6ES7132-6BH01-0BA0 (32DO to 16DO so will be twice the quantity) 6ES7 331-1KF02-0AB0 > 6ES7134-6GD01-0BA1 (8AI to 4AI so will be twice the quantity) 6ES7 332-5HF00-0AB0 > 6ES7135-6HD00-0BA1 (8AO to 4AO so will be twice the quantity) Is this hardware conversion accurate? I also checked the wiring diagrams, I believe there shouldn't be much wiring difference. Thanks you so much again! Attachment Profibus IM ET200SP.PNG (173 Downloads)
	Last edited by: G_R_E_Y_31 at: 04/16/2025 09:15:56 Last edited by: G_R_E_Y_31 at: 04/16/2025 09:24:28
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4/16/2025 9:57 AM	Rate (0)
G_R_E_Y_31 Bronze Member Joined: 5/26/2011 Last visit: 9/9/2025 Posts: 480 Rating: (7)	I tried to HWConfigure the ET200SP in PCS7 v10.0, it appears the data length for the signal modules are still the same (8 bytes for each 4AI and 2bytes for each 16DI), so perhaps there's no "signal" data I'm imagining that might change the address allocation.. But if this is the case, will there still be hardware addressing change? Because it appears I can perfectly adapt the old symbol table.. This might also suggest that keeping the ET200SP IM Profibus is just fine with the upgrade since the data of each rack doesn't increase? Attachment ET200SP HWconfig PCS7.png (166 Downloads)
	Last edited by: G_R_E_Y_31 at: 04/17/2025 02:49:35
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4/22/2025 7:12 AM	Rate (0)
Techno_Taru Bronze-Expert Joined: 1/11/2019 Last visit: 8/14/2025 Posts: 899 Rating: (171)	Just check ET200SP IM supports with your configuration, if yes go ahead and give try and update the solution part here

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