Siemens 6ES7138-4CF02-0AB0 Retrofit-Ready PM-E for ET 200S

Siemens 6ES7138-4CF02-0AB0 Retrofit-Ready PM-E for ET 200S Control Systems

The Siemens 6ES7138-4CF02-0AB0 is a 24VDC power module (PM-E) designed for the ET 200S distributed I/O system, widely deployed in PROFIBUS-DP-based automation architectures across manufacturing, process control, and machine-building industries. As legacy ET 200S installations approach end-of-life or require capacity expansion, this module remains a critical retrofit component — enabling engineers to restore power distribution segments, replace failed units, and extend the operational life of existing control cabinets without a full system overhaul.

Our stock of the 6ES7138-4CF02-0AB0 is sourced from authorized channels, individually tested prior to shipment, and backed by a 12-month warranty. Whether you are replacing a failed PM-E in an active production line or pre-stocking spares for a scheduled maintenance window, this module ships ready for immediate installation.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Integrating the 6ES7138-4CF02-0AB0 into an existing ET 200S station requires a structured approach to avoid configuration mismatches and unplanned downtime. The PM-E module supplies 24VDC to a group of electronic modules on the same rail segment; therefore, the first step in any retrofit plan is to audit the current power budget across all downstream I/O modules — including digital input modules such as the 6ES7131-4BF00-0AA0 (4DI × 24VDC) and digital output modules such as the 6ES7132-4BF00-0AA0 (4DO × 24VDC/0.5A) — to confirm the replacement PM-E’s current capacity is not exceeded.

For stations using the IM 151-1 Standard interface module (6ES7151-1AA05-0AB0) or the IM 151-3 PN (6ES7151-3BA23-0AB0) for PROFINET migration, the PM-E module operates independently of the communication layer, meaning a PM-E swap does not require changes to the DP/PN configuration in STEP 7 or TIA Portal — provided the hardware configuration reflects the correct module order. Engineers should verify the slot assignment in the hardware catalog and confirm that the GSD/GSDML file version matches the installed IM firmware.

Terminal module compatibility is a common source of commissioning delays. The 6ES7138-4CF02-0AB0 is designed for use with the TM-P15S23-A0 or TM-P15C23-A0 terminal modules. If the existing terminal module shows signs of contact wear or mechanical damage, it should be replaced concurrently. Attempting to reuse a degraded terminal module with a new PM-E can introduce intermittent power faults that are difficult to diagnose under load.

In control cabinets where the ET 200S rack is mounted alongside a SIMATIC S7-300 CPU (e.g., CPU 315-2 DP, 6ES7315-2AH14-0AB0) or a CPU 317-2 DP, the PM-E retrofit should be coordinated with a review of the PROFIBUS segment topology. Confirm bus termination resistors are correctly placed, especially if the ET 200S station is at the physical end of the DP segment. A PROFIBUS connector 6ES7972-0BB52-0XA0 with integrated termination is recommended for end-of-line nodes.

For sites migrating from PROFIBUS to PROFINET, the PM-E module itself requires no modification — only the interface module changes (e.g., replacing IM 151-1 with IM 151-3 PN). This makes the 6ES7138-4CF02-0AB0 a protocol-agnostic power supply component that remains valid across both communication generations, protecting the investment in existing I/O wiring and terminal infrastructure.

Where analog signals are present in the same ET 200S station — for example, using 2AI U ST analog input modules (6ES7134-4FB01-0AB0) or 2AO U ST analog output modules (6ES7135-4FB01-0AB0) — the PM-E must be positioned correctly in the module sequence to ensure the analog segment receives clean, regulated 24VDC. Noise on the supply rail from an undersized or failing PM-E is a known cause of analog drift and measurement instability in process control applications.

Downtime Control During System Migration

Minimizing production interruption during a PM-E replacement requires preparation before the maintenance window opens. The recommended procedure is to export the current hardware configuration from STEP 7 or TIA Portal and save a backup of the CPU program, including all data blocks, function blocks, and symbol tables. If the station uses a SIMATIC Micro Memory Card (6ES7953-8LF31-0AA0), a card backup should be created before any physical work begins.

For hot-swap scenarios — where the ET 200S station must remain partially operational — the PM-E controls power to a defined module group. By mapping which I/O modules fall within the affected power segment, engineers can identify which field signals will be interrupted and coordinate with the process control team to place the affected loops in manual or safe-state mode prior to the swap. HMI screens built on WinCC or a SIMATIC TP700 Comfort Panel should display the affected I/O tags in a suppressed or maintenance state to prevent false alarms during the replacement window.

After physical installation of the 6ES7138-4CF02-0AB0, the commissioning sequence should include: (1) visual inspection of terminal module seating and locking lever engagement; (2) 24VDC supply voltage measurement at the PM-E input terminals before powering the segment; (3) CPU online diagnostics via STEP 7 or TIA Portal to confirm the module is recognized in the correct slot; (4) I/O force test on representative digital and analog channels to verify signal integrity; and (5) a timed observation period of at least 15 minutes under normal load before returning the station to automatic control. This structured commissioning approach reduces the risk of latent faults and supports the 12-month warranty claim process if issues arise post-installation.

Retrofit Support FAQ

Q1: Is the 6ES7138-4CF02-0AB0 a direct replacement for the 6ES7138-4CF00-0AB0 or 6ES7138-4CF01-0AB0?
Yes. The -0AB0 suffix revision series of the ET 200S PM-E 24VDC module is functionally and mechanically compatible across the CF00, CF01, and CF02 variants. No hardware configuration change is required in STEP 7 when substituting one revision for another within the same module family, provided the terminal module type is identical.

Q2: What pre-shipment testing is performed on this module?
Each unit undergoes functional power-on testing, output voltage verification under load, and visual inspection for connector and housing integrity before dispatch. A test report is available upon request. The module is covered by a 12-month warranty from the date of shipment.

Q3: Can this PM-E be used in a PROFINET-based ET 200S station?
Yes. The PM-E module is communication-protocol independent. It provides 24VDC power to the electronic module segment regardless of whether the station uses an IM 151-1 (PROFIBUS) or IM 151-3 PN (PROFINET) interface module. No wiring or configuration changes to the PM-E are required during a PROFIBUS-to-PROFINET migration.

Q4: What should I verify during wiring before powering up the replacement module?
Confirm that the terminal module (TM-P15S23-A0 or TM-P15C23-A0) is correctly seated and locked. Verify that the 24VDC supply polarity is correct at the L+ and M terminals. Check that the load current of all downstream electronic modules in the power segment does not exceed the PM-E’s rated output current. Measure supply voltage at the PM-E input terminals before engaging the segment. After power-up, use STEP 7 or TIA Portal online diagnostics to confirm the module status is green before returning to automatic operation.

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