Siemens 6GK5116-0BA00-2AC2 Migration-Ready Ethernet Switch

Overview

Siemens 6GK5116-0BA00-2AC2 Migration-Ready Ethernet Switch: Legacy System Retrofit & Compatibility Upgrade

The Siemens 6GK5116-0BA00-2AC2 is a 16-port unmanaged Industrial Ethernet switch from the SCALANCE X116 series, engineered for reliable data communication in demanding automation environments. As legacy PROFINET and Industrial Ethernet infrastructures approach end-of-life, the 6GK5116-0BA00-2AC2 serves as a proven drop-in replacement and migration-ready upgrade path for aging network infrastructure integrated with Siemens S7-300, S7-400, and early S7-1500 control platforms. Whether you are modernizing a legacy control cabinet, expanding an existing PROFINET ring, or replacing a discontinued unmanaged switch, this module delivers the port density, DIN-rail form factor, and protocol transparency required for seamless integration without reprogramming the host PLC.

Engineers undertaking retrofit projects must verify several critical parameters before commissioning the 6GK5116-0BA00-2AC2 as a replacement unit. Power supply compatibility is the first checkpoint: the module accepts 24 VDC nominal input, and the existing 24 VDC rail — typically sourced from a Siemens SITOP PSU100S or equivalent power supply module — must be confirmed to deliver sufficient current capacity for the full 16-port load. Terminal wiring follows standard two-wire 24 VDC connection to the onboard screw terminals; no special adapter or backplane connector is required, which simplifies direct substitution in existing cable trays. Installation space on the DIN rail must accommodate the module’s 32 mm width; in densely populated control cabinets housing S7-300 CPU modules, SM321/SM322 digital I/O modules, and CP343-1 communication processors, available rail space should be measured before ordering.

From a network topology perspective, the 6GK5116-0BA00-2AC2 operates as a store-and-forward unmanaged switch with auto-negotiation on all 16 RJ45 ports at 10/100 Mbps. It does not support PROFINET MRP (Media Redundancy Protocol) ring management in managed mode, which means migration planners integrating this switch into an existing MRP ring must account for the topology change and update the ring configuration in the STEP 7 or TIA Portal project accordingly. For systems where ring redundancy is mandatory, the SCALANCE X204-2 or SCALANCE XC208 managed switches should be evaluated as alternatives; however, for linear or star topologies — common in legacy S7-300 distributed I/O networks using ET 200S or ET 200M remote I/O stations — the 6GK5116-0BA00-2AC2 is a cost-effective and fully compatible solution.

Communication protocol migration is straightforward: the switch is transparent to PROFINET IO, Modbus TCP, EtherNet/IP, and standard TCP/IP traffic, requiring no firmware configuration. This makes it particularly suitable for hybrid environments where legacy Modbus TCP devices — such as older SIMATIC HMI panels running WinCC flexible or TP177B operator panels — coexist with newer PROFINET IO devices on the same subnet. No changes to the PLC program’s hardware configuration (HW Config in STEP 7 Classic or Device Configuration in TIA Portal) are required when substituting this switch for an equivalent unmanaged predecessor, preserving existing I/O addresses, module slots, and communication parameters.

Migration Compatibility Table

Retrofit Planning for Existing Automation Systems

Successful integration of the 6GK5116-0BA00-2AC2 into a legacy automation system requires a structured pre-installation audit. Begin by documenting all devices currently connected to the switch being replaced: SIMATIC S7-300 CPU 315-2 PN/DP or CPU 317-2 PN/DP controllers, ET 200S distributed I/O stations, CP343-1 Advanced communication processors, and any third-party PROFINET IO devices sharing the subnet. Each device’s IP address, subnet mask, and PROFINET device name must be recorded, as the new switch — being unmanaged — will not alter these parameters but any physical port reassignment during cabling may affect network diagnostics in TIA Portal’s online view.

For control cabinets that also house a SITOP PSU100S 24 VDC/10 A power supply module, confirm that the total current draw of all connected devices — including the 6GK5116-0BA00-2AC2 itself (approximately 200 mA at 24 VDC) — remains within the power supply’s rated output. In retrofit scenarios involving older S7-400 backplanes with IM153-2 interface modules connecting to remote ET 200M I/O racks, the Ethernet switch serves as the backbone for PROFINET communication between the CPU rack and remote stations; any interruption during switch replacement must be planned as a controlled shutdown with the PLC placed in STOP mode to prevent uncontrolled output states.

Where the existing installation includes a SIMATIC NET CP 343-1 Lean communication processor for S7-300 systems, the 6GK5116-0BA00-2AC2 connects directly to the CP’s RJ45 port without any adapter. Similarly, for systems using a SCALANCE W788-2 wireless access point to bridge wireless field devices into the wired PROFINET segment, the switch’s auto-negotiation ports accommodate the access point’s 100 Mbps uplink without configuration. Programming cables such as the PC Adapter USB A2 or SIMATIC NET CP 5711 used for online diagnostics during commissioning connect to the engineering workstation’s standard Ethernet port and route through the switch transparently, enabling live monitoring of PROFINET device states during the retrofit validation phase.

Downtime Control During System Migration

Minimizing production downtime during switch replacement is a primary concern for maintenance engineers. The 6GK5116-0BA00-2AC2’s plug-and-play nature — requiring no firmware upload, no VLAN configuration, and no SNMP setup — means that physical replacement can be completed in under 15 minutes when pre-staged with all cables labeled and port mapping documented. The recommended procedure is to place the S7-300 or S7-400 CPU in STOP mode, de-energize the 24 VDC supply rail feeding the old switch, remove the DIN-rail mounted unit, install the 6GK5116-0BA00-2AC2, reconnect all RJ45 cables in the documented port sequence, restore 24 VDC power, and return the CPU to RUN mode.

To protect existing program logic, no changes to the STEP 7 or TIA Portal hardware configuration are required for a like-for-like unmanaged switch substitution. The PLC’s PROFINET IO controller will automatically re-establish communication with all IO devices (ET 200S, ET 200M, ET 200SP remote I/O) within the standard PROFINET watchdog timeout period — typically 100–500 ms depending on the configured update time. HMI screens on connected TP700 Comfort or TP1500 Comfort panels will briefly show communication fault alarms during the switchover window and automatically recover once PROFINET links are re-established; operators should be informed in advance to avoid unnecessary manual interventions. For systems with safety-rated devices on the same network segment, a formal risk assessment per IEC 62061 or ISO 13849 should be conducted before any live network modification.

Retrofit Support FAQ

Q1: Is the 6GK5116-0BA00-2AC2 a direct replacement for older SCALANCE X116 variants?
Yes. The 6GK5116-0BA00-2AC2 is mechanically and electrically compatible with earlier SCALANCE X116 series switches sharing the same DIN-rail form factor and 24 VDC power input. No wiring modifications are required for a direct substitution. Verify the port count and cable labeling before removal of the legacy unit.

Q2: Will replacing the switch require changes to the TIA Portal or STEP 7 project?
No changes are required for unmanaged-to-unmanaged substitution. The switch is transparent to the PROFINET IO controller. If replacing a managed switch (e.g., SCALANCE X204-2) with this unmanaged unit, the managed switch’s device entry must be removed from the hardware configuration and the project must be recompiled and downloaded to the CPU.

Q3: What pre-shipment testing is performed on each unit?
Each 6GK5116-0BA00-2AC2 unit undergoes functional port verification, 24 VDC power-on testing, and link/activity LED confirmation across all 16 ports prior to shipment. Units are shipped with original or equivalent protective packaging. A support terms confirmed by quotation cover hardware defects from the date of invoice.

Q4: What is the stock availability and lead time?
Units are available from in-stock inventory. Standard orders ship within 1–3 business days. For bulk procurement or project-based reservations, contact our sales team to confirm allocation and delivery scheduling.

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