Automating Multiproject Backups and Version Archiving in SIMATIC PCS 7 via Version Trail

In SIMATIC PCS 7, attempting to automate multiproject backups using raw command-line PKZIP commands directly against active project folders is strongly discouraged because locked database files (SQL Server MDF/LDF files and Sybase/Access indices) will result in corrupted archives. The official, certified mechanism for automated and scheduled multiproject backups is the 'SIMATIC Version Trail' optional package. Version Trail integrates natively with SIMATIC Manager, automatically handling database detaching, generating unique version numbers, enforcing user comments, and supporting scheduled unattended archives via Windows Task Scheduler.

Why Raw PKZIP Scripting Fails on Active PCS 7 Projects

Engineers frequently investigate methods to automate daily or weekly backups of SIMATIC PCS 7 Multiprojects. Because SIMATIC Manager utilizes an internal PKZIP executable (s7pkzip.exe) when users select File -> Archive, engineers often attempt to write Windows batch files or PowerShell scripts calling command-line PKZIP or 7-Zip directly against the project directory.

This approach creates critical database corruption hazards:
1. Locked Relational Databases: A PCS 7 Multiproject is not a static collection of files; it contains active databases (Microsoft SQL Server for WinCC projects, internal indices for STEP 7, and CFC chart pointers). External archive scripts execute while files are locked in exclusive write mode, resulting in incomplete copies.
2. Broken Cross-Project Pointers: Multiprojects span multiple sub-projects, Master Data Libraries, and OS servers linked via global unique identifiers (GUIDs). Raw compression utilities can miss open temporary pointers.
3. Restoration Failures: An archive created via raw command-line compression frequently fails when restored via SIMATIC Manager with errors such as Database cannot be attached or Project is inconsistent.

SIMATIC Version Trail Architecture and Capabilities

Documented in the SIMATIC PCS 7 Compendium Part A (Section 7.7), the certified Siemens solution for automated and controlled engineering archiving is SIMATIC Version Trail:
* Autonomous Version Engine: Version Trail is an add-on engineering package (e.g., 6ES7658-1EX18-2YB5) that operates within SIMATIC Manager.
* Safe Archiving Protocol: Before creating an archive, Version Trail safely flushes database transactions and releases file handles without stopping engineering workflows.
* Automatic Version Tracking: Each archive is tagged with a sequential version string (e.g., V1.0.0, V1.0.1), creation timestamp, user account, and mandatory change description.
* Command-Line & Task Scheduler Interface: Version Trail exposes an automated batch interface that can be triggered unattended via Windows Task Scheduler during off-shift hours.

Comparison Table - PCS 7 Archiving Methodologies

The following table compares different methods for archiving SIMATIC PCS 7 multiprojects.

Archiving MethodAutomated ExecutionDatabase ConsistencyVersion ManagementCommercial LicensingRecommended StatusSIMATIC Version TrailYes (Task Scheduler / CLI)100% GuaranteedAutomatic (Sequential)Licensed Add-on (6ES7658-1EX18-2YB5)Industry StandardSIMATIC Manager (File -> Archive)Manual only100% GuaranteedManual file namingIncluded with STEP 7Recommended for manual milestonesExternal 7-Zip / Batch ScriptYesHigh risk of corruptionRequires custom scriptFree / Open sourceStrictly ProhibitedVMware Snapshot / Disk ImageYes (Hypervisor level)Guaranteed (if VM quiesced)Managed by IT storageIT InfrastructureExcellent complementary disaster recovery

Step-by-Step Configuration of Automated Version Trail Backups

To configure automated multiproject backups using SIMATIC Version Trail, execute the following steps:

Install and License SIMATIC Version Trail:
* Install SIMATIC Version Trail from the PCS 7 supplementary installation media.
* Transfer the license key (SIMATIC Version Trail) onto the Engineering Station via Automation License Manager (ALM).
Configure Version Trail in SIMATIC Manager:
* Open SIMATIC Manager and load your Multiproject.
* Select the Multiproject root folder.
* In the menu bar, select Options -> Version Trail -> Configure.
* Specify the primary archive target directory (e.g., a dedicated NAS share or high-capacity secondary drive: D:\PCS7_Archives\).
* Configure version numbering rules and check Enforce comment upon archiving if manual milestones require change logs.
Create Batch Automation Script:
* Version Trail provides the command-line utility S7VerTrlCmd.exe located in the STEP 7 binary path (C:\Program Files (x86)\SIEMENS\STEP7\S7BIN\).
* Create a batch script AutoArchive.bat:
cmd @echo off "C:\Program Files (x86)\SIEMENS\STEP7\S7BIN\S7VerTrlCmd.exe" /ARCHIVE "D:\Projects\MyPlant_MP\MyPlant_MP.s7p" /DEST "D:\PCS7_Archives" /COMMENT "Automated Scheduled Backup"
Schedule Execution in Windows Task Scheduler:
* Open Windows Task Scheduler on the Engineering Station.
* Create a new task: PCS7_Daily_Multiproject_Backup.
* Set the trigger to daily at 02:00 AM.
* Set the action to run AutoArchive.bat with administrative privileges.
* Check Run whether user is logged on or not.

Verification

Confirm that automated archiving operates reliably and generates clean backups:

Trigger Immediate Script Execution:
* Right-click the scheduled task in Windows Task Scheduler and select Run.
* Wait for task completion (Return code 0x0).
Inspect Version Trail History:
* Open SIMATIC Manager. Select the Multiproject root.
* Select Options -> Version Trail -> Show History.
* Confirm that a new entry appears displaying the correct timestamp, version string, comment, and healthy status badge.
Perform Test Retrieval:
* Create a test directory.
* In SIMATIC Manager, select File -> Retrieve.
* Select the newly generated archive zip file.
* Confirm that the project retrieves completely without database attachment errors or missing file warnings.

Limitations and Operational Precautions

Storage Capacity Management: Automated daily archiving generates large zip files (often 500 MB to 3 GB per archive). Implement an automated purge policy to archive older versions to secondary cold storage.
Avoid Archiving During Full AS Downloads: Do not schedule automated archives during active plant turnaround hours when continuous controller downloading or OS compilation is taking place.
Commercial Accuracy Disclaimer: Verify licensing requirements for SIMATIC Version Trail (6ES7658-1EX18-2YB5) and optional Version Cross Manager (VXM) against current Siemens catalogs and authorized distributor quotations.

Engineer FAQ

Can Version Cross Manager (VXM) compare two Version Trail archives?

Yes. SIMATIC Version Cross Manager (VXM) integrates seamlessly with Version Trail, allowing engineers to compare any two historical archives and graphically highlight modified CFC blocks, parameters, and hardware changes.