Configuring Cross-Project Server Data for Multi-Project Client Access Across Separate Engineering Stations

In SIMATIC PCS 7 multi-project architectures where independent Multiprojects reside on separate Engineering Stations (ES 1 and ES 2), enabling OS Clients on ES 1 to visualize the plant hierarchy, tags, and graphics of redundant OS servers on ES 2 requires configuring cross-project Server Data (.pck). Because SIMATIC Manager's 'Assign OS Server...' wizard only discovers servers within the local Multiproject, cross-project access requires a manual two-step workflow. First, compile the OS server and execute 'Generate Server Data' on ES 2, producing the package file (.pck). Second, copy this .pck file across the network to ES 1, open WinCC Explorer for the OS Client, navigate to 'Server Data', right-click and select 'Load...', and import the external package. Download the updated client project to the OS clients.

Executive Summary

Large industrial production sites frequently partition automation into distinct physical or technological zones, each managed by an independent Multiproject on a dedicated Engineering Station (e.g., Multiproject A for Utilities, Multiproject B for Processing). However, central control room operator clients must maintain seamless operational visibility across both plant sections. Following hardware replacements, computer renaming, or server data re-generation, engineers discover that the standard 'Assign OS Server...' dialog on ES 1 only lists local servers, failing to locate servers belonging to ES 2. This technical guide explains the decentralized Server Data architecture of WinCC and outlines the procedure to establish robust cross-project client access.

Architecture and Fundamental Mechanics

The distributed client-server architecture of SIMATIC PCS 7 WinCC relies on Server Data packages to establish remote routing:
1. Role of the Server Data Package (.pck):
- When an OS Server project is compiled, WinCC generates a Server Data file named <ProjectName>.pck located in wincproj\<OS_Name>\packages.
- This binary package contains:
a. The complete tag dictionary (all Process Tags and internal tags).
b. Message and alarm class definitions.
c. The Plant Hierarchy area structure.
d. Redundant server network endpoints (Terminal Bus computer names and IP routing).
2. Local vs Cross-Project Multiproject Boundaries:
- Within a single Multiproject, SIMATIC Manager automatically cross-references all contained PC stations.
- When Multiprojects are physically separated across distinct Engineering Stations, SIMATIC Manager has no automated database bridge to external multiproject files.
3. The Manual Package Import Mechanism:
- WinCC Explorer allows OS Client projects to manually load external server data packages via Server Data -> Load....
- Once the external .pck file is loaded into the client project, the client's Picture Tree Manager, Alarm Logging, and Tag Management incorporate the external plant hierarchy areas alongside local areas.

Step-by-Step Implementation Procedure

Generate Updated Server Data on Remote Engineering Station (ES 2):
a. On ES 2, open the remote Multiproject in SIMATIC Manager.
b. Compile the redundant OS Server project (Scope: Changes or Entire OS).
c. In the project tree under the OS Server object, open the Server Data folder.
d. Right-click and select Generate Server Data.
e. Locate the generated package file on ES 2 disk: e.g., D:\Siemens\Step7\s7proj\Project2\wincproj\OS_SRV2\packages\OS_SRV2.pck.
Transfer the Server Data Package to Local Engineering Station (ES 1):
a. Copy the OS_SRV2.pck file from ES 2 across the terminal bus network share (or via secure USB) to ES 1.
b. Store the file in a permanent local project folder on ES 1 (e.g., C:\Siemens\CrossProject_Packages\OS_SRV2.pck).
Assign Local Servers First in SIMATIC Manager (ES 1):
a. On ES 1, open the local Multiproject in SIMATIC Manager.
b. Select the target OS Client object (e.g., CLNT_01).
c. Execute Options -> 'Assign OS server...'.
d. Check the local OS servers belonging to Multiproject 1 and click 'OK'.
Manually Load External Server Data into the OS Client Project:
a. In SIMATIC Manager on ES 1, open the WinCC Explorer project for CLNT_01.
b. In the WinCC Explorer tree, locate Server Data.
c. Right-click 'Server Data' and select Load....
d. Browse to the transferred OS_SRV2.pck file and click 'Open'.
e. Verify that OS_SRV2 now appears in the list of loaded packages alongside the local server package.
Configure Preferred Servers and Picture Tree Integration:
a. Right-click the loaded OS_SRV2 package, select Configure..., and set the Preferred Server for redundant failover.
b. Open Picture Tree Manager on the client: confirm that Plant Hierarchy areas from both Multiproject 1 and Multiproject 2 are mapped.
c. Save and close WinCC Explorer on the ES.
Download Updated Project to OS Clients:
a. In SIMATIC Manager on ES 1, right-click CLNT_01 and select PLC -> Download.
b. Transfer the updated client project to the physical OS client PC.

Verification

Launch WinCC Runtime on the OS Client: verify that the top navigation banner displays overview area buttons for both Multiproject 1 and Multiproject 2.
Click an area button from Multiproject 2: confirm the graphic picture renders and process tags populate dynamically with live data from OS Server 2.
Trigger an alarm in Multiproject 2: confirm the alarm appears instantly in the OS Client's central alarm control banner.

Limitations and Operational Precautions

Whenever changes are made to the Plant Hierarchy, tags, or alarms on ES 2, the Server Data package must be re-generated on ES 2, manually copied back to ES 1, re-loaded in the client project, and re-downloaded to all OS clients.

Engineer FAQ

Why does 'Assign OS Server...' only show local servers in SIMATIC Manager?

Because the wizard queries only the local Multiproject database; servers in external multiprojects cannot be discovered automatically.

What file contains WinCC server routing information for external clients?

The Server Data package file with the .pck extension.

How do I import external server data into an OS Client?

Open the OS Client's WinCC Explorer, right-click 'Server Data', select 'Load...', and browse to the external .pck file.

Must the .pck file be re-copied every time the remote project changes?

Yes. Any addition of tags, alarms, or graphic pictures on the remote server requires re-generating, re-copying, and re-loading the .pck file.

Can an OS Client visualize graphics from three or more separate multiprojects?

Yes. An OS Client can load multiple external .pck files simultaneously, consolidating visualization across multiple independent automation plants.

Technical References

Related Tags

Cross-Project
Server Data
.pck File
Multi-Project
OS Clients
WinCC Architecture

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Configuring Cross-Project Server Data for Multi-Project Client Access Across Separate Engineering Stations