Configuring the Engineering Station (ES) PC Station and OS Project Structure in PCS 7

In SIMATIC PCS 7, in a distributed architecture comprising an Engineering Station (ES) and a redundant OS Server pair, all plant process screens (.pdl), tag archives, and alarm messages belong strictly inside the OS project assigned to the OS Server PC Stations. The Engineering Station PC Station in Component View requires only its physical network communications card (e.g. IE General or CP 1623) to compile and download. You should NOT create a duplicate production OS project under the ES station node; any extra empty 'OS object' under the ES can be safely deleted. A WinCC Application is configured on the ES PC Station only if local OS Simulation (testing graphics on the ES without physical servers) is required.

Executive Summary

When organizing a multi-station distributed control system in SIMATIC Manager, automation engineers frequently face confusion regarding how to configure the physical Engineering Station (ES) inside Component View. A common point of uncertainty arises when an engineer notices an 'OS object' under the ES PC Station in addition to the OS objects under the redundant OS Server stations: should process pictures be added to the ES OS object or the Server OS object, and is deleting the ES OS object safe? This article clarifies the structural roles of the ES versus OS Server PC Stations, outlines the purpose of local WinCC applications for OS Simulation, and provides the approved step-by-step configuration procedure.

Architecture and Fundamental Mechanics

SIMATIC Manager Component View Architecture, Engineering Master Roles, and OS Object Placement:

Structural Role of the OS Server PC Stations (OS_SRV_1 and OS_SRV_2):
In a distributed PCS 7 architecture, the runtime human-machine interface lives on the OS Server PC Stations.
In Component View, OS_SRV_1 contains a WinCC Application and an OS(1) project object.
OS_SRV_2 contains a WinCC Application (stby) representing the redundant partner.
The Master Location Rule: All process graphic files (.pdl), faceplates, tag logging archives, alarm logging message classes, and scripts MUST be configured under this OS Server project. When an OS compilation executes, STEP 7 compiles the automation controllers directly into this project database.
Structural Role of the Engineering Station (ES) PC Station:
The physical ES computer is an engineering development host that stores the central multiproject directory.
In Component View, the ES PC Station exists primarily to define the engineering computer's hardware communication interface (e.g. IE General network card or CP 1623) on the Terminal Bus and Plant Bus.
Does the ES Need an OS Object?:
- For normal production operations: NO. The ES does not run runtime operations; having an OS project under the ES is redundant and causes compilation confusion.
- If an empty OS object exists under the ES, deleting it is completely safe and standard engineering practice.
When is a WinCC Application Configured on the ES?:
OS Simulation / Pre-Commissioning Testing:
- If an engineer wishes to test WinCC graphics and faceplate dynamics locally on the engineering laptop/desktop using S7-PLCSIM before downloading to physical plant servers, the ES requires a local WinCC Application.
- However, rather than maintaining a separate project, the engineer simply opens the OS Server project directly on the ES and launches OS Simulation (PLC -> Start OS Simulation).

Step-by-Step Implementation Procedure

Verify Component View Structure in SIMATIC Manager:
* In SIMATIC Manager, switch to Component View.
* Observe the configured PC Station nodes:
- ES_Station: Represents the Engineering Station.
- OS_Server_1: Represents OS Server Master.
- OS_Server_2: Represents OS Server Standby.
Configure the OS Server PC Stations:
* In HW Config for OS_Server_1, insert the communication processor in Slot 1 and WinCC Application in Slot 2.
* In HW Config for OS_Server_2, insert the communication processor in Slot 1 and WinCC Application (stby) in Slot 2.
* In SIMATIC Manager, verify that the master OS project (OS_Server_Prj) resides under OS_Server_1.
* Assign all process pictures (.pdl), scripts, and plant hierarchy folders to this OS project.
Clean Up the ES PC Station Configuration:
* Open the ES PC Station node in Component View.
* If an unneeded, empty OS object exists under the ES station:
- Right-click the empty OS object and select Delete.
- Confirm that this does NOT delete the OS project under the OS Server station.
- Open HW Config for the ES PC Station:
- Ensure the communication card (e.g. IE General or CP 1623) is configured and assigned to the Terminal Bus and Plant Bus subnets.
- If OS Simulation is not actively configured as a standalone runtime station, leave virtual slot 2 empty.
- Save and compile hardware configuration.
Perform OS Compilation to the Server Project:
* Right-click the OS project under OS_Server_1 -> Compile.
* Select the S7-400 controllers to compile.
* Ensure the target compilation points strictly to the OS Server stations.
* Execute compilation; verify that tags, messages, and block icons generate cleanly into the server database.

Verification

In SIMATIC Manager Component View, confirm that only the OS Server PC Stations host the production OS runtime projects.
Open the OS project from OS_Server_1; verify that all plant graphics (.pdl) open in Graphics Designer.
Execute PLC -> Download from the ES to OS_Server_1 and OS_Server_2; confirm successful download across the Terminal Bus.
Start WinCC Runtime on the servers; verify complete process visualization and control.

Limitations and Operational Precautions

Never create process pictures inside an OS project under the ES if you intend to download to OS Servers; copying pictures between disparate OS projects manually breaks tag prefixes and plant hierarchy linking. Always develop graphics within the master OS Server project opened from the central ES.

Engineer FAQ

Where should I add my process pictures: under ES or OS Server?

Always add and edit process pictures under the OS Server project. The OS Server is the production runtime target.

Can I delete the OS object under the ES PC Station?

Yes. If the ES is an engineering-only station, any empty OS object under the ES node can be safely deleted.

What is the purpose of configuring a WinCC Application on the ES?

It is used primarily for local OS Simulation, allowing engineers to test graphics and logic on the ES before plant download.

How do I test the OS project on the ES without physical servers?

Select the OS Server project in SIMATIC Manager and execute PLC -> Start OS Simulation.

Does the ES PC Station need a CP 1623 card?

A CP 1623 is recommended if connecting the ES directly to a redundant Industrial Ethernet Plant Bus; standard office network cards (IE General) can also be used with Softnet-IE.