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Connecting and Backing Up Legacy SIMATIC MP Panels in PCS 7 V9.0 Environments

Connecting and Backing Up Legacy SIMATIC MP Panels in PCS 7 V9.0 Environments

Connecting and backing up legacy SIMATIC Multi Panels (MP 177, MP 277, MP 377) from a modern SIMATIC PCS 7 V9.0 engineering station running Windows 10 requires utilizing standalone SIMATIC ProSave over an Ethernet TCP/IP connection. Legacy software packages such as WinAC MP 2008 cannot run natively on Windows 10 or within PCS 7 V9.0. Furthermore, passing legacy USB-to-MPI adapters through VMware Workstation virtual machines running on Windows 10 causes host hypervisor lockups, making direct Ethernet ProSave backups the standard reliable approach.

Table of Contents

Compatibility Restrictions and Communication Architectures

Legacy SIMATIC Multi Panels (MP 177, MP 277, and MP 377) run the Windows CE operating system and were historically engineered using WinCC flexible 2008 and integrated into SIMATIC PCS 7 V7.x/V8.x environments using WinAC MP.

When plants upgrade to SIMATIC PCS 7 V9.0 (and V9.1 / V10) on Windows 10 Enterprise LTSC:
1. Operating System Incompatibility: WinAC MP 2008 is strictly 32-bit software supported only on Windows XP and Windows 7 (32-bit). It cannot be installed or executed on Windows 10 64-bit architectures.
2. PCS 7 Engineering Integration: WinCC flexible 2008 SP5 is the only release with Windows 10 support, but direct PCS 7 V9.0 integration for WinAC MP software PLC controllers was discontinued.
3. Hypervisor USB Pass-Through Instability: Engineers attempting to run Windows XP or Windows 7 inside VMware Workstation 15 on Windows 10 hosts to connect via USB-to-MPI adapters (e.g., PC Adapter USB A2 6GK1571-0BA00-0AA0) frequently encounter host blue screens (BSOD) or VM lockups due to VMware USB 3.0 xHCI controller handoff bugs with legacy Siemens kernel drivers.

The robust, industry-standard approach to servicing, backing up, and restoring these panels in PCS 7 V9.0 environments is to bypass MPI/Profibus adapters entirely and communicate directly over industrial Ethernet using SIMATIC ProSave.

Backup and Migration Procedures Using Ethernet and ProSave

Follow this procedure to establish Ethernet communications and extract a complete image backup from an operational MP panel without disrupting plant operations.

Prerequisites

  • SIMATIC ProSave V15, V16, or V17 installed on the Windows 10 host or engineering VM (ProSave installs standalone without requiring a full WinCC flexible or TIA Portal license).
  • Direct CAT5e/CAT6 Ethernet patch cable or access to the panel's industrial switch port.
  • The IP address, subnet mask, and default gateway currently assigned to the MP panel.

Step 1: Configure MP Panel Ethernet Interface

  1. On the physical MP panel, exit runtime to access the Windows CE Control Panel (or use the loader menu during panel startup).
  2. Double-click ProSave / Transfer.
  3. Under the Channel settings:
    - Enable Channel 1 (Ethernet).
    - Check the box for Enable Remote Control (this allows ProSave on your laptop to automatically place the panel into transfer mode).
  4. In the Control Panel, open Network and Dial-up Connections -> PN_IO / ERTEC.
  5. Note the static IP address and subnet mask assigned to the panel (e.g., 192.168.0.50, subnet 255.255.255.0).

Step 2: Configure PC Network Interface

  1. On your Windows 10 engineering laptop, open Network Connections (ncpa.cpl).
  2. Assign a static IP address on the same subnet as the panel (e.g., 192.168.0.200, subnet 255.255.255.0).
  3. Open a command prompt and execute ping 192.168.0.50 to confirm physical network connectivity.

Step 3: Extract Complete Image Backup in SIMATIC ProSave

  1. Launch SIMATIC ProSave on Windows 10.
  2. On the General tab:
    - Device type: Select the exact panel model (e.g., MP 277 10" Touch or MP 377 15" Touch).
    - Connection: Select Ethernet.
    - IP address: Enter the panel's IP address (192.168.0.50).
  3. Click the Backup tab:
    - Data type: Select Complete backup (creates an image containing Windows CE, runtime configuration, recipe data, and licenses).
    - Save to: Browse to a secure destination and name the backup file (e.g., MP277_Backup_Line1_2023.psb).
  4. Click Start Backup.
  5. The panel will automatically enter transfer mode, and ProSave will extract the complete flash ROM contents into the .psb binary image.

Verification

  • Confirm that the generated *.psb file size matches typical flash memory capacities for the panel series (typically between 16 MB and 128 MB depending on the panel model).
  • Verify that the ProSave status bar reports Backup completed successfully without packet timeout warnings.
  • Confirm that upon completion of the backup, the panel automatically exits transfer mode and restarts the operator runtime application without manual power cycling.

Limitations and Operational Precautions

  • The .psb backup created by ProSave is a compiled binary flash image. It cannot be opened or edited in WinCC flexible or TIA Portal; it can only be restored to an identical hardware model.
  • A Complete backup includes user passwords and active recipe records. When restoring to a replacement panel, ensure recipe data is not overwritten with obsolete values if batch changes occurred after the backup date.
  • If MPI communication via PC Adapter USB is strictly mandatory inside a VM, configure VM hardware compatibility to Workstation 10 and set the USB controller to USB 2.0 (EHCI) rather than USB 3.0/3.1 (xHCI).

Engineer FAQ

  • Can I edit the screens of an MP 277 panel backed up with ProSave?
    No. ProSave extracts a compiled executable binary (.psb). To edit screens, tags, or scripts, you require the original uncompiled WinCC flexible project source file (.hmi).
  • Is WinCC flexible 2008 SP5 compatible with Windows 10?
    Yes. WinCC flexible 2008 SP5 is supported on Windows 10 (64-bit). However, direct integration into SIMATIC PCS 7 V9.0 engineering trees is unsupported for WinAC MP software controllers.
  • Why does VMware Workstation crash when connecting a Siemens PC Adapter USB?
    VMware Workstation 15 has known driver incompatibilities with the Siemens USB virtual serial driver under Windows 10 xHCI USB 3.0 controllers. Downgrading the virtual USB port to USB 2.0 inside VM settings or upgrading to VMware Workstation 17 resolves the crash.
  • Can an MP 277 panel be replaced with a modern Comfort Panel in PCS 7?
    Yes. The recommended migration path is replacing the MP 277 with a SIMATIC TP1200 Comfort Panel, engineered using TIA Portal WinCC Comfort.
  • Can I back up the panel using a USB flash drive directly plugged into the panel?
    Yes. From the Windows CE Control Panel on the MP panel, open the Backup/Restore utility and choose an external FAT32 USB flash drive (maximum 32 GB) to save an image file directly.

Technical References

  • Siemens Industry Online Support Entry ID 58210344: Backup and Restore with SIMATIC HMI Panels using ProSave.
  • Siemens Industry Online Support Entry ID 109748382: Delivery Release: WinCC flexible 2008 Service Pack 5 for Windows 10.
  • VMware Knowledge Base Article 2149806: Resolving USB Controller Lockups and Pass-Through Failures on Windows 10 Hosts.

Related Articles

Related Tags

  • PCS 7
  • WinCC Flexible
  • ProSave
  • SIMATIC
  • HMI
  • Windows CE
  • Industrial Automation
  • VMware
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