Deploying Multiproject Revisions to Production Redundant S7-400H and WinCC OS Stations in PCS 7 V8.0

In SIMATIC PCS 7 V8.0 SP2, transferring an offline project revision—containing new ET 200M distributed I/O modules, CFC/SFC logic, and modified WinCC graphics—back to an active production plant requires a strict commissioning workflow. First, archive the current live plant project as a baseline. Restore the modified project on the physical Engineering Station, verify that new I/O modules adhere to Configuration in RUN (CiR) boundaries, and execute a delta AS compilation. Next, compile WinCC OS with scope 'Changes', generate the updated Server Data package, and download 'Changes only' to the Standby OS server first. Verify Standby runtime activation and redundancy synchronization before updating the Master server. Finally, download AS changes to the redundant CPU 414-4H/417-4H in RUN mode. Validate hardware and licensing with an authorized Siemens distributor or the Siemens Industry Mall.

Executive Summary

Process plants operating redundant S7-400H controllers and redundant WinCC OS servers (SRV1A/SRV1B) often require substantial logic and hardware expansions—such as adding new ET 200M racks with digital and analog I/O modules, developing new CFC/SFC control logic, and updating operator screens. When development occurs offline on an engineering virtual machine, returning the modified project to the live facility without causing process trips or operator blindness demands rigorous deployment discipline. This guide outlines the sequential procedure for importing multiproject revisions, managing Configuration in RUN (CiR) for distributed I/O, compiling OS server data, and executing bump-free online downloads.

Architecture and Fundamental Mechanics

Deploying offline revisions to an active PCS 7 V8.0 SP2 environment requires orchestrating multiple synchronized automation tiers:
1. Controller Hardware and Configuration in RUN (CiR):
- S7-400H redundant controllers allow distributed I/O additions in RUN mode via the CiR facility, provided a CiR object was previously inserted into the PROFIBUS DP master system.
- If new ET 200M modules are placed within the allocated CiR upper address boundary, HW Config can be downloaded to the redundant AS in RUN mode without transitioning the CPUs to STOP.
2. AS Logic and Instance Data Consistency:
- When new CFC charts and SFC types are added offline, the compiler assigns new DB numbers and chart execution pointers.
- Compiling with 'Scope: Changes only' ensures that existing instance DB allocations remain intact, enabling delta downloading in RUN.
3. WinCC Server Data Package Architecture:
- In multi-station environments with redundant OS servers and separate OS clients (CLNTF1, CLNTF2, CLNTHAM), clients do not read AS tags directly.
- OS compilation generates a Server Data package (<ProjectName>.pck) containing updated tag dictionaries, alarm archives, and server communication endpoints. This package must be generated on the ES and downloaded to redundant servers.
4. Redundant OS Download Sequencing:
- Redundant servers must be updated sequentially: always download the Standby server first, allow WinCC Redundancy synchronization to complete, transfer client focus, and update the Master server.

Step-by-Step Implementation Procedure

Baseline Backup of Active Production Multiproject:
a. On the live physical Engineering Station, connect online to the running AS and OS stations.
b. Execute Charts -> Read Back to capture all online operator tuning parameters and setpoints.
c. Archive the live project (File -> Archive) and store it securely as Plant_Baseline_PreMigration_<Date>.
Import and Align Revised Multiproject on the ES:
a. Transfer the revised project archive from the development VM to the physical ES and retrieve it via SIMATIC Manager.
b. Verify PG/PC Interface settings (set to CP1623(ISO) or active network card connected to the plant bus).
c. Open NetPro and confirm network node addresses match physical IP and MAC addresses in the plant.
Download Hardware Configuration in RUN (CiR):
a. Open HW Config for the AS 400H station.
b. Verify that newly added ET 200M stations occupy pre-allocated CiR address spaces on the redundant PROFIBUS DP bus.
c. Execute Station -> Check CiR Compatibility.
d. Select PLC -> Download to Module: download the hardware configuration to the running CPU pair in RUN-Redundant mode.
Compile AS Charts and WinCC OS:
a. In SIMATIC Manager, select the AS S7 Program and execute Options -> Charts -> Compile (Scope: Changes only, with 'Generate module drivers' enabled).
b. Right-click the OS Server object (SRV1A) and select Compile (Scope: Changes, select associated AS controllers).
c. Select the Server Data folder under the OS, right-click, and select Generate Server Data.
Execute Sequential Redundant OS Download and AS Delta Download:
a. Identify the currently active Standby OS server (e.g., SRV1B).
b. Right-click SRV1B in SIMATIC Manager, select PLC -> Download (Scope: Changes only).
c. Confirm runtime reloads on SRV1B and verify @RedundancyState indicates complete archive sync.
d. Deactivate runtime on SRV1A (or trigger client failover), download changes to SRV1A, and reactivate runtime.
e. In CFC, select PLC -> Download -> Changes only to download updated control logic to the S7-400H CPUs in RUN.

Verification

In STEP 7 HW Config online, verify the new ET 200M station reports healthy status without bus fault (BF) or system fault (SF) indicators.
In CFC online, monitor the newly added channels: confirm raw field signals update dynamically on channel driver blocks.
On OS Client stations (CLNTF1, CLNTF2), open the new graphic pictures: verify all process values display with good signal quality (16#80) and faceplates operate properly.

Limitations and Operational Precautions

If new ET 200M stations exceed allocated CiR memory boundaries or if CiR was not configured in the original hardware baseline, downloading hardware changes will require stopping the controller. Never perform a full download on an active production system.

Engineer FAQ

Can new ET 200M I/O modules be added to an S7-400H in RUN mode?

Yes, provided the PROFIBUS DP line has a configured Configuration in RUN (CiR) object with sufficient unassigned address memory.

Why must the Standby OS server be downloaded before the Master?

Downloading to a server reloads runtime files; updating the Standby first ensures operator clients remain connected to the Master server without operational disruption.

What is the purpose of generating Server Data (.pck)?

Server Data contains tag references and server connection information required by OS clients to visualize process objects from the OS servers.

What happens if I compile charts with 'Entire program' instead of 'Changes only'?

Compiling the entire program clears delta tracking and may force a full AS download in STOP.

How do I ensure tuning parameters are not lost during offline project import?

Perform an AS Read Back on the live controller before archiving the baseline, and copy OCM parameters into the offline project prior to compilation.

Technical References

Related Tags

PCS 7 V8.0
S7-400H
CiR
Redundant OS
Project Migration
Server Data

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Deploying Multiproject Revisions to Production Redundant S7-400H and WinCC OS Stations in PCS 7 V8.0