How to Resolve 'Insert DVD 2' Installation Loops During PCS 7 Multi-DVD Setup

During SIMATIC PCS 7 V8.0 SP1 software installation, the setup wizard enters an unrecoverable 'Insert DVD 2' prompt loop when the installer cannot locate the second installation disc due to missing volume label metadata or collapsed directory structures. Combining files from DVD 1 and DVD 2 into a single folder breaks setup path scripts, while burning physical media without setting the exact volume label 'DVD_2' causes detection failure. To resolve this, keep DVD 1 and DVD 2 in separate folders named 'DVD_1' and 'DVD_2', or mount both ISO images simultaneously using virtual drive tools (such as Virtual CD or native OS mounting) to dedicated drive letters.

PCS 7 Multi-DVD Media Packaging and Detection Architecture

SIMATIC PCS 7 is delivered as a multi-volume software package consisting of three distinct media volumes:
* DVD 1: Core Engineering System, STEP 7, CFC, SFC, and primary framework setup.
* DVD 2: WinCC OS, Advanced Process Library, options packages, and runtime components.
* DVD 3: Comprehensive multilingual PDF documentation and manual collections.
During installation, the main bootstrap installer (Setup.exe on DVD 1) executes prerequisites, installs base components, and then spawns secondary installation batches that expect DVD 2 to be mounted and detectable via specific Windows volume queries and relative path structures.

Root Causes of the 'Insert DVD 2' Detection Loop

When field engineers encounter a persistent prompt requesting DVD 2 that reappears even after inserting the physical disc or selecting a folder:
1. Missing or Mismatched Volume Label: The Siemens installer validates physical media by querying the volume label of the optical drive. If the ISO was burned to a physical disc using burning software that assigned a default label (e.g., NEW_DISC or timestamp) instead of the exact case-sensitive label DVD_2, the installer rejects the disc.
2. Merging Files into a Single Folder: Copying the contents of DVD 1 and DVD 2 into one consolidated folder on drive C: overwrites duplicate root setup manifests (Setup.ini, CD_INFO.txt), corrupting the multi-volume state machine.
3. Restricted UAC and Temp Drive Paths: Running the setup from deeply nested paths or mapped network drives with spaces triggers path truncation in legacy 32-bit setup scripts.

Correct Offline Directory Structure for Network Installations

If installing from a local hard drive without physical optical drives, maintain the strict folder structure documented in the PCS 7 Readme (Chapter 3.4.1):

C:\PCS7_Install    ├── DVD_1    │   ├── Setup.exe
    │   ├── CD_INFO.txt (Volume Label: DVD_1)
    │   └── Products\...
    ├── DVD_2    │   ├── Setup.exe
    │   ├── CD_INFO.txt (Volume Label: DVD_2)
    │   └── Products\...
    └── DVD_3        └── Manuals\...

Execution Rule: Navigate to C:\PCS7_Install\DVD_1\ and run Setup.exe as Administrator.
When the setup wizard prompts for DVD 2, click Browse..., navigate to C:\PCS7_Install\DVD_2\, and click OK. The installer validates CD_INFO.txt and continues installation without prompting again.

Virtual Drive Mounting Method for Multi-ISO Setups

The most robust, Siemens-recommended method for installing PCS 7 on modern workstations and virtual machines (VMware ESXi, Hyper-V) is mounting ISO images simultaneously:

Assign Virtual Drives:
* Mount PCS7_V80_SP1_DVD1.iso to virtual drive letter D:.
* Mount PCS7_V80_SP1_DVD2.iso to virtual drive letter E:.
* Mount PCS7_V80_SP1_DVD3.iso to virtual drive letter F:.
Execute Installation:
* Open drive D: and launch Setup.exe.
* When the installation process requires components from DVD 2, the installer scans all mounted local drives, automatically detects the volume label DVD_2 on drive E:, and proceeds without requiring manual user intervention.

Comparison of Multi-Disc PCS 7 Installation Methods

The table below compares the reliability and requirements of various PCS 7 installation media setups.

Installation MethodSetup ComplexityRisk of 'Insert DVD 2' LoopRecommended UsageSimultaneous Virtual ISO MountLow (Mount to separate drive letters)Zero (Auto-detects volume labels)Standard Industry Best PracticeSeparated Folders (DVD_1, DVD_2)Low (Requires folder discipline)Very Low (Requires manual browse)Recommended for Local Disk CopyPhysical Burned DVDsHigh (Requires optical burning)Moderate (Fails if volume label wrong)Legacy field workbenchesMerged Flat FolderLow (Blind copy)High (Guaranteed failure)Prohibited

Verification

To confirm that the PCS 7 installation completed successfully:
1. Observe the setup wizard progress bar: confirm that it completes Phase 2 (WinCC and options) and transitions to the completion screen.
2. In the Windows Start Menu, verify that Siemens Automation > SIMATIC > SIMATIC Manager and WinCC Explorer are installed and launch without missing DLL errors.
3. Open Installed Software (SIMATIC Manager > Help > About... > Installed Software) and confirm that all components reflect version V8.0 SP1.
4. Check Windows Event Viewer under Application Logs: verify no MSI installation errors (Error 1603) were logged during the setup.

Limitations and Operational Precautions

Never attempt to install PCS 7 over an active Remote Desktop Protocol (RDP) session without console session binding (mstsc /admin), as RDP session virtualization disrupts device driver installations.
Always disable antivirus heuristic scanning and Windows Defender real-time scanning during the installation process to prevent installation file locking.
Ensure drive C: has at least 30 GB of contiguous uncompressed free space before beginning installation.
Reboot the computer immediately when prompted by the installer before launching SIMATIC applications.

Engineer FAQ

Why does combining DVD 1 and DVD 2 into one folder fail?

Both DVDs contain root files with identical names (such as Setup.exe, Setup.ini, and CD_INFO.txt). Overwriting these files destroys the specific media volume descriptor, causing the installer to fail volume validation.

What is the exact volume label required for DVD 2?

The volume label of the second disc must be formatted exactly as DVD_2 (case-sensitive, with an underscore).

Can I install PCS 7 from a USB flash drive?

Yes, by creating separate folders DVD_1 and DVD_2 on the root of the USB drive, or by storing the ISO images on the USB drive and mounting them locally.