C135 PCS 7 (PCS7)
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How to Safely Remove an AS Project from a PCS 7 Multiproject with Redundant OS Servers

How to Safely Remove an AS Project from a PCS 7 Multiproject with Redundant OS Servers

To cleanly remove an Automation System (AS) controller project from a SIMATIC PCS 7 multiproject with redundant OS servers without leaving orphaned database artifacts or losing engineering licenses, you must execute a strict multi-step decommissioning workflow. Deleting the project folder in Windows Explorer or SIMATIC Manager without preparation corrupts cross-project references, causes NetPro compilation failures, and permanently forfeits allocated Process Object (PO) licenses. You must first book back Process Objects from the CFC charts to the master license pool, delete cross-AS interconnections and NetPro communication links, clean up the Plant Hierarchy, remove the project via SIMATIC Manager, and execute an Entire OS Compile with memory reset (Urlöschen) across the redundant OS Server pair.

Table of Contents

Consequences of Improper AS Project Deletion

In a large SIMATIC PCS 7 multiproject (for example, a plant with 6 Automation Systems, redundant OS Servers, and Process Historian), projects are tightly coupled through cross-project databases:
* Orphaned WinCC Process Tags: If an AS is removed without compiling the OS with memory reset, the WinCC database retains thousands of inactive tags and alarm definitions. OS servers continue attempting to acquire data from non-existent controller addresses, generating alarm floods and event log write errors.
* NetPro S7 Connection Faults: Peer controllers and OS servers that maintained S7 connections to the deleted CPU retain unresolved connection endpoints. Future network compilations will flag these partner connections in red, blocking Configuration in Run (CiR) downloads.
* Forfeited PO Licenses: Process Object licenses allocated to CFC charts in the deleted AS remain marked as consumed in the engineering database, permanently reducing your available master license count.

Process Object (PO) License Recovery Mechanics

SIMATIC PCS 7 enforces licensing based on the total number of instantiated process objects (motor blocks, valves, analog monitors, PID controllers).
* Booking Mechanism: When you create blocks in CFC charts, the Engineering Station checks out PO licenses from the master license pool stored on the ES hard drive.
* Mandatory Book-Back: Before deleting an AS project or its chart folder, you must execute the Book Back Process Objects function. This utility scans all charts, de-allocates the checked-out blocks, and credits the licenses back to the central license counter. Once a project is deleted from the disk, its allocated POs cannot be recovered automatically.

Decommissioning Cross-AS and NetPro Network Connections

Before unlinking the AS project, inspect and sever all communication pathways:
1. Cross-AS Interconnections: Open the CFC Cross-Reference list (Options > Cross References). Filter for cross-AS signals. Delete these interconnections in the source charts. If the AS is deleted while partner charts still hold open references, those partner charts will suffer chart compilation locks.
2. NetPro Connection Deletion: In NetPro, select the obsolete CPU. Locate all configured S7 connections to OS Servers and peer controllers. Delete the connections. Then open the NetPro tables of the remaining partner projects, delete the obsolete partner connections, and compile NetPro.

Method: Step-by-Step AS Project Removal Procedure

Follow this 7-step engineering procedure to remove an AS project cleanly:

Step 1: Book Back Process Object Licenses

  1. In SIMATIC Manager Plant View, navigate to the AS project to be deleted.
  2. Right-click the Charts folder and select Process Objects > Book Back Process Objects.
  3. Verify the license return dialog confirms that all allocated AS and OS PO licenses are returned to the master pool.

Step 2: Delete Cross-AS Interconnections

  1. In SIMATIC Manager, select Options > Reference Data > Display.
  2. Select Cross-AS Interconnections.
  3. Open the indicated CFC charts in both the target AS and partner AS projects. Delete the signal lines and compile the partner charts.

Step 3: Clean Up NetPro Connections

  1. Open NetPro.
  2. Select the obsolete CPU and delete all configured connections.
  3. Select each remaining AS CPU and OS Server in turn: delete any redundant S7 connections pointing to the obsolete CPU.
  4. Select each remaining CPU, click Save and Compile, and download the connection table online via Download to Current Project > Connections and Gateways (supported in RUN).

Step 4: Clean Up Plant Hierarchy (TH)

  1. In Plant View, inspect the hierarchy folders assigned to the obsolete AS.
  2. If specific unit or area folders were used exclusively by this AS, delete them.
  3. Confirm that no process pictures or Picture Tree levels intended for retention are located inside the deleted hierarchy branch.

Step 5: Remove and Delete AS Project in SIMATIC Manager

  1. In SIMATIC Manager Component View, select the AS project root.
  2. Select File > Multiproject > Remove from Multiproject.
  3. Once unlinked, select the standalone project and choose File > Delete within SIMATIC Manager. This cleanly purges the database without leaving orphaned Windows Explorer directories.

Step 6: Entire OS Compile with Memory Reset (Urlöschen)

  1. In SIMATIC Manager, right-click the OS project on the OS Server and select Compile OS.
  2. In the wizard, select Scope: Entire OS (do not select Changes only).
  3. Check the critical box: With memory reset (Urlöschen).
  4. Under the AS connection list, ensure only the remaining 5 active AS controllers are selected.
  5. Check the box Generate server data.
  6. Execute compilation. The compiler purges all tags, messages, and raw data archives associated with the removed AS while rebuilding the clean Picture Tree hierarchy.

Step 7: Sequential Download to Redundant OS Servers

  1. Open Simatic Shell on the ES.
  2. Download the OS project to Standby OS Server 2 first. Wait for runtime synchronization.
  3. Initiate client redundancy switchover to Server 2.
  4. Download the OS project to Primary OS Server 1 and reactivate runtime.

Verification

To verify that the AS project was removed cleanly without residue:

  1. In SIMATIC Manager, select Options > Process Objects > Display. Verify that the available license count reflects the credited licenses.
  2. Open NetPro and click Compile and check all. Verify that compilation reports 0 Errors, 0 Warnings and that no red orphaned connections remain.
  3. In WinCC Explorer on the OS Server, open Tag Management. Expand the Named Connections driver:
    - Confirm that the connection to the deleted AS is completely gone.
    - Confirm that only active AS controllers are listed.
  4. In WinCC Runtime, open the Alarm Logging display. Confirm that no system alarms report Connection fault to AS... for the decommissioned controller.

Limitations and Operational Precautions

  • Memory Reset Purges Unlinked User Variables: When checking With memory reset during OS compilation, automatically generated tags from removed blocks are deleted. However, internal user tags created manually in WinCC are preserved.
  • Mandatory Backup Before Beginning: Always create an uncompressed multiproject archive (File > Archive) before starting project deletion. If an interconnection is missed or a required hierarchy folder is deleted by accident, restoring from archive is the only recovery method.
  • Picture Tree Regrouping: If your Picture Tree was manually arranged rather than derived automatically from the Plant Hierarchy, verify picture container assignments in Picture Tree Manager after the entire compile.

Engineer FAQ

Can I recover my Process Object licenses if I already deleted the AS project?
No. If the project files were deleted from the disk without executing Book Back Process Objects, the licenses cannot be restored automatically; you must contact Siemens Customer Support with proof of purchase to request license reactivation.

Why does Siemens mandate an 'Entire OS Compile with Memory Reset'?
A changes-only OS compilation only appends new or modified tags; it does not purge deleted controller tags from the WinCC Sybase/SQL Server database. Memory reset is the only mechanism that purges obsolete tags.

Can remaining controllers continue running in RUN mode during this entire procedure?
Yes. Deleting connections in NetPro and downloading Connections and Gateways is fully supported in RUN. Only the decommissioned AS needs to be powered off.

Technical References

  • Siemens Industry Online Support Entry ID 109742323: SIMATIC Process Control System PCS 7 Engineering System Manual
  • SIMATIC PCS 7 Engineering System Manual (Document No. A5E02779836)
  • Siemens Industry Online Support Entry ID 22261695: How do you remove an AS from a PCS 7 multiproject?

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Related Tags

  • https://industrialautomation.net/search?query=simatic+pcs7
  • https://industrialautomation.net/search?query=multiproject
  • https://industrialautomation.net/search?query=process-objects
  • https://industrialautomation.net/search?query=netpro
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