How to Test PCS 7 OS Changes on an Engineering Station
Use PCS 7's documented OS simulation to test one OS configuration on an engineering station, but do not treat it as a complete multistation test. The V9.0 SP1 manual provides a direct Start OS Simulation procedure and explicitly excludes communication among operator stations in that mode. Testing actual server/client interactions requires a separately designed and version-approved test environment; an ES VM and PLC network bridge alone do not establish that coverage.
Table of Contents
- Choose What the Test Must Demonstrate
- Method 1 — Start the Documented OS Simulation
- Method 2 — Build a Test Architecture for Multiple Roles
- Separate Reported Workarounds from the Verified Route
- Verification
- Limitations and Operational Precautions
- Engineer FAQ
- Technical References
- Related Articles
- Related Tags
Choose What the Test Must Demonstrate
The requirement is to test changes to a customer's multistation project using only an ES virtual machine. Distinguish testing one OS configuration from demonstrating real OS server/client communication, server data exchange or redundancy.
A network bridge for a simulated PLC does not, by itself, instantiate the missing OS server and clients.
Method 1 — Start the Documented OS Simulation
The PCS 7 V9.0 SP1 OS manual, chapter 20, gives this procedure:
- In SIMATIC Manager, open Component View.
- Select the OS whose process mode is to be simulated.
- Choose Options > OS > Start OS Simulation.
The selected OS uses temporary configuration data, refreshed when simulation is started again. The manual says the OS configuration cannot be changed while that simulation is running.
This is the verified local test route. It does not reproduce communication among the project's operator stations. Establish the applicable procedure for the actual installed PCS 7 release before use.
Method 2 — Build a Test Architecture for Multiple Roles
For server/client behavior, define the required test roles and use a supported PC or virtualized configuration for each role being exercised. The V9.1 PC Configuration manual describes the multistation architecture; it is not blanket approval for arbitrary VM combinations.
As project-specific preparation:
- Preserve the original multiproject and record the change being tested.
- Define the required ES, OS server and client roles and their component versions.
- Establish approved virtualization, operating systems, licenses and test networks for that combination.
- Configure controller communication through a separately verified physical or simulated AS route.
- Accept server/client functions using observations from the actual test roles.
For SIMIT V10.2, Siemens also provides a documented Virtual Controller/device-simulation example. Its applicability and dependencies must be matched to the test project; it is not a drop-in replacement for every PCS 7 installation.
Separate Reported Workarounds from the Verified Route
The discussion reports a local-runtime adaptation and a multi-VM arrangement using NetToPLCSIM. Neither is independently established here as a manufacturer-supported end-to-end procedure for an identified product combination.
The adaptation includes deleting an OS.dcf file and changing computer, target and standby assignments. Do not treat those steps as a universally necessary simulation procedure. The OS manual separately documents Allow activation on ES, but that setting alone does not verify the entire adaptation or its alarm behavior.
Verification
For local OS simulation, verify only the display and functions actually exercised. Do not record it as successful multistation communication: the manual explicitly excludes inter-OS communication in this mode.
For a multirole test, demonstrate the intended client/server data path and the actual changed behavior. Record the controller source, versions and isolation arrangement. Keep the simulation-adapted project separate from the production engineering baseline.
Limitations and Operational Precautions
The actual PCS 7 release, available licenses and virtualization resources are unspecified. A complete ES-only emulation of the entire multistation installation is not established. The article provides the closest documented local procedure and a bounded multirole implementation plan.
An OS simulation can affect a connected process according to the manufacturer warning. Establish isolation or a reviewed test connection before operating it. Do not deploy a locally adapted simulation project back to production without reviewing every environment-specific change.
Engineer FAQ
Can local OS simulation prove server/client behavior?
No. Its documented scope excludes communication among the project's operator stations.
Must the reported file-deletion workaround be followed?
It is not established as a required manufacturer procedure here.
Does Allow activation on ES create a full multistation system?
No such behavior is established by that setting.
Technical References
- Siemens: Operator Station V9.0 SP1, A5E39219159-AB — chapter 20, OS simulation and limitations; section 7.3.2, Allow activation on ES.
- Siemens: PCS 7 PC Configuration V9.1, A5E50303177-AA — sections 3.4 and 3.6, single/multiple station roles; use only for its stated version.
- Siemens: Creating a template-based device simulation with PCS 7 and SIMIT, V10.2 example — section 2.5, Virtual Controller implementation; match its stated component prerequisites.