C135 PCS 7 (PCS7)
6C
6 Cielo Ciencia y Tecnología
·Publicada en C135 PCS 7 (PCS7)

Managing PCS 7 Project Revisions, Archiving Workflows, and Windows ProgramData Roles

Managing PCS 7 Project Revisions, Archiving Workflows, and Windows ProgramData Roles

Never overwrite an active SIMATIC PCS 7 project by directly copy-pasting folders in Windows Explorer; doing so corrupts locked SQL Server databases and orphan project descriptors. The correct revision workflow is to archive the project in SIMATIC Manager using 'File > Archive' (PKZip), perform revisions on the engineering workstation, and restore it on the plant station using 'File > Retrieve' into a dedicated project directory. The Windows 'ProgramData' directory is an operating system cache used by WinCC runtime services for machine-wide dynamic data; engineers must never manually modify, overwrite, or store master engineering projects inside 'ProgramData'.

Table of Contents

Executive Summary

Managing engineering revisions across distributed multi-user engineering stations in SIMATIC PCS 7 (V8.0 through V9.1) requires strict adherence to database management protocols. A frequent and perilous practice among novice engineers is copying modified project directories directly over existing directories in Windows Explorer while PCS 7 services or WinCC client processes are running. This results in severe relational database desynchronization between STEP 7 (.s7p) files and Microsoft SQL Server database files (.mdf/.ldf). This article details the authorized archiving and retrieval lifecycle, explains the role of the Windows ProgramData cache, and describes how to use Version Cross Manager (VXM) for revision verification.

Architecture and Fundamental Mechanics

Architectural Mechanics of PCS 7 Project Storage and Windows ProgramData:

  • Multi-Database Project Structure:
  • A PCS 7 project is not a simple collection of flat files. It consists of a dual-tier relational database: the STEP 7 engineering database (storing CFC charts, SFC charts, HW Config, and symbol tables in proprietary dBase/S7F structures) and the WinCC project database managed by Microsoft SQL Server (storing alarms, tag archives, and graphic descriptors).

  • While SIMATIC Manager or WinCC is open, SQL Server holds active write locks on .mdf and .ldf files. Copying folders over active projects in Windows Explorer fails to copy locked files or produces split-brain database states.

  • The PKZip Archiving and Retrieval Engine:

  • SIMATIC Manager's built-in File -> Archive utility cleanly dismounts WinCC SQL Server instances, flushes cached buffers, verifies index integrity, and bundles the multiproject into a compressed .zip archive.

  • File -> Retrieve automatically decompresses the files, adjusts internal path registries, registers database instances with the local SQL Server, and validates file permissions.

  • Storage Location Best Practices:

  • Operating systems enforce User Account Control (UAC) virtualization on C:\Program Files and C:\Program Files (x86). Master engineering projects must never be located in Program Files\Siemens\Step7\s7proj.

  • Recommended path: Store projects on a dedicated physical or partition drive, e.g. D:\SIEMENS_PROJECTS\.

  • Role of the Windows ProgramData Folder:

  • C:\ProgramData is a hidden, machine-wide Windows system directory used by applications to store shared runtime state, temporary communication buffers, and local client caches.
  • When an OS Client runs, WinCC caches local server package data and temporary runtime logs in C:\ProgramData\Siemens\....
  • Engineers should never manually edit, move, or store project files in ProgramData, as these directories are automatically purged and rebuilt by system daemons.

Step-by-Step Implementation Procedure

Step-by-Step Procedure for Safe Project Revision and Deployment:

  1. Create Master Archive on Plant Engineering Station:
    - Close all active editors (CFC, SFC, WinCC Explorer).
    - In SIMATIC Manager, select menu File -> Archive....
    - Select the target Multiproject; choose a secure local backup folder.
    - Archive using internal PKZip format, naming the file with a clear timestamp and revision tag (e.g. PlantA_Rev02_20261014.zip).
  2. Transfer and Retrieve on Development/Revision Laptop:
    - Transfer the .zip file via secure media or network share to the revision PC.
    - In SIMATIC Manager, select File -> Retrieve....
    - Choose a target directory on drive D: (e.g. D:\Projects_Dev\).
    - Perform the required engineering modifications.
  3. Prepare Revised Archive:
    - After testing logic and completing revisions, close all editors.
    - Create a new archive: File -> Archive... (e.g. PlantA_Rev03_20261015.zip).
  4. Deploy to Plant Station and Compare with Version Cross Manager (VXM):
    - On the plant ES, do NOT overwrite the running project. Retrieve the archive into a parallel folder (e.g. D:\SIEMENS_PROJECTS\PlantA_Rev03).
    - Launch Version Cross Manager (VXM).
    - Select the running plant project as Reference (Source) and the newly retrieved project as Target.
    - Execute cross-comparison. Review all changes in blocks, charts, parameters, and HW Config to ensure no unintended modifications exist.
  5. Execute Download to Automation Station and OS:
    - Once validated, open the revised project in SIMATIC Manager.
    - Execute Changes-Only download to AS controllers and OS servers during scheduled plant maintenance windows.

Verification

Verification Procedure:
1. Database Registration Check: Open SIMATIC Manager and browse the retrieved project. Verify that all AS stations, CFC charts, and WinCC OS projects open cleanly without SQL connection errors.
2. VXM Comparison Audit: Ensure the Version Cross Manager report accurately reflects only authorized engineering modifications.
3. Compiler Consistency: Run Options -> Check Consistency -> Charts as Program on the retrieved project; verify zero database cross-reference warnings.

Limitations and Operational Precautions

Operational Precautions and System Boundaries:
- Multi-User Concurrency: In active multi-user engineering environments, merging changes from an offline laptop requires strict discipline; manual folder replacements will overwrite concurrent changes made by other engineers.
- Licensing for Comparison: Version Cross Manager (VXM) requires a dedicated software license key on the Engineering Station.
- Never delete or rename files inside C:\ProgramData\Siemens unless explicitly executing an authorized Siemens Industry Support troubleshooting script.

Engineer FAQ

Can I copy and paste a PCS 7 project folder directly using Windows Explorer?

No. Direct file copying in Windows Explorer while projects are active will corrupt SQL Server database instances and leave locked files uncopied. Always use SIMATIC Manager 'Archive' and 'Retrieve'.

Why shouldn't I store PCS 7 projects in 'C:\Program Files'?

Windows User Account Control (UAC) virtualizes files written to Program Files, redirecting file writes to user-specific AppData folders and causing multi-user database desynchronization.

What is the purpose of the 'ProgramData' directory in PCS 7?

It is an operating system cache folder where WinCC and PCS 7 store machine-wide runtime logs, communication caches, and temporary client runtime states. Master projects should never be placed there.

How can I compare my revised project against the running plant project?

Use SIMATIC PCS 7 Version Cross Manager (VXM) to perform a structured graphical and parameter difference analysis between two projects.

What tool does SIMATIC Manager use to compress archives?

SIMATIC Manager uses an integrated PKZip compression engine optimized for STEP 7 and WinCC relational database files.

Technical References

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Related Tags

  • Project Archiving
  • Version Cross Manager
  • Project Revision
  • ProgramData
  • SIMATIC Manager
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