C135 PCS 7 (PCS7)
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6 Cielo Ciencia y Tecnología
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Migrating WinCC Projects to Multi-User Servers and Resolving Station Manager 125 Errors on OS Clients

Migrating WinCC Projects to Multi-User Servers and Resolving Station Manager 125 Errors on OS Clients

To migrate a WinCC OS project from a Single-User to a Multi-User Server in PCS 7 V9.0, update the project type in WinCC Explorer to 'Multi-User Project', update the computer name to match the server hostname, re-assign network adapters in Simatic Shell, generate Server Data (.pck), and configure the WinCC Server license (6AV6381-2BM07-5AX0). If downloading to an OS Client generates 'Unable to establish connection to module Stationmanager (Index 125)', the engineering station is improperly attempting a hardware/NetPro download on a client node that lacks a Station Configuration Editor. OS Clients only require a WinCC project download via Windows network share; ensure the download scope targets OS Project files only.

Table of Contents

Executive Summary

As industrial facilities expand from localized skid automation to plant-wide supervisory control, systems originally deployed as standalone WinCC Single-User stations must often be migrated to dedicated Multi-User OS Servers supporting distributed OS Clients. During this transition in SIMATIC PCS 7 V9.0, engineering teams encounter two frequent roadblocks: configuring the server database for multi-user operation with proper server data generation, and resolving the diagnostic error 'Unable to establish connection to module Stationmanager (Index 125)' when attempting to download to newly commissioned OS Clients. Understanding the structural distinctions between full PC Stations and lightweight OS Clients eliminates download stalls and prevents licensing non-compliance.

Architecture and Fundamental Mechanics

The transition from Single-User to Multi-User architecture and the OS Client download model are governed by specific subsystem mechanics:

  1. Single-User vs. Multi-User Architecture: In a Single-User project, WinCC Runtime executes locally on the workstation and serves graphics directly to its local monitor; it cannot export runtime packages or accept client connections. Converting to a Multi-User Project activates WinCC Server services, enables the generation of Server Data (<Project>.pck), and permits up to 64 OS Clients to bind to the server's Tag Management and Alarm Logging archives.

  2. The Server License Requirement: Converting a station into a Multi-User Server requires a dedicated WinCC Server license (e.g., MLFB 6AV6381-2BM07-5AX0 for WinCC Server V7.5/PCS 7 V9.0), in addition to standard WinCC Runtime and Process Object (PO) licenses. Always verify required order numbers and license counts with an authorized Siemens distributor or the Siemens Industry Mall before deployment.

  3. The Station Manager (Index 125) Error: When an Engineering Station (ES) downloads a target station from SIMATIC Manager, it evaluates whether it is downloading Hardware/NetPro Configuration or OS Project Data:
    - A full PC Station (OS Server or ES) runs the SIMATIC NET Station Configuration Editor (SCE), represented by firmware Index 125.
    - A standard OS Client does not install or require the SIMATIC NET Station Configuration Editor because it communicates exclusively over the terminal bus via standard Windows TCP/IP networking and Simatic Shell.
    - If an engineer right-clicks the OS Client PC Station in SIMATIC Manager and selects PLC -> Download (or selects 'Configuration' in Compile and Download Objects), the ES attempts to connect to Station Manager (Index 125). Because the service does not exist on the OS Client, the download aborts with Error 125.

  4. OS Client Download Pathway: The ES transfers project files to an OS Client purely through a Windows network shared folder configured with full read/write permissions for the SIMATIC HMI user group, without engaging the STEP 7 Station Manager.

Step-by-Step Implementation Procedure

Execute the migration and client deployment using the following procedures:

Part 1: Convert Project to Multi-User Server

  1. In SIMATIC Manager, open the target OS project on the server or ES.
  2. Open WinCC Explorer.
  3. Right-click the root project name and select Properties.
  4. On the General tab, change the Type of Project from Single-User Project to Multi-User Project.
  5. Open Computer Properties -> change the computer name to match the target server's exact Windows hostname.
  6. In WinCC Explorer, right-click Server Data and select Generate to compile the client package file (.pck).
  7. Ensure the WinCC Server license is transferred to the machine via Automation License Manager (ALM).

Part 2: Configure OS Client in SIMATIC Manager

  1. In SIMATIC Manager Component View, right-click the project root and select Insert -> New Object -> Pre-configured Station or SIMATIC PC Station.
  2. Name the PC Station to match the OS Client Windows computer name.
  3. Open the PC Station HW Config. Insert a WinCC Client application into Index 1.
  4. Save and compile HW Config. (Do not attempt to download HW Config to the client).
  5. Open the WinCC Client project in WinCC Explorer. Select Server Data -> Assign, check the server package, and assign it to the client.

Part 3: Configure Network Share and Execute OS Download

  1. On the physical OS Client PC, create a folder (e.g., C:\WinCC_Projects).
  2. Right-click the folder, select Properties -> Sharing -> Advanced Sharing. Share the folder as WinCC_Projects.
  3. Under Permissions, grant Full Control to SIMATIC HMI and the engineering user account.
  4. On the Engineering Station, right-click the OS Client object under the PC Station in SIMATIC Manager, select Object Properties -> Target OS and Standby OS Computer.
  5. Browse to the network share: \\ClientPC\WinCC_Projects.
  6. Right-click the OS Client object and select Target System -> Download. In the download dialog, select OS Project only (do NOT select Configuration/Hardware). Click Download.

Verification

Verify the multi-user server migration and client operation:

  1. Server Multi-User Verification: In WinCC Explorer on the OS Server, verify that the project header indicates Multi-User. Inspect Automation License Manager to confirm that the WinCC Server license shows status In Use without licensing popups.

  2. Client Project Receipt: On the OS Client PC, inspect the target shared directory. Confirm that all WinCC client project files (.mcp, @*.pdl, server data package) were transferred successfully.

  3. Runtime Activation: Launch WinCC Runtime on the OS Client. Confirm that the client connects to the OS Server over the terminal bus, displays process graphics smoothly, and receives live tag values and alarms.

Limitations and Operational Precautions

Never attempt to force an installation of the SIMATIC NET Station Configuration Editor onto a standard OS Client, as OS Clients are intentionally designed as lightweight nodes that communicate solely via Simatic Shell. When planning server and client licensing, note that OS Clients require OS Client Runtime licenses, while the server requires runtime, process object, and server option licenses. Procurement specifications must always be confirmed with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why did the download fail with 'Unable to establish connection to module Stationmanager (Index 125)'?

The Engineering Station attempted to download the hardware configuration (.xdb / NetPro) to a PC Station that lacks the Station Configuration Editor. OS Clients do not use Index 125; download only the WinCC OS project via network share.

Can a Single-User project serve graphics to remote clients?

No. A Single-User project cannot export Server Data packages or host OS Clients. It must be converted to a Multi-User Project and equipped with a WinCC Server license.

Why must the shared folder grant permissions to the 'SIMATIC HMI' group?

Siemens PCS 7 and WinCC services run under local system accounts tied to the 'SIMATIC HMI' Windows user group. If this group lacks Full Control, the ES cannot write runtime project files across the network.

What role does Simatic Shell play during client download?

Simatic Shell resolves computer names and coordinates terminal bus authentication between the ES, OS Server, and OS Client. Both machines must have Simatic Shell bound to the active network adapter.

Do I need to generate Server Data every time I modify a graphic picture?

No. Server Data (.pck) only needs regeneration when tags, alarms, archives, or server package configurations change. Pure graphic picture updates do not alter server data.

Technical References

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Related Tags

  • WinCC Multi-User
  • OS Client
  • Station Manager
  • Index 125
  • Server Data
  • Project Migration
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