Modifying and Deploying WinCC Faceplates Online in PCS 7 V7.1 Without Line Stoppage

In SIMATIC PCS 7 V7.1, modifying faceplates on an active plant without interrupting production depends on whether changes are purely graphical or involve new controller tags. For purely graphical modifications: edit the faceplate screen (@PG_*.pdl) in Graphics Designer on the Engineering Station (ES) and copy the modified file over the network directly into the GraCS folders of both redundant OS Servers (Server A and Server B); when operators reopen the faceplate, WinCC reloads the new PDL immediately from disk without restarting Runtime. However, if modifications involve newly added CFC blocks or new tags: you must perform an AS compile and delta download to the controller, followed by an AS-OS compile and an OS delta download ('Changes Only') sequentially to Standby Server B, then Master Server A.

Executive Summary

In 24/7 continuous process manufacturing automated with SIMATIC PCS 7 V7.1, control room operators rely on WinCC faceplates to operate valves, motors, and controllers. Plant engineers frequently need to improve faceplates—such as adding descriptive text, repositioning buttons, or embedding extra analog indicators—without taking the plant offline. System integrators often struggle with the correct deployment methodology: copying files out-of-band may update graphics but cause subsequent delta compile errors, while adding new tags requires formal AS-OS synchronization. This technical guide outlines the exact workflows for deploying graphical faceplate changes and structural tag additions without line stoppage.

Architecture and Fundamental Mechanics

Deployment Workflows: Graphical vs. Structural Faceplate Changes

WORKFLOW A: PURELY GRAPHICAL CHANGES (No new tags, only visual edits)
+-------------------------------------------------------------------------+
| Engineering Station (ES): Edit @PG_MotL.pdl in Graphics Designer        |
+-----------------------------------|-------------------------------------+
                                    |
                                    v Network File Copy (Windows SMB)
+-------------------------------------------------------------------------+
| OS Server A (Master) GraCS Folder      OS Server B (Standby) GraCS      |
| - Overwrite @PG_MotL.pdl               - Overwrite @PG_MotL.pdl         |
|                                                                         |
| RUNTIME RESULT:                                                         |
| - WinCC Runtime continues operating seamlessly!                         |
| - Closing & reopening the faceplate loads the new PDL from disk!        |
+-------------------------------------------------------------------------+

WORKFLOW B: STRUCTURAL MODIFICATIONS (New CFC blocks, new tags, new alarms)
+-------------------------------------------------------------------------+
| 1. CFC Engineering on ES: Add new blocks & tags                         |
| 2. AS Compile & Delta Download: Load changes to running AS controller   |
| 3. AS-OS Compile: Generate tags & messages in WinCC CS database         |
| 4. OS Delta Download ('Changes Only'):                                  |
|    - Step 4A: Download to Standby OS Server B -> Wait for Sync         |
|    - Step 4B: Download to Master OS Server A  -> Production Unaffected!|
+-------------------------------------------------------------------------+

The Operational Distinction

Graphics Cache Mechanics: WinCC Runtime loads process pictures and faceplates (@PG_*.pdl) dynamically from the local project GraCS directory. When a faceplate window is closed, its memory cache is released. If the file on disk has been replaced, opening the faceplate causes WinCC to render the updated file immediately without restarting Runtime.
The Out-of-Band Copy Risk: If you manually copy .pdl files from the ES to the OS Servers via Windows Explorer, the Engineering Station database does not record that the server already possesses the new picture. During the next formal OS Delta Download, SIMATIC Manager will detect timestamp differences, which can trigger an unexpected warning that files were modified externally.
Tag Dependencies: If a faceplate links to a tag that does not exist in the OS Server's Tag Management, WinCC displays an invalid tag marker (yellow triangle or slashed value) and generates script error logs in WinCC_Sys_*.log.

Step-by-Step Implementation Procedure

Approach A: Deploying Graphical-Only Faceplate Modifications in RUN

On the Engineering Station, open the WinCC OS project in WinCC Explorer.
Open the target faceplate picture in Graphics Designer (e.g., @PG_C_DRV_1D.pdl or @PG_MotL.pdl).
Make your graphical adjustments (e.g., resize text boxes, add static labels, modify background colors).
Save the picture and close Graphics Designer.
In Windows Explorer on the ES, navigate to the project directory: [Project_Path]\GraCS\.
Copy the modified .pdl file.
Paste the file directly into the shared GraCS folders of both OS Servers:
- \\OS_SRV_A\WinCC_Projects\[Project]\GraCS\
- \\OS_SRV_B\WinCC_Projects\[Project]\GraCS\
If using multi-clients that store local GraCS copies, copy to OS Clients as well.
On the operator client, close the active faceplate and reopen it; the updated layout appears instantly.

Approach B: Deploying Changes Involving New CFC Blocks and Tags in RUN

In SIMATIC Manager, make the required logic additions in the CFC charts.
In CFC, execute Chart > Compile > Changes Only.
In SIMATIC Manager, select the Chart folder, choose PLC > Download > Changes Only, and confirm the download to the operating AS.
Open the faceplate in Graphics Designer on the ES and bind your graphical elements to the newly created tag structures.
Save the faceplate picture.
In SIMATIC Manager, right-click the OS project and select Compile (Scope: Changes only).
In the OS Download dialog:
- Select Scope: Changes.
- Download first to the Standby OS Server (Server B).
- Confirm that WinCC Redundancy synchronization completes.
- Download to the Master OS Server (Server A).
Verify that newly added tags animate and control the process dynamically.

Verification

Visual Inspection: On an OS Client in runtime, open the faceplate for an operating drive or valve. Confirm that modified buttons, text labels, and layouts display accurately.
Tag Communication Verification: If new tags were bound, verify that live values update and that control commands from the modified faceplate execute on the physical actuator.
Diagnostic Log Check: Open C:\Program Files\Siemens\WinCC\Diagnostics\WinCC_Sys_01.log. Verify that no Tag not found or PDL load error messages are recorded.

Limitations and Operational Precautions

System Template Overwrites: Never modify system faceplates directly in C:\Program Files\Siemens\WinCC\bin or base library folders; always edit within the project's local GraCS folder to avoid being overwritten during OS Project Editor execution.
Full Download Requirement on Structural Changes: Certain modifications—such as modifying alarm message classes or changing project-wide screen resolution—cannot be loaded via delta download and mandate an Entire Download during scheduled plant shutdowns.

Engineer FAQ

Can I update faceplate graphics without stopping WinCC Runtime?

Yes. For purely graphical changes, copying the modified .pdl file into the OS Server GraCS directory updates the screen immediately upon reopening.

Why did newly added tags not show up after copying the PDL?

Because tags must be compiled from CFC into WinCC Tag Management via AS-OS compilation and loaded to the server via OS download.

Does copying PDLs manually cause problems later?

It can cause the next OS delta download to warn about timestamp differences. Performing a formal OS delta download is the cleanest approach.

Do OS Clients need the modified PDL copied locally?

Standard multi-clients load PDLs directly from the OS Server; clients with local project copies require updating their local GraCS folder.

In what order should redundant OS servers be updated?

Always download changes to the Standby Server first, verify redundancy sync, and then download to the Master Server.

What happens if a faceplate references a non-existent tag?

The graphical object displays a broken link or yellow exclamation mark, and script errors are logged in WinCC_Sys_*.log.

Can I modify faceplates on PCS 7 V7.1 while AS is in RUN?

Yes, both graphical PDL updates and CFC delta downloads are fully supported while the AS and OS are running.

Where are faceplate PDL files stored in a project?

Inside the project directory under the GraCS subdirectory (Graphic Screens).

What does the OS Project Editor do to faceplates?

The OS Project Editor copies standard template faceplates from the system library to GraCS, potentially overwriting user changes if not protected.

How do I protect custom faceplates from OS Project Editor overwrites?

Save custom modifications under unique file names or configure the OS Project Editor not to overwrite existing basic pictures.

Technical References

Related Tags

WinCC Faceplates
PCS 7 V7.1
GraCS
Delta Download
Online Modification
Redundant OS
Graphics Designer

20 respuestas

Modifying and Deploying WinCC Faceplates Online in PCS 7 V7.1 Without Line Stoppage