Preventing OS Compilation from Overwriting Custom Picture Resolutions in PCS 7

In SIMATIC PCS 7, small popup windows and auxiliary dialogs (e.g. 200x200 or 200x100 pixels) are automatically resized back to full screen working dimensions (such as 1280x825 or 1920x950) during OS compilation if those pictures are assigned to folders in the Plant Hierarchy. By design, the OS compiler and OS Project Editor force all Plant Hierarchy picture files (.pdl) to conform to the standardized monitor working area resolution. To prevent OS compilation from altering custom picture geometry: create and maintain popup dialogs directly in WinCC Explorer Graphics Designer without linking them to the Plant Hierarchy in SIMATIC Manager. Auxiliary pictures not called in the Plant Hierarchy retain their custom width and height permanently across all OS compilation passes.

Executive Summary

During human-machine interface (HMI) engineering in SIMATIC PCS 7, developers frequently create compact operator dialogs-such as setpoint entry keypads, auxiliary confirmation prompts, or specialized valve controls measuring 200x100 or 300x200 pixels. A frequent source of frustration occurs when an engineer organizes these popup pictures inside the Plant Hierarchy in SIMATIC Manager: following an OS compilation, WinCC automatically stretches and forces these small pictures into massive full-screen resolutions (e.g. 1280x825 or 1920x950 pixels). This article explains how the OS Project Editor governs screen geometry across the Plant Hierarchy, outlines picture classification rules, and provides verified implementation methods for deploying fixed-geometry popup windows using WinCC Picture Windows.

Architecture and Fundamental Mechanics

WinCC Screen Hierarchy, OS Project Editor Layout Rules, and Geometry Enforcement:

Plant Hierarchy Picture Management in PCS 7:
In SIMATIC PCS 7, the Plant Hierarchy (PH) in SIMATIC Manager automatically generates the runtime picture navigation tree in WinCC OS.
Any graphic picture (.pdl) created under a hierarchy folder or assigned to an area/unit node is classified by the compiler as an Area Overview or Process Screen.
During an OS compilation (Compile OS), the compiler invokes internal routines from the OS Project Editor. The editor inspects the configured monitor resolution (e.g. 1280x1024 or 1920x1080), calculates the available process workspace by deducting the top Overview Area (@Overview1.pdl, ~120px) and bottom Button Bar (@Buttons11.pdl, ~79px), and forcefully rewrites the Width and Height attributes of every Plant Hierarchy picture to match the workspace (e.g. 1280x825 or 1920x950).
Segregation of Process Screens vs Auxiliary Popups:
Popup windows, faceplates, and floating dialogs are not primary process navigation displays. They are intended to open dynamically inside WinCC Picture Window objects (@PictureWindow) floating above the active screen.
If an auxiliary picture is created directly inside WinCC Explorer (GraCS) and not referenced by a Plant Hierarchy folder in SIMATIC Manager, the OS compiler ignores its internal geometry during compilation, permanently preserving its custom pixel dimensions.
Custom Monitor Layout Templates in OS Project Editor:
If an entire facility utilizes non-standard monitor resolutions (e.g. ultra-wide 3840x1080 or custom industrial displays), a custom layout template must be created in the WinCC installation directory under <Siemens_Dir>/WinCC/Options/PDL/Base_Data_Pool. However, for individual dialog windows, decoupling the picture from the Plant Hierarchy is the standard and correct DCS methodology.

Step-by-Step Implementation Procedure

Remove Popup Pictures from the Plant Hierarchy:
* In SIMATIC Manager on the Engineering Station, switch to Plant View (View -> Plant View).
* Inspect your hierarchy folders; locate any small popup or setpoint dialog pictures (e.g. Popup_Setpoints.pdl).
* Right-click the picture object and select Delete (or move it out of the Plant Hierarchy).
* Note: Deleting the picture reference in Plant View removes the hierarchy link but does not delete the physical .pdl file from the WinCC project directory.
Manage and Edit Popups Directly in WinCC Graphics Designer:
* Open WinCC Explorer on the ES or OS project.
* In the navigation tree, click Graphics Designer.
* Open Popup_Setpoints.pdl.
* In the Properties window, select the root picture node (Picture).
* Set Geometry -> Picture Width to 200 (or desired pixel size).
* Set Geometry -> Picture Height to 100.
* Place your setpoint inputs, confirmation buttons, and static text within this compact canvas.
* Save the picture.
Configure a Dynamic Picture Window in the Primary Screen:
* Open the primary plant mimic screen where the popup should appear.
* From the Object Palette -> Standard Objects, drag a Picture Window into the screen.
* In the Picture Window Properties -> Miscellaneous:
- Set Picture Name to Popup_Setpoints.pdl.
- Set Adapt Picture to No (or Yes to preserve scale).
- Set Adapt Size to Yes (the window automatically snaps to 200x100 pixels).
- Set Display (Visible) to No (hidden by default).
- Set Title to Yes and assign a caption (e.g. 'Setpoint Adjustment').
Add an Operator Call Script or Dynamic Toggle:
* On the button or block icon that opens the popup, add a Mouse Click C-action:
SetVisible('MainScreen.pdl', 'PictureWindow1', TRUE);
or in VBScript:
ScreenItems('PictureWindow1').Visible = True
Execute OS Compilation and Verify Geometry:
* In SIMATIC Manager, perform an OS compilation (Compile OS).
* Re-open Popup_Setpoints.pdl in Graphics Designer; confirm that its width and height remain exactly 200x100.

Verification

Verify Screen Resolution Retention and Runtime Operation:
1. In Graphics Designer, verify that Popup_Setpoints.pdl retains its 200x100 pixel geometry after a full OS compilation.
2. Activate WinCC Runtime; click the operator prompt button on the main process screen.
3. Confirm that the popup window appears as a crisp, floating 200x100 dialog centered or positioned over the calling object without stretching or full-screen distortion.

Limitations and Operational Precautions

Operational Precautions and Picture Management Rules:
- Never assign popup dialogs or faceplate sub-pictures to the Plant Hierarchy; only full-screen process area displays belong in the hierarchy tree.
- When using Picture Windows with Adapt Size = Yes, ensure that the popup canvas contains no off-screen elements; any graphical element positioned outside the nominal boundary will expand the window bounding box.

Engineer FAQ

Why did compiling the OS resize my 200x100 popup to 1280x825?

Because the picture was linked to a folder in the Plant Hierarchy. The OS compiler forces all Plant Hierarchy pictures to match the full-screen process workspace defined in the OS Project Editor.

How do I keep a small picture from being resized by the compiler?

Create and save the picture directly in WinCC Graphics Designer without adding it to the Plant Hierarchy in SIMATIC Manager.

Can I create custom monitor resolutions for the entire plant?

Yes. In OS Project Editor, you can select standard resolutions or create custom layout templates in the Base_Data_Pool directory, but this applies to full-screen displays, not individual popups.