C135 PCS 7 (PCS7)
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Procedure for Migrating WinCC OS Projects Across Multiprojects in SIMATIC PCS 7

Procedure for Migrating WinCC OS Projects Across Multiprojects in SIMATIC PCS 7

Copying an Operator Station project (including OS Master Server, Standby Server, and OS Clients) from one SIMATIC PCS 7 Multiproject to another is fully supported, provided cross-project communication and hierarchy dependencies are systematically reconciled. Engineers must open both multiprojects in SIMATIC Manager, copy the PC Station objects from the source Component View to the target Component View (which automatically transfers graphic screens, scripts, and Plant Hierarchy layouts), reassign the Plant Hierarchy folders to the target AS controller, update S7 fault-tolerant connection endpoints in NetPro, generate server data (*.pck), and execute a full OS compilation with Picture Tree recalculation.

Table of Contents

Executive Summary

In large SIMATIC PCS 7 industrial control systems, automation architectures are structured as Multiprojects to facilitate multi-user engineering, modular plant commissioning, and project standardization. During facility expansions, revamping projects, or software consolidation, automation engineers frequently need to transfer an existing Operator Station (OS) configuration—such as a redundant OS Server pair with associated OS Clients, extensive custom graphics (*.pdl), and alarm archives—from one Multiproject into another. While copying raw Windows folders corrupts internal project indices, SIMATIC Manager provides structured procedures to copy PC stations cleanly across Multiproject boundaries. This technical article details the transfer mechanics, NetPro connection realignment, and Plant Hierarchy reassignments required for seamless migration.

Multiproject Architecture: Decoupling and Recombining Distributed AS and OS Projects

The SIMATIC PCS 7 Multiproject framework serves as an overarching umbrella coordinating independent project containers:

  • AS Projects: Contain S7-400 or CPU 410 hardware configurations, CFC charts, SFCs, and controller logic.
  • OS Projects: Contain WinCC Server and Client PC station definitions, process graphics, Tag Logging archives, and alarm messages.
  • Master Data Library: Holds shared block types and technological templates across all sub-projects.
  • Multiproject Cross-References: Network subnets (Industrial Ethernet, PROFIBUS) and S7 connections span across individual project boundaries, allowing stations in Project A to communicate with stations in Project B.

Prerequisites Before Transferring OS Stations Between Multiprojects

Before copying OS stations into a target Multiproject, complete these prerequisites:

  1. Software Version Parity: Both Multiprojects must share identical PCS 7 versions, service packs, and update bundles.
  2. Subnet Alignment: Verify that the Industrial Ethernet subnet names (e.g. Plant_Bus_1, Terminal_Bus) exist with matching properties in both Multiprojects.
  3. Archive Backups: Create complete archive backups (File -> Archive...) of both source and target Multiprojects.
  4. Close Active Runtimes: Ensure WinCC Runtime is deactivated on all stations involved.

Component View vs Plant View Transfer Mechanics

Understanding view mechanics in SIMATIC Manager is vital for error-free transfers:

  • Component View: Governs physical and software containers (PC Station hardware, WinCC project files, S7 Programs). Copying must always be initiated from the Component View to ensure that graphic screens, C-scripts, and database files are transferred.
  • Plant View (Technological Hierarchy): Organizes equipment hierarchically into plant areas, units, and functions. When a PC Station is copied in Component View, SIMATIC Manager automatically replicates associated technological hierarchy structures into the target Multiproject.

Reassigning Plant Hierarchy Folders to Target Controllers

After copying the OS PC Station into the target project, the Plant Hierarchy must be realigned:

  • The copied hierarchy folders initially retain pointers referencing the original AS controller in the source Multiproject.
  • In the target project's Plant View, open the properties of each copied hierarchy folder.
  • Under AS Assignment, reassign the folder to the target AS controller located in the new Multiproject.
  • This ensures that subsequent OS compilations extract tags from the correct local controller.

Reconfiguring S7 Fault-Tolerant Connections in NetPro

Communication connections must be reconstructed in the target environment:

  • S7 connections between WinCC OS Servers and automation stations do not automatically bind to new controllers.
  • Open NetPro in the target Multiproject.
  • Select the WinCC Application inside the copied OS Server PC Station.
  • In the connection table, delete obsolete cross-project connections and insert fresh S7 Connection (or S7 Fault-Tolerant Connection) links to the target AS controller CP 443-1 / CPU interface.
  • Compile NetPro with Compile and check everything.

Step-by-Step Procedure for Cross-Multiproject OS Migration

Execute this sequence to migrate the OS stations without errors:

  1. Open Both Multiprojects Simultaneously: In SIMATIC Manager, open both the Source Multiproject (S7_Pro1) and Target Multiproject (S7_Pro2).
  2. Arrange Windows in Cascade: Press Shift + F2 to arrange Component and Plant Views in a four-window cascade.
  3. Copy PC Stations in Component View:
    * In S7_Pro1 Component View, select the OS Master Server, OS Standby Server, and OS Clients.
    * Right-click and select Copy.
    * In S7_Pro2 Component View, select the target project node, right-click, and select Paste.
    * Allow the file copy transaction to complete (may take 10 to 30 minutes depending on graphic count).
  4. Reassign Hierarchy in Plant View: In S7_Pro2 Plant View, verify folder structures and reassign AS controller targets.
  5. Rebuild NetPro Connections: Open NetPro in S7_Pro2, configure S7 connections from OS Servers to AS controllers, and compile NetPro.
  6. Generate Server Data: In the target OS Server project, right-click Server Data and select Generate.
  7. Update OS Clients: In the OS Client projects, open Server Data, select Implicit Update, and assign the new server package.
  8. Compile Entire OS: Right-click the OS Server in SIMATIC Manager, select Compile, and execute Entire OS compilation.

Multiproject OS Migration Task and Verification Matrix

The following table provides verified actions and failure prevention rules during cross-multiproject migration:

Migration PhaseOperational ActionPrimary EditorPotential Failure ModePrevention / Corrective Action1. PreparationVerify subnet names & IP rangesNetPro / HW ConfigSubnet name collisionAlign Industrial Ethernet subnet properties2. File TransferCopy PC StationsComponent ViewBroken graphic linksAlways copy in Component View, never via File Explorer3. HierarchyReassign AS targetPlant ViewTag compile to wrong ASUpdate 'AS Assignment' on all hierarchy folders4. NetworkingReconnect S7 communicationNetProDisconnected WinCC tagsRebuild S7 fault-tolerant connections and compile NetPro5. Server DataGenerate *.pck server packageWinCC ExplorerClients cannot find serverRight-click Server Data -> Generate on OS Server6. OS CompileCompile Entire OSSIMATIC ManagerMissing process tagsCompile Entire OS with Picture Tree recalculation

Verification

Confirm that the migrated OS project operates with full fidelity:

  1. OS Compilation Log Review: Verify that OS Compilation completes with 0 errors and zero missing tag warnings.
  2. NetPro Connection Status Check: In NetPro, select the OS Server and verify that S7 connections indicate valid partner endpoints.
  3. Graphics Designer Inspection: Open migrated screens in Graphics Designer. Confirm that @GroupDisplay objects and faceplates reference valid WinCC tag names without disconnected dynamic dialogs.
  4. Runtime Operational Test: Start WinCC Runtime. Verify that live process values update dynamically, alarms populate the alarm banner, and operator commands execute cleanly to the target AS controller.

Server Data Generation and Client Package Update Best Practices

When multi-client architectures are involved:

  • Always Regenerate Server Data First: Never attempt to configure OS Clients until the OS Server pair has successfully generated its server data package (*.pck).
  • Use Implicit Package Update: In OS Client projects, configure Server Data properties for Implicit Update so client stations automatically adopt newly compiled server packages without manual intervention.

Limitations and Operational Precautions

Never copy OS project files using Windows File Explorer outside SIMATIC Manager. External file copying breaks internal Sybase/Access relational database GUIDs, rendering the project unusable.

When sizing additional OS Servers or Clients in the target Multiproject, all runtime tags, archive licenses, and client connection entitlements must be verified against official Siemens ordering guidelines and confirmed through an authorized Siemens distributor quotation.

Engineer FAQ

Can I copy an OS project while WinCC Runtime is active?

No. WinCC Runtime locks project database files (.mdf, .ldf, *.dcf); runtime must be completely stopped before copying.

Do custom PDL graphic screens copy over automatically?

Yes. Copying the PC Station in Component View transfers the entire WinCC project folder, including all GraCS pictures and scripts.

Why must I reassign hierarchy folders in Plant View?

Because copied folders still point to the old AS controller in the source project; reassigning links them to the new controller.

Does copying an OS project copy historical alarm archives?

No. Historical archive database files (*.mdf) in the ArchiveManager folder are omitted to conserve space; only the project configuration is copied.

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