C135 PCS 7 (PCS7)
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Rebuilding a SIMATIC PCS 7 Engineering Station - Hardware Support Packages, GSD Files, and Add-On Libraries

Rebuilding a SIMATIC PCS 7 Engineering Station - Hardware Support Packages, GSD Files, and Add-On Libraries

When rebuilding a SIMATIC PCS 7 Engineering Station (ES) from a bare operating system or replacement PC, merely reinstalling the base PCS 7 DVD and copying the Step 7 S7DATA\GSD folder is insufficient to restore full engineering capabilities. A complete rebuild requires three discrete hardware catalog tiers: first, install third-party field device GSD/GSDML files via HW Config -> 'Options > Install GSD Files...'; second, install Siemens Hardware Support Packages (HSPs) via 'Options > Install Hardware Updates...' to recognize specific module firmware revisions; third, install dedicated setup packages for intelligent weighing or specialty hardware (such as SIWAREX, AddFEM, or communication drivers) using their official installation media. These add-ons inject mandatory function blocks, symbol tables, and WinCC faceplates that raw GSD files do not provide.

Table of Contents

Prerequisites and Pre-Rebuild Inventory: The Installed Software Audit

Rebuilding an Engineering Station (ES) is an intensive operational task. Field engineers often hesitate to wipe or replace an ES out of fear that custom drivers, device descriptions, or software hotfixes will be permanently lost, resulting in compilation failures or disabled CFC blocks.

Before decommissioning or formatting the old engineering machine, engineers must execute a rigorous baseline audit:

  1. Full Disk Image: Create an image of the physical hard drive (e.g., using Acronis True Image, Clonezilla, or Siemens Image Creator).

  2. License Transfer: Transfer all floating, upgrade, and single licenses from the local drive to a secure USB storage key or centralized license server using Automation License Manager (ALM). Never format a drive with active licenses!

  3. Installed Software Inventory: In SIMATIC Manager, select Help > About SIMATIC Manager > Installed Software... > Save to file. This exports a definitive CSV/text list detailing every installed Siemens component, service pack, update level, and hotfix (e.g., CFC V8.2 Upd1, S7-SCL V5.6, TH V8.2 Upd2, WinCC V7.4 Upd3).

Hardware Catalog Tiers: GSD/GSDML Files vs Hardware Support Packages (HSPs)

A common misconception during ES rebuilds is assuming that copying the S7DATA\GSD directory transfers all hardware definitions:

  • GSD / GSDML Files (General Station Description): Text and XML files provided by third-party device manufacturers (e.g., Endress+Hauser, Yokogawa, Danfoss, Festo) that define PROFIBUS DP/PA or PROFINET cyclic I/O structures. They can be installed into HW Config via Options > Install GSD Files....

  • Hardware Support Packages (HSPs): Proprietary Siemens hardware definitions required for Siemens ET 200 distributed I/O interface modules, new S7-400 CPU firmware versions, CP communication processors, and power supplies. HSPs cannot be imported as raw GSD files; they must be installed via HW Config -> Options > Install Hardware Updates... from a downloaded Siemens HSP archive.

Specialty Hardware Add-On Packages: The Case of SIWAREX and Weighing Modules

Certain intelligent modules—most notably SIWAREX weighing systems (SIWAREX U, FTA, FTC, WP), AddFEM turbine modules, and condition monitoring systems—require much more than hardware catalog entries:

  • Driver Function Blocks: They require technological function blocks (e.g., FB1012 SIWA_FTA) that execute complex multi-cycle handshakes and calibration routines in the S7-400 CPU.

  • CFC Symbol Tables and Module Drivers: The PCS 7 Driver Generator (Generate Module Drivers) requires specific metadata to automatically connect diagnostic alarms and channel drivers.

  • WinCC OS Faceplates and Typicals: Dedicated @PG_SIWAREX... graphic pictures and block icons must reside in the OS project GraCS folder.

Merely copying GSD files leaves the system without these critical libraries. The engineer must run the dedicated SIWAREX PCS 7 Add-on Library Setup executable matching the PCS 7 version.

Network Configuration, Simatic Shell, and User Administrator Rights

Once software packages are installed, network and security environments must be configured to enable multi-station engineering:

  • Network Binding Order: Windows must prioritize the Terminal Bus network adapter. Assign static IP addresses and ensure NetBIOS name resolution is functional.

  • Simatic Shell: In Windows Explorer, right-click Simatic Shell -> Settings. Select the Terminal Bus adapter and configure encrypted communication passwords to match the OS servers.

  • User Accounts: The logged-in Windows user must belong to local groups SIMATIC HMI, Siemens TIA Engineer, and Administrators.

Comparative Hardware Catalog Matrix: GSD vs HSP vs Add-On Library

The following table delineates the differences between hardware expansion mechanisms in SIMATIC PCS 7:

MechanismTarget DevicesInstallation MethodInjected ComponentsFailure Symptom if MissingGSD / GSDML3rd-Party DP/PA/PN DevicesHW Config > Install GSD FilesHardware catalog entry, generic I/O modulesModule appears as 'Order number unknown'Hardware Support Package (HSP)Siemens S7-400, ET 200, CP modulesHW Config > Install Hardware UpdatesCatalog entries, parameter dialogs, firmware tablesRed question mark in HW Config rackAdd-On Library (e.g., SIWAREX)Intelligent Weighing / Process ModulesStandalone Installer (Setup.exe)AS Function Blocks, WinCC Faceplates, CFC TypicalsCFC block missing from catalog; compile aborts

Step-by-Step Checklist for Rebuilding an Engineering Station

Follow this rigorous checklist when commissioning a replacement Engineering Station:

  1. Operating System Foundation:
    - Install certified Windows OS build from Siemens Restore DVD (or clean Windows 10 LTSB / Server 2012/2016).
    - Assign exact target computer name and static IP addresses.
    - Add user to SIMATIC HMI, Siemens TIA Engineer, and Administrators.

  2. Base Software and Updates Installation:
    - Install base SIMATIC PCS 7 release matching the plant version.
    - Cross-check against the saved 'Installed Software' inventory text file.
    - Install all required PCS 7 Service Packs and Cumulative Updates (e.g., PCS 7 V8.2 Upd1).

  3. Install Hardware Support Packages (HSP):
    - Open HW Config -> Options > Install Hardware Updates....
    - Browse to the Siemens HSP offline repository and install all required packages.

  4. Install Third-Party GSD Files:
    - In HW Config, select Options > Install GSD Files....
    - Browse to the backed-up GSD folder and install all field device files.

  5. Install Add-On Libraries and Tooling:
    - Execute setups for SIWAREX PCS 7 Add-on Library, SIMATIC PDM, SIMIT, and third-party tools (e.g., RealVNC, antivirus exclusions).

  6. Restore Licenses and Simatic Shell:
    - Transfer licenses back from USB using ALM.
    - Configure Simatic Shell Terminal Bus adapter.

  7. Test Multiproject Opening:
    - Retrieve the plant project archive and execute a test compilation.

Verification

Verify the rebuilt Engineering Station through the following validation steps:

  1. Open SIMATIC Manager and load the active plant multiproject. Verify that no warning dialogs appear regarding missing software packages.
  2. Open Hardware Configuration for all AS stations. Confirm that no rack slots show red question marks or unknown MLFBs.
  3. Open CFC Editor. Verify that all block libraries (APL, SIWAREX, custom blocks) appear in the block catalog.
  4. Execute CFC > Compile > Changes only. Verify error-free compilation.
  5. Open Simatic Shell. Verify that all OS Servers and Clients appear without blue question marks and pass remote communication tests.

Limitations and Operational Precautions

  • Software Update Parity: Even minor update discrepancies (e.g., CFC V8.2 Upd1 on the ES vs base V8.2 on an older ES) can trigger unwanted block version differences. Always align updates to the exact build.
  • Never Manually Copy DLLs: Never copy software binaries directly into C:\Program Files (x86)\Siemens\. System components require COM registration, registry entries, and database hooks created exclusively by official setup engines.
  • Antivirus Configuration: Configure antivirus software exclusions strictly according to Siemens whitepapers; real-time scanning of project database files causes severe corruption.

Engineer FAQ

Can I copy the S7DATA directory to transfer all hardware updates?

No. S7DATA contains partial database files. Directly copying the folder between machines can cause internal catalog database corruption. Always install GSDs and HSPs through the formal HW Config menus.

Where can I download the latest Siemens Hardware Updates (HSPs)?

Siemens publishes cumulative HSP archives on Siemens Industry Online Support (SIOS) under entry ID 23183356.

Why are my SIWAREX blocks missing even though the module appears in HW Config?

The hardware catalog entry (HSP/GSD) only defines the module's I/O addresses in HW Config. The AS technological blocks (SIWA_FTA) and faceplates require installing the separate SIWAREX PCS 7 Add-on software package.

What is the difference between GSD and GSDML?

GSD files are classic ASCII text files for PROFIBUS DP and PA devices. GSDML (GSD Markup Language) files are XML-based definitions for PROFINET IO field devices.

How do I backup Automation License Manager licenses safely?

Open ALM, select your local drive, select all licenses, and click License Key > Transfer... to move them to an external USB drive.

Technical References

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Related Tags

  • Engineering Station
  • Rebuild
  • HSP
  • GSD Files
  • SIWAREX
  • Hardware Configuration
  • PCS 7 Installation
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