C135 PCS 7 (PCS7)
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Resolving AS-OS Compile Error 15454 in SIMATIC PCS 7

Resolving AS-OS Compile Error 15454 in SIMATIC PCS 7

In SIMATIC PCS 7, encountering 'Error number: 15454' during an AS-OS compilation after making minor logic modifications (such as adding an AND gate in CFC) indicates internal database corruption or desynchronized cross-reference pointers between the Step 7 project database and the WinCC CS engineering database. To resolve this error: 1) Close all CFC charts and WinCC editors; 2) In SIMATIC Manager, perform a project reorganization via File > 'Save As...' with 'Reorganization (slow)' selected; 3) In Windows Explorer, open the WinCC OS project folder and delete temporary compilation cache files (.asl and .loc); and 4) Re-execute the AS-OS compilation with Scope set to 'Entire OS' with 'With memory reset' checked.

Table of Contents

Executive Summary

During routine automation engineering in SIMATIC PCS 7, system engineers rely on the AS-OS Compile wizard to parse CFC chart interconnections, translate block attributes, and populate WinCC tag management and alarm logging. Occasionally, an engineer adds an elementary instruction (such as a boolean logic gate or timer) and triggers an incremental compilation, only for the compiler to abort abruptly with the cryptic diagnostic 'Error number: 15454'. This error originates within the Step 7 / WinCC COM compilation bridge (s7hcom.dll) and signals broken internal relational indexes. This guide analyzes the database mechanics responsible for Error 15454 and details the verified four-step restoration procedure.

Architecture and Fundamental Mechanics

The AS-OS Database Interface and Error 15454 Mechanics

+-------------------------------------------------------------------------+
|                         SIMATIC Manager Multiproject                    |
|                                                                         |
|   Step 7 Relational Database (*.s7p / Sybase ASA / MS Access format)    |
|   - CFC Charts, Block Instances, Symbolic Address Table                 |
+-----------------------------------|-------------------------------------+
                                    |
                                    v AS-OS Compiler Engine (s7hcom.dll)
+-------------------------------------------------------------------------+
|               Intermediate Cross-Reference Parsing                      |
|                                                                         |
|   FAILURE CONDITION:                                                    |
|   - Broken internal pointer, fragmented table index, or orphaned tag ID |
|   - Language identifier desynchronization (e.g. English US vs German)   |
|   - Compiler encounters unresolvable pointer -> THROWS ERROR 15454!     |
+-----------------------------------|-------------------------------------+
                                    |
                                    v Recovery Procedure
+-------------------------------------------------------------------------+
|             'Save As...' with 'Reorganization (slow)'                   |
|                                                                         |
|   1. Physically purges deleted and orphaned database records            |
|   2. Re-indexes all relational keys and symbol cross-references         |
|   3. Cleans temporary OS compilation caches (*.asl / *.loc)             |
|   4. Restores complete project integrity for successful OS compile      |
+-------------------------------------------------------------------------+

Root Causes for Error 15454

  1. Database Fragmentation: Routine block deletions, chart renumbering, and incomplete prior compilations leave orphaned records in the Step 7 database. When the compiler encounters an orphaned pointer referencing a non-existent block pin, s7hcom.dll encounters an unhandled exception and exits with Error 15454.
  2. Temporary Lock and Cache Files: When an AS-OS compile is interrupted (due to a crash or power failure), temporary lock files (*.loc) and incomplete compiler log files (*.asl) in the WinCC project directory prevent subsequent write operations.
  3. Language Incongruence: If the AS program text library is configured for English (US) while the WinCC project default language is set differently without matching text table mappings, the tag compiler can fail during message generation.

Step-by-Step Implementation Procedure

Step 1: Close Active Engineering Editors

  1. Save and close all open CFC charts.
  2. Close WinCC Explorer and all WinCC sub-editors (Graphics Designer, Alarm Logging, Tag Management).
  3. In Task Manager, verify that background processes s7tgtopx.exe, CCConfigStudio.exe, and s7hcom.exe have terminated cleanly.

Step 2: Delete Temporary OS Compilation Cache Files

  1. In Windows Explorer, navigate to the affected WinCC OS project folder on the Engineering Station.
  2. Search for and delete any files with the following extensions:
    - *.asl (AS-OS intermediate transfer logs)
    - *.loc (Database lock files)
    - *.tmp (Temporary compilation work files)
  3. Delete TRANSFER.LOG so a completely fresh log will be written.

Step 3: Execute Slow Project Reorganization in SIMATIC Manager

  1. Open SIMATIC Manager.
  2. Open the multiproject.
  3. In the menu bar, select File > 'Save As...'.
  4. In the Save As dialog, check the checkbox: With Reorganization (slow) (or Mit Reorganisation (langsam)).
  5. Specify a new folder destination on your local drive (e.g., D:\Projects_Reorg\Plant_Rev2).
  6. Click OK. SIMATIC Manager will perform a block-by-block and table-by-table database reconstruction, defragmenting all tables and purging orphaned pointers (this process may take 5 to 20 minutes depending on project size).

Step 4: Recompile the OS with Memory Reset

  1. Once reorganization finishes, open the newly saved multiproject in SIMATIC Manager.
  2. Right-click the OS project and select Compile.
  3. In the compile wizard, select Scope: Entire OS.
  4. Check the box With memory reset.
  5. Click Compile.
  6. Confirm that the compilation executes through all phases and finishes with status 0 errors.

Verification

  1. Compilation Summary Check: Verify that the compile wizard completes with a green checkmark and message: Compilation completed with 0 errors and 0 warnings.
  2. Transfer Log Verification: Open TRANSFER.LOG in the WinCC project directory. Verify that all AS blocks, newly added logic, and alarm messages were transferred cleanly.
  3. WinCC Tag Management Audit: Open WinCC Explorer on the ES. Confirm that newly instantiated tags under the S7 Named Connection match the modified CFC logic.

Limitations and Operational Precautions

  1. Entire OS Compilation Downtime: Running an Entire OS compile with memory reset requires that the OS project on the ES is synchronized; the next download to an operating OS Server must be carefully scheduled as an incremental delta or during plant maintenance.
  2. Severe Database Corruption: If 'Save As with Reorganization (slow)' fails or terminates with a fatal SQL error, the project database is critically damaged and must be restored from an uncompressed backup archive or repaired by Siemens Technical Support.

Engineer FAQ

What does Error 15454 mean in PCS 7?

It is an internal database inconsistency error within the AS-OS compilation engine, indicating broken cross-reference pointers or corrupted project tables.

Why did a simple AND instruction trigger Error 15454?

The error is not caused by the AND instruction itself, but by latent database corruption in the Step 7 project that was exposed when the compiler attempted to re-index the chart.

What does 'Save As with Reorganization (slow)' do?

It copies only valid database records to a new project location, physically rebuilding table indexes and eliminating orphaned pointers.

Can I delete *.asl files safely?

Yes, *.asl files are temporary compile logs generated during AS-OS compilation and can be deleted without data loss.

Why is 'With memory reset' recommended after reorganization?

It forces the compiler to re-generate all WinCC tag structures and message IDs from scratch, eliminating stale database artifacts.

Does Error 15454 affect the running PLC controller?

No, Error 15454 is strictly an engineering database error on the ES; the running AS continues executing normally.

How often should slow reorganization be performed?

It is recommended before major project milestones, after major library upgrades, or whenever recurring compile errors occur.

What if reorganization fails to fix Error 15454?

Retrieve a prior verified archive from File > Retrieve, or contact Siemens Technical Support for database repair.

Does language setting affect Error 15454?

Yes, desynchronized languages between Step 7 Text Libraries and WinCC project languages can trigger compiler crashes.

Where is the AS-OS compilation engine located?

It is implemented primarily in s7hcom.dll inside the Step 7 and WinCC installation folders.

Technical References

Related Articles

Related Tags

  • Error 15454
  • OS Compile
  • Reorganization
  • Database Corruption
  • s7hcom.dll
  • TRANSFER.LOG
  • SIMATIC Manager
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