Resolving Plant Hierarchy Changes Not Updating on PCS 7 OS Clients

When Plant Hierarchy (PH) modifications made in SIMATIC Manager appear in the OS Server's project explorer areas but fail to appear on OS Client stations, the discrepancy is caused by outdated Server Data Packages (*.pck) or uncompiled Picture Tree structures on the client. OS Clients do not query SIMATIC Manager directly; they derive their area navigation buttons and overview hierarchy from the server package and local OS Project Editor generation. To resolve this, compile the OS Server, generate server data (Options -> Generate Server Data), update and assign the server package on the OS Client project, run the OS Project Editor on the client, and download the updated client project to the physical OS Client station.

Plant Hierarchy and OS Client Area Navigation Architecture

In SIMATIC PCS 7, the Plant Hierarchy (PH) defined in SIMATIC Manager Plant View establishes the plant's technological structure (Plant -> Unit -> Function). During OS compilation, the PH is mapped into the WinCC Picture Tree Manager, generating the hierarchy of overview screens, area selection buttons, and group display alarm hierarchies.

In a distributed multi-client architecture, an OS Client has no direct database link to the Engineering Station's STEP 7 database. Instead, an OS Client operates on a lightweight project that imports a Server Data Package (<ServerProjectName>.pck) generated by each OS Server. The OS Client reads technological area names, server tags, and picture paths through this package. If the server data is not regenerated, re-imported, and processed by the client's local OS Project Editor, the client continues to render the obsolete area overview structure.

Root Causes of Plant Hierarchy Desynchronization

The failure of updated Plant Hierarchy areas to appear on OS Clients typically stems from four missing steps in the engineering workflow:

Server Data Not Regenerated: While compiling the OS Server updates the server's local SQL database, the exported .pck file is only updated if the compiler's server data generation option is executed.
Server Package Not Updated on Client: In the OS Client WinCC project, the server package reference remains locked to the old package timestamp until an explicit Update command is executed.
Picture Tree Manager Not Rebuilt on Client: The client's runtime navigation buttons in @Overview1.pdl are statically compiled by the OS Project Editor. If the OS Project Editor is not run on the client project, the client interface retains old button layouts.
Missing Project Download to Client PC: Modifying the OS Client project on the Engineering Station has no runtime effect until the project files are downloaded over the Terminal Bus to the physical OS Client PC.

Server Data and OS Client Synchronization Matrix

The following table details the lifecycle stages and artifacts involved in propagating hierarchy updates:

Engineering StepExecution LocationGenerated File / ActionImpact on SystemOS Server CompilationEngineering StationUpdates OS Server SQL DatabaseServer acquires new PH areas and picturesGenerate Server DataWinCC Explorer (OS Server)<ServerName>.pck in Packages\Creates portable tag and area definition packageUpdate Server Data on ClientWinCC Explorer (OS Client)Reads new .pck into Client projectClient recognizes new server tags and areasRun OS Project EditorWinCC Explorer (OS Client)Rebuilds @Overview1.pdl and Picture TreeCreates new navigation buttons on clientDownload OS Client ProjectSIMATIC Manager (ES -> Client)Copies project folder to target clientTarget PC displays new hierarchy in Runtime

Step-by-Step Procedure to Propagate Plant Hierarchy to OS Clients

To synchronize the updated Plant Hierarchy across all OS Client stations:

Compile OS Server and Generate Server Data:
- In SIMATIC Manager, perform an OS Compile for the OS Server (Compile OS -> Changes Only).
- In WinCC Explorer on the OS Server (or via SIMATIC Manager), right-click Server Data and select Generate.
- Verify that <ServerName>.pck is created with a current timestamp in the project's Packages directory.
Update Server Data on the OS Client:
- In SIMATIC Manager Component View, open the OS Client project in WinCC Explorer.
- Navigate to Server Data in the project navigation tree.
- Right-click the server package corresponding to your OS Server and select Update (or Implicit Update).
Assign OS Server and Configure Area Authorization:
- Right-click the server data package and select Configure.
- Verify that all newly created Plant Hierarchy areas are checked and assigned to the server.
Run OS Project Editor on OS Client:
- In the OS Client WinCC Explorer, open the OS Project Editor.
- Navigate to the Areas tab. Confirm that the newly created hierarchy areas appear in the area list.
- Click OK to rebuild the Picture Tree, screen layout, and navigation button macros.
Download Client Project to Physical Station:
- In SIMATIC Manager, right-click the OS Client object and select PLC -> Download.
- Select the target client PC and confirm the transfer.
- If runtime was active on the client, WinCC will automatically reload the project or prompt for a client restart.

Verification

Verify hierarchy synchronization on the client:
1. Open WinCC Runtime on the physical OS Client station.
2. Inspect the top overview navigation bar (@Overview1.pdl).
3. Confirm that the new area buttons corresponding to the modified Plant Hierarchy folders are visible.
4. Click an area button to ensure it navigates to the expected process screen without picture loading errors.
5. Verify that group displays on the new area buttons reflect active alarms originating from that hierarchy branch.

Limitations and Operational Precautions

User Authorization Gaps: If new hierarchy areas are created, existing user profiles in WinCC User Administrator may lack authorization for the new areas. Verify user permissions in User Administrator.
Client Runtime Interruption: Re-downloading the OS Client project momentarily closes the client runtime session. Coordinate downloads during non-critical production intervals.
Redundant Server Packages: Ensure server data is generated from the master OS Server; redundant partner packages synchronize automatically if redundancy is active.

Engineer FAQ

Why do area changes appear on the OS Server immediately but not on Clients?

The OS Server compiles directly from the Engineering Station database. OS Clients operate independently and rely on imported Server Data packages and local OS Project Editor compilation.

Do I need to compile the OS Client in SIMATIC Manager?

No, OS Clients do not have an 'OS Compile' action in SIMATIC Manager. They require updating Server Data, running the OS Project Editor, and executing a project download.

Can I automate server data package updates on the client?

Yes, in the OS Client's Server Data properties, enable the option 'Update automatically' (Implicit Update) to automatically load new packages whenever the project opens.

Why is an area button visible on the server but greyed out on the client?

The logged-in user on the client lacks authorization for that specific area in WinCC User Administrator, or the picture file referenced by that area is missing from the client GraCS folder.