Resolving WinCC Database Locking and Runtime Startup Errors in SIMATIC PCS 7 TDC Systems

In SIMATIC PCS 7 systems interfacing with SIMATIC TDC (Technology and Drive Control) racks, frequent application crashes, project open failures, and prompts to restart Windows are caused by orphaned WinCC runtime processes holding exclusive locks on the Step 7 / WinCC Sybase and SQL databases. To resolve this without frequent machine reboots, execute the Siemens script 'reset_wincc.vbs' from an elevated command prompt to terminate hung runtime processes ('CCDataMgr.exe', 'pdlcs.exe', 's7tgtopx.exe'), perform 'File > Save As... > with Reorganization (slow)' on the multiproject to rebuild database indices, and verify TDC communication driver compatibility.

Executive Summary

In heavy industrial automation (such as metals rolling mills, paper machines, and large mining winders), SIMATIC PCS 7 is frequently paired with SIMATIC TDC (Technology and Drive Control)—a specialized, high-speed multi-processor controller platform executing sub-millisecond motion control loops. In these combined architectures, the supervisory PC workstation acts as both an Engineering Station and an Operator Station, communicating with TDC racks via CP 1616/1623 interface cards, GDM (Global Data Memory), and WinCC communication channels.

Maintenance personnel frequently report severe operational instability on these stations: projects fail to open in SIMATIC Manager, runtime crashes with ambiguous 'incomplete installation' or database access errors, and the workstation must be rebooted multiple times per shift to regain system operation. This instability is almost never an actual software installation defect; rather, when a high-speed TDC communication channel faults or WinCC runtime experiences an unhandled script termination, backend processes fail to exit cleanly, leaving exclusive locks on Microsoft SQL Server and Sybase database files. This guide outlines the rapid reset script procedure, database reorganization steps, and driver diagnostic checks required to permanently restore stability.

Architecture and Fundamental Mechanics

The interaction between SIMATIC PCS 7, WinCC runtime, and SIMATIC TDC relies on tightly coupled inter-process communication:

Multi-Tiered Process and Database Locking:
- SIMATIC Manager manages engineering cross-references using Sybase SQL Anywhere.
- WinCC manages runtime tags, historical archives, and graphics through Microsoft SQL Server and background executables (CCDataMgr.exe, pdlcs.exe, Script.exe, s7tgtopx.exe).
- SIMATIC TDC integrates via specialized DCOM communication drivers (e.g., TDC DCOM Server, GDM drivers) exchanging data with TDC subracks.
The Orphaned Process Deadlock:
- When an unhandled error occurs—such as a network glitch to the TDC rack or an abnormal termination of an operator screen—the graphical user interface closes, but background worker processes remain active in memory.
- These lingering processes retain exclusive lock handles on database files (*.db, *.mdf, *.ldf).
- When an engineer attempts to reopen SIMATIC Manager or launch WinCC, the new process cannot acquire database locks and crashes, displaying generic 'installation incomplete' or 'database inaccessible' warnings.
Function of the reset_wincc.vbs Utility:
- Rather than executing time-consuming operating system reboots, Siemens provides the maintenance script reset_wincc.vbs (located in C:\Program Files (x86)\Siemens\WinCC\bin\).
- This utility forcefully identifies and terminates all lingering WinCC and Step 7 worker threads, releases locked file handles, and resets IPC shared memory segments cleanly.

Step-by-Step Implementation Procedure

Follow these steps to clear locked processes and stabilize the PCS 7 / TDC workstation:

Execute reset_wincc.vbs to Clear Orphaned Processes:
- Close all visible Siemens applications.
- Click Start > type cmd > right-click 'Command Prompt' and select 'Run as administrator'.
- In the command window, execute:
reset_wincc.vbs
- Wait for the script to execute. A pop-up message will display 'WinCC reset finished' (or command line output confirming termination of CCDataMgr, pdlcs, Script, and database connection stubs).
Reorganize Multiproject Database:
- Launch SIMATIC Manager.
- Open your plant multiproject.
- Select 'File > Save As...'.
- In the 'Save As' dialog, select the radio button 'with Reorganization (slow)'.
- Specify a target storage directory and click 'OK'.
- Allow Step 7 to sweep the internal Sybase database tables, remove fragmented database pages caused by crashes, and rebuild internal relational index structures.
Verify SIMATIC TDC Hardware and Network Communication:
- Check physical fiber-optic and Ethernet cabling linking the PC (CP 1616/1623) to the TDC rack.
- Verify that TDC subrack CPU modules (e.g., CPU551) are in steady RUN mode without red fault LEDs (SF).
- Inspect Windows Event Viewer ('Application' and 'System' logs) for TDC communication timeout errors or DCOM permission warnings.
Verify WinCC Channel Diagnostics:
- Open the WinCC project in WinCC Explorer.
- Navigate to 'Channel Diagnostics' (WinCCChannelDiagnostics.exe).
- Verify that the communication driver linking to the TDC station shows green checkmarks with zero error counter increments.
Test Runtime Activation:
- Activate WinCC Runtime: confirm that process screens load smoothly and communicate bidirectionally with TDC memory blocks.

Verification

Run reset_wincc.vbs: verify that Windows Task Manager confirms zero remaining CCDataMgr.exe, pdlcs.exe, or s7tgtopx.exe processes.
Open SIMATIC Manager: confirm that the project opens immediately without database connection delays.
Verify WinCC Runtime stability: operate the plant across a full shift and confirm that no spontaneous crashes or reboot prompts occur.
Check Windows Event Viewer: confirm that no DCOM or database corruption events are logged.

Limitations and Operational Precautions

Do NOT execute reset_wincc.vbs while an online automation download or firmware update is actively in progress, as terminating compiler processes mid-write can corrupt project binaries. Ensure that SIMATIC TDC software releases (e.g., D7-SYS) match the compatibility matrix of your specific PCS 7 version. System components, software packages, and hardware maintenance should be verified through an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

What does reset_wincc.vbs do?

It forcefully terminates all background WinCC and Step 7 processes, releases locked database file handles, and clears IPC shared memory without requiring a Windows reboot.

Where is reset_wincc.vbs located?

In C:\Program Files (x86)\Siemens\WinCC\bin\reset_wincc.vbs (or directly executable from Command Prompt if the WinCC bin folder is in the system PATH).

Why did the system report 'Installation incomplete' when software was installed?

Because lingering processes holding database locks prevent new application sessions from initializing, triggering misleading installation error prompts.

How does 'Save As with Reorganization (slow)' help after a crash?

It removes fragmented gaps, purges orphaned pointer records, and recalculates database indices corrupted by abrupt process terminations.

What is SIMATIC TDC?

SIMATIC Technology and Drive Control (TDC) is a high-performance modular rack controller system designed for ultra-high-speed motion control, rolling mills, and power electronics.