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Resolving WinCC Graphics Designer Crashes During Dynamic Tag Assignment in SIMATIC PCS 7

Resolving WinCC Graphics Designer Crashes During Dynamic Tag Assignment in SIMATIC PCS 7

WinCC Graphics Designer crashes during tag assignment typically occur due to corrupted local tag browser caches, missing cumulative WinCC updates, or buffer faults in the WinCC Configuration Studio cross-reference engine. To resolve this issue, install the latest released WinCC update (such as WinCC V7.3 Update 8 or higher for PCS 7 V8.1), clear the temporary Graphics Designer cache files located in the project's 'GraCS' directory, and rebuild the project header information by executing 'Tools > Convert Project Data' in WinCC Explorer. Additionally, ensure that third-party antivirus software excludes the WinCC project directory from active scanning.

Table of Contents

Executive Summary

Automation engineers designing Human-Machine Interface (HMI) screens in SIMATIC PCS 7 occasionally face abrupt crashes of the WinCC Graphics Designer application (pdlrt.exe or GraphicsDesigner.exe) when browsing and assigning dynamic animation tags to process objects (such as indicator lamps, buttons, or custom faceplate instances). The crash typically occurs after assigning two or three tags in succession, producing an unhandled exception without an explicit error dialog. This instability stems from memory buffer exhaustion in legacy WinCC tag browser DLLs, outdated WinCC minor builds, corrupted temporary picture display files, or aggressive file locking by endpoint security scanners. This technical guide outlines the systematic procedure to isolate crash logs, apply vendor hotfixes, and repair corrupted graphics caches.

Root Cause Analysis: Why Graphics Designer Crashes During Tag Browsing

When an engineer opens the Tag Browser dialog within the Object Properties window, Graphics Designer queries the local Microsoft SQL Server WinCC configuration database (<ProjectName>.mdf). In PCS 7 environments, the tag database is populated with thousands of structured APL technological tags generated by CFC compilations.

In unpatched releases of WinCC V7.0, V7.2, and V7.3, several known vulnerabilities lead to application crashes:
* Tag Browser Buffer Overrun: Querying complex tag filters across deep plant hierarchies can overflow the internal memory allocation of CCProjectStudio.exe or PDLCS.dll.
* Corrupted Temporary PDL Cache: When graphic pictures (.pdl) are saved repeatedly during active tag browsing, temporary swap files (*.tmp, ~*.pdl) can become locked or desynchronized from the SQL Cross-Reference database.
* Antivirus File Interception: Real-time antivirus scanners intercepting file writes to the GraCS directory prevent Graphics Designer from releasing file handles, triggering access violations.

Software Patching and Cumulative Update Mechanics

Siemens regularly addresses graphics engine exceptions and memory management bugs through cumulative updates. For example, WinCC V7.3 Update 8 resolved multiple documented memory leaks and unhandled exceptions in the Tag Browser and Object Property dialogs.

Engineers must consult the Siemens Compatibility Tool (Entry ID 64847781) and review the specific update Readme documentation. Installing the latest cumulative update for the corresponding PCS 7 release updates critical runtime binaries (PDLCS.dll, CCTextDistributor.exe, CCDynamicDialog.dll) to stable revisions.

Graphics Designer Cache and Project Data Rebuilding

WinCC caches picture header metadata, OLE automation components, and ActiveX controls locally within the project structure. When database pointers diverge, opening pictures and assigning tags causes memory access collisions.

Executing the utility Tools > Convert Project Data forces WinCC to reread the underlying database schemas, recompile all global scripts and dynamic dialogs, and purge stale object references. Furthermore, deleting temporary hidden files in the GraCS folder restores clean editor operation.

Diagnostic Matrix for WinCC Configuration Crashes

The following table correlates diagnostic symptoms, log file signatures, and proven engineering resolutions:

Diagnostic SymptomLog File / SourceError Signature / Event CodeUnderlying Fault MechanismProven Engineering ResolutionCrash during Tag SelectionWinCC_Sys_*.logException 0xC0000005 (Access Violation) in PDLCS.dllKnown tag browser buffer defect in unpatched WinCC build.Install latest cumulative WinCC Update (e.g. V7.3 Upd 8+).Crash on 2nd or 3rd AssignmentWindows Event ViewerEvent ID 1000, Faulting application: GraphicsDesigner.exeStale temporary files or corrupted graphic picture cache.Purge temporary files (~*.pdl, *.tmp) and re-save picture.Freeze when expanding Tag TreeCCProjectStudio.logDatabase timeout / Deadlock on CC_ExternalTagsSQL Server query lock caused by background OS compilation.Wait for AS-OS compile completion; restart WinCC Explorer.Crash on Object Property ChangePDLCS.logFailed to load OLE control / ActiveX registration errorMissing or unregistered OCX component in Windows.Re-register WinCC OCX controls using regsvr32.Intermittent Crash on Picture SaveWinCC_Sys_*.logSharing violation on GraCS\<Picture>.pdlAntivirus file scanner locking PDL file during write.Add WinCC directories to antivirus exclusion list.

Step-by-Step Resolution and Cache Rebuilding Procedure

Method 1: Identifying and Installing the Appropriate Update

  1. Open WinCC Explorer and navigate to Help > About SIMATIC WinCC to verify the exact build number and installed update level.
  2. Visit Siemens Industry Online Support (SIOS) and search for the latest update for your specific WinCC version (e.g., Entry ID 109481418 for WinCC V7.3 Update 8).
  3. Close all SIMATIC applications, restart the engineering workstation, and install the cumulative update package.

Method 2: Purging Temporary Graphics Files and Rebuilding Project Data

  1. Close WinCC Explorer and ensure no WinCC processes (CCProjectStudio.exe, pdlrt.exe) are active in Windows Task Manager.
  2. Open Windows File Explorer and navigate to the project directory: <ProjectPath>\GraCS\.
  3. Enable hidden files in File Explorer and delete any temporary backup files with extensions *.tmp, ~*.pdl, or *.bak.
  4. Open the project in WinCC Explorer.
  5. Select Tools > Convert Project Data from the main menu.
  6. Check Pictures and Faceplates and Global Script, select language English (USA), and click OK.
  7. Reopen the target .pdl picture in Graphics Designer and resume tag assignments.

Verification

To verify that Graphics Designer operates reliably without crashing:

  1. Continuous Tag Assignment Test: Open the previously failing graphic picture. Assign dynamic tags to at least 10 indicator buttons or graphic objects in continuous succession. Confirm that the Tag Browser opens and closes smoothly.
  2. Log File Inspection: Open C:\Program Files (x86)\Siemens\WinCC\Diagnostics\PDLCS.log. Confirm that no access violations or unhandled exception warnings were logged during the session.
  3. Picture Compilation & Runtime Check: Save the picture, activate WinCC Runtime, and verify that all dynamic animations execute correctly without graphical glitches.

Limitations and Operational Precautions

  • Multiproject Compatibility: When installing a WinCC cumulative update on an Engineering Station (ES), ensure that all Operator Stations (OS Servers and OS Clients) in the multiproject are updated to the exact same update level.
  • Antivirus Exclusions: Operating WinCC without configuring official Siemens antivirus exclusions (for folders GraCS, ArchiveManager, and SQL Server data directories) can cause file corruption and runtime hangs.
  • Official Support Escalation: If crashes persist after updating and rebuilding project data, generate a diagnostic package using the Siemens SIMATIC Assessment Suite - Data Collector (SAS-DC) and submit a Service Request to Siemens Technical Support.

Engineer FAQ

Where can I find the crash logs when WinCC Graphics Designer closes abruptly?

Crash details are logged in Windows Event Viewer (Application log, Event ID 1000) and within the Siemens diagnostic folder at C:\Program Files (x86)\Siemens\WinCC\Diagnostics\ (specifically PDLCS.log and WinCC_Sys_01.log).

Will running 'Convert Project Data' erase my customized C-scripts or graphics?

No. 'Convert Project Data' does not delete user code or graphic objects; it recompiles binary headers and resynchronizes picture files with the current graphics engine.

Does installing a WinCC update require a new software license?

No. Minor updates, service updates, and hotfixes for an existing major release (e.g. updating WinCC V7.3 to Upd 8) do not require new licenses.

Technical References

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