C135 PCS 7 (PCS7)
6C
6 Cielo Ciencia y Tecnología
·Publicada en C135 PCS 7 (PCS7)

Resolving WinCC User Archive Synchronization Failures Across Redundant OS Servers in SIMATIC PCS 7

Resolving WinCC User Archive Synchronization Failures Across Redundant OS Servers in SIMATIC PCS 7

When WinCC User Archives fail to synchronize across a redundant OS Server pair (displaying 'No Runtime Data Yet' or preventing operators from modifying recipes after an OS download), the primary root cause is having the project setting 'Allow activation on ES' inadvertently enabled in WinCC Explorer on the Engineering Station. When this option is active on the ES, opening the User Archive Editor binds the archive database GUIDs and process tokens to the ES computer name. Downloading this project to the OS Servers causes the User Archive server (CCUsrAcV.exe) to crash or abort synchronization. To resolve this, disable 'Allow activation on ES' on the ES, disable Redundancy, delete all .dcf files and temporary logging files, re-enable Redundancy, execute an OS compile with memory reset, and perform a clean download to both servers.

Table of Contents

WinCC User Archive Redundancy Architecture: Role of CCUsrAcV.exe and CCRedEngine

In SIMATIC PCS 7 and WinCC, the User Archive (UA) option package manages structured technological recipes, batch parameter tables, and material profiles stored in Microsoft SQL Server database tables. In a high-availability environment with redundant OS Servers (OS1 and OS2), recipe consistency is paramount: if an operator adjusts a recipe parameter on OS1, that change must synchronize across the redundant partner server within milliseconds.

This synchronization is orchestrated by two cooperating subsystems:

  • User Archive Server (CCUsrAcV.exe): Manages the local SQL database tables, record locking, and recipe read/write handshakes from technological faceplates and AS communication blocks (APF or custom SCL scripts).

  • WinCC Redundancy Engine (CCRedEngine.exe): Monitors delta changes between OS1 and OS2. When a recipe record is modified, CCRedEngine replicates the modified SQL record over the Terminal Bus / Redundancy Network to the partner server.

The Fatal Mechanism of 'Allow Activation on ES' in User Archive Redundancy

A pervasive, highly disruptive issue occurs where User Archives stop synchronizing immediately after downloading the OS project from the ES. Operators find that recipe tables are empty or display 'No Runtime Data Yet', and modifying recipes fails.

The root cause trace reveals a subtle configuration error on the Engineering Station:

  1. In WinCC Explorer on the ES, under Project Properties, there is a checkbox: 'Allow activation on ES' (often enabled by engineers to test WinCC graphics locally without dedicated servers).

  2. When 'Allow activation on ES' is enabled, merely opening the User Archive Editor on the ES causes the engineering software to initialize the local User Archive database engine.

  3. In doing so, the ES writes its own Windows computer name, local database GUIDs, and local user tokens into the project's .dcf cache files and master project database.

  4. When the engineer executes an Entire Download to OS1 and OS2, the servers inherit these corrupted ES computer name bindings!

  5. Upon activation on the servers, CCUsrAcV.exe attempts to connect to a data server named after the ES rather than the local OS Server. The process stalls, crashes, or refuses to synchronize with its redundant partner.

Diagnosing User Archive Crashes: Task Manager Verification and Process Dumps

To verify if the User Archive server has crashed or locked up on OS1 or OS2:

  • Open Windows Task Manager (Ctrl + Shift + Esc) on both OS Servers.

  • Search the Details/Processes list for CCUsrAcV.exe.

  • State A (Process Missing): If CCUsrAcV.exe is absent from the process list, the process crashed upon startup. Configure Microsoft AdPlus (adplus -crash -pn CCUsrAcV.exe) or Windows Error Reporting to capture a memory crash dump.

  • State B (Process Running but Frozen): If CCUsrAcV.exe is running with 0% CPU utilization and recipe writes time out, the process is deadlocked waiting on database socket responses from stale ES network pointers.

The Complete Multi-Step ES Project Database Cleanup and Re-Commissioning Procedure

Siemens Technical Support and experienced commissioning engineers have established a definitive protocol to permanently purge these corrupted ES tokens from the multiproject database:

  • Disable 'Allow activation on ES' in WinCC Explorer.

  • Strip redundant server packages and deactivate the WinCC Redundancy setting temporarily.

  • Delete all .dcf project cache files and stale transaction logs (*Alg.ldf/mdf, *Tlg.ldf/mdf).

  • Perform an OS Compile with memory reset (Complete OS with memory reset).

  • Re-enable Redundancy and download clean project structures to both OS Servers.

Comparative State Matrix: Healthy vs Corrupted User Archive Redundancy

The following table compares operational indicators between healthy and corrupted User Archive environments:

Diagnostic IndicatorHealthy Redundant ArchitectureCorrupted Architecture ('Allow Activation on ES')CCUsrAcV.exe ProcessRunning continuously on OS1 and OS2Missing (crashed) or deadlocked at 0% CPUUser Archive Editor in RuntimeDisplays live recipe recordsDisplays 'No Runtime Data Yet'Operator Recipe ModificationInstant write and partner synchronizationValues rejected; write handshakes time out.dcf Project Cache FilesPoint exclusively to OS1/OS2 server namesContain ES computer name and orphaned GUIDsWinCC Redundancy StatusFull synchronization activeRedundancy error; delta queue accumulates indefinitely

Step-by-Step Recovery Procedure to Restore User Archive Synchronization

Follow this exact sequence on the Engineering Station and OS Servers to resolve User Archive synchronization failures:

  1. Correct Settings on Engineering Station (ES):
    - In SIMATIC Manager, open the OS project in WinCC Explorer.
    - Open Project Properties. Strictly UNCHECK the checkbox 'Allow activation on ES'.
    - In WinCC Explorer, expand Server Data. Delete all created and loaded server packages.
    - Open the Redundancy editor. Uncheck 'Activate Redundancy' and click OK.
    - Close the project and exit WinCC Explorer completely.

  2. Purge Corrupted Database Cache Files on ES:
    - Open Windows Explorer and navigate to the OS project directory on the ES.
    - Delete all files with extension .dcf and any backup copies (*.dc*).
    - Delete the temporary database files: <ProjectName>Alg.ldf, <ProjectName>Alg.mdf, <ProjectName>Tlg.ldf, and <ProjectName>Tlg.mdf.

  3. Regenerate Packages and Recompile:
    - Reopen WinCC Explorer on the ES. In Server Data, click Create... to generate fresh packages.
    - Open the Redundancy editor. Check 'Activate Redundancy' and configure the partner server.
    - In SIMATIC Manager, run Compile OS via Tools > Multiple OS Compilation Wizard > Start....
    - Select the option: 'Complete OS with memory reset'.

  4. Deploy Clean Project to OS Servers:
    - Deactivate WinCC Runtime on OS1 and OS2.
    - On OS1 and OS2, back up historical archives, then delete the old project directories on both servers.
    - From SIMATIC Manager on the ES, perform an Entire Download to OS1 and OS2.

  5. Re-activate and Verify:
    - Activate OS1 first. Wait for full runtime startup, then activate OS2.
    - Test recipe modification and verify instant partner synchronization.

Verification

Verify User Archive operational integrity through these validation checks:

  1. On both OS1 and OS2, open Windows Task Manager and confirm that CCUsrAcV.exe is active and running.
  2. Open the recipe control screen on an OS Client. Verify that all recipe records display without 'No Runtime Data Yet' errors.
  3. Modify a recipe setpoint (e.g., change Mixing Time from 100s to 120s) and save.
  4. Check the User Archive table on the redundant partner server: confirm that the new value (120s) appears within 1–2 seconds.
  5. Check WinCC Redundancy internal tags: verify that @RedundancyServerState indicates full redundant health.

Limitations and Operational Precautions

  • Never Open User Archive Editor on ES in Runtime: When 'Allow activation on ES' is disabled, opening the User Archive Editor on the ES is safe for schema design, but never attempt to activate Runtime on the ES without reverting to a dedicated single-station test project.
  • Backup User Archive Data: User Archive records are stored in SQL tables. Performing a complete OS download with project deletion wipes runtime recipe modifications. Always export user archives to CSV via the User Archive Editor before downloading entire projects.
  • Entire OS Compile Timing: In massive projects, Entire OS Compile can take significant time. Ensure adequate engineering maintenance windows before initiating full memory resets.

Engineer FAQ

Why does User Archive stop working after an OS download?

The OS project on the ES inherited corrupted computer names and local GUIDs because 'Allow activation on ES' was enabled. Downloading the project transfers these broken references to the servers.

Can I export User Archive data to prevent data loss during downloads?

Yes. In the User Archive Editor, select Archive > Export... to save all recipe tables into a CSV file. After downloading, select Archive > Import... to restore recipes.

What is the function of CCUsrAcV.exe?

CCUsrAcV.exe is the Siemens WinCC User Archive runtime server process that manages SQL database operations for recipe and parameter archives.

Why is deleting .dcf files effective?

The .dcf file is a temporary cache file that stores local station bindings. Deleting it forces WinCC to rebuild clean connections from the primary project database.

Does WinCC Redundancy automatically synchronize User Archives?

Yes, provided WinCC Redundancy is activated, the redundancy network is healthy, and CCUsrAcV.exe is running cleanly on both servers.

Technical References

Related Articles

Related Tags

  • User Archives
  • CCUsrAcV
  • Redundancy
  • Allow Activation on ES
  • DCF File
  • Recipe Management
  • WinCC OS
6 respuestas