Updating Faceplates and OS Project Editor Basic Data Following PCS 7 Migration

When migrating SIMATIC PCS 7 from V7.1 SP4 to V8.1 SP1, accept the preselected replacement list in OS Project Editor (OSPE) Basic Data tab, provided custom graphics were renamed to avoid overwriting standard templates. Regarding block types, updating SFB35 (ALARM_8P) in the offline block folder synchronizes block header definitions with the new library, but the executable logic runs in S7 CPU firmware and does not alter controller firmware. Finally, while legacy multiprojects functioned without an explicitly declared Engineering Station (ES), defining the ES as a dedicated SIMATIC PC Station in Component View is strongly recommended to stabilize S7ONLINE network routing, Simatic Shell terminal bus resolution, and central time synchronization.

Executive Summary

Upgrading SIMATIC PCS 7 across major product generations (such as moving from V7.1 SP4 on Windows XP to V8.1 SP1 on Windows 7) requires rigorous synchronization across Automation Systems (AS) and Operator Stations (OS). Commissioning engineers frequently encounter uncertainty during the post-migration phase when reviewing the OS Project Editor 'Basic Data' tab: a long list of system pictures and faceplates is preselected for replacement, raising fears of losing graphics customizations. Concurrently, questions arise over whether System Function Blocks like SFB35 (ALARM_8P) require updating in the CPU, and whether legacy multiprojects lacking an explicitly configured Engineering Station (ES) must be restructured. This article clarifies the mechanics of OS Project Editor replacements, firmware block boundaries, and ES station modeling.

Architecture and Fundamental Mechanics

The post-migration synchronization architecture connects three core engineering domains:

OS Project Editor (OSPE) Basic Data Mechanics: OSPE maintains standard WinCC system graphics (@*.pdl), screen splits, alarm line banners, and faceplates. The 'Basic Data' tab compares timestamps and file versions in the WinCC installation directory (Siemens\WinCC\Options\PDL\Base_Data_Pool) against the project's local GraCS directory. The preselected files represent updated system graphics delivered with PCS 7 V8.1 SP1 to support enhanced screen resolutions, new APL features, and security fixes. If project engineers adhered to Siemens guidelines by creating customized faceplates with unique prefixes (e.g., @PG_CustomMotor.pdl), accepting the pre-selection safely modernizes standard graphics without touching proprietary designs.
Firmware Block (SFB) Boundaries: System Function Blocks—such as ALARM_8P (SFB35)—reside permanently in the operating system firmware of the S7-400 CPU. The SFB entry in the STEP 7 offline block folder (bausteine) is merely a symbolic interface header. Updating SFB35 from V1.0 to V1.1 in the offline project during library updates synchronizes interface timestamp consistency for the compiler; it does not and cannot overwrite CPU firmware.
Engineering Station (ES) Representation in Component View: In PCS 7 V7.1 and older releases, engineering stations were frequently operated as 'floating' programming nodes without an explicit SIMATIC PC Station representation in STEP 7 Component View. Starting with PCS 7 V8.0+, defining the ES as a formal PC Station with a WinCC Application Client or Standard ES application is necessary to configure named terminal bus connections, enforce NetPro S7ONLINE access points, and bind Simatic Shell network adapters.

Step-by-Step Implementation Procedure

Execute post-migration updates following this standardized sequence:

Back Up Local Project Graphics:
- In Windows Explorer, navigate to the OS project folder: <Project_Path>\wincproj\<OS_Name>\GraCS.
- Create a complete backup copy of the GraCS folder before running OSPE.
Execute OS Project Editor (Basic Data):
- Open WinCC Explorer on the migrated OS project.
- Open OS Project Editor.
- On the Layout tab, select the target monitor resolution (e.g., 1920*1080).
- On the Basic Data tab, review the file replacement list. Leave all preselected standard @*.pdl files checked to ensure compatibility with V8.1 SP1 faceplates.
- If any standard system file was previously modified directly (e.g., @AreaButtons.pdl), uncheck it or ensure the custom script logic is backed up.
- Click OK to execute basic data synchronization.
Update Block Types in Master Data Library and AS:
- In SIMATIC Manager, open the Master Data Library block folder.
- Copy updated technological blocks (e.g., CTRL_PID, ALARM_8P) from PCS 7 Library V7.1 SP3 Upd4 or APL V8.1 into the MDL.
- Select Options -> Block Types -> Update Block Types.
- Select the target AS CPU programs and click Execute to update block headers and instance data blocks.
Model the Engineering Station in Component View:
- In SIMATIC Manager Component View, right-click the multiproject root and select Insert -> New Object -> SIMATIC PC Station.
- Name the station to match the physical Windows hostname of the ES.
- Open HW Config for the PC Station. Insert a WinCC Application Client or Standard ES at Index 1, and an IE General network adapter at Index 2.
- Configure the network IP and connect to the Plant and Terminal buses.
- Save, compile, and configure S7ONLINE access in Set PG/PC Interface.

Verification

Verify post-migration consistency across AS and OS:

Faceplate Runtime Test: Activate WinCC Runtime. Open standard APL faceplates (e.g., motors, valves, PID controllers). Confirm that graphic faceplates open without script errors, rendering buttons, bar graphs, and alarm banners correctly.
Alarm System Validation: Generate a test alarm from a block utilizing ALARM_8P. Confirm that the message posts to the WinCC alarm list with accurate timestamps and process values.
ES Communication and Download Check: In SIMATIC Manager, execute a test compile and Changes-Only download to an OS Client and AS controller. Verify that S7ONLINE and terminal bus paths resolve instantly without communication timeouts.

Limitations and Operational Precautions

Never overwrite custom-engineered faceplates by blindly running OSPE without a GraCS backup. If your facility modified standard Siemens faceplates without renaming them, OS Project Editor will overwrite those customizations with factory defaults. Furthermore, updating SFB35 interface definitions offline does not upgrade controller hardware; if CPU firmware has known errata, the physical CPU firmware must be updated via memory card or SIMATIC Manager firmware loader.

Engineer FAQ

Why are so many files preselected in the OS Project Editor Basic Data tab?

OSPE preselects all standard system graphic files (@*.pdl) whose timestamps or versions in the PCS 7 software installation pool are newer than those in the project's local GraCS folder, ensuring all system faceplates receive modern bug fixes.

Does updating SFB35 in the block container update the CPU firmware?

No. SFB35 (ALARM_8P) is embedded in the CPU operating system firmware. Updating the block in STEP 7 only updates the compiler's offline interface header and instance DB templates.

Why should I add the Engineering Station to Component View if the project works without it?

Configuring the ES as a formal PC Station enables consistent NetPro routing, binds Simatic Shell network adapters, supports central time synchronization, and is required for downloading to redundant OS servers and clients in modern PCS 7 releases.