Pcs7 Compendium Part D en-US en-US

Compendium Part D Preface 1
___________________
Operation and Maintenance (V8.1) 2
___________________
What's new?
Installing updates and

SIMATIC
___________________
service packs 3
___________________
Replacing hardware 4
Process Control System PCS 7
Compendium Part D Firmware update of
___________________
hardware 5
Operation and Maintenance (V8.1)
___________________
Service and maintenance of
SIMATIC PDM 6
Operating Manual
___________________
AS and OS expansions 7
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Backing up and restoring
data 8
Valid for PCS 7 V8.1
01/2015
A5E35031848-AA
Legal information
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DANGER
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WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
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The product/system described in this documentation may be operated only by personnel qualified for the specific
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Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
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described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
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Security information
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components in a holistic industrial security concept. With this in mind, Siemens products and
solutions undergo continuous development. Siemens recommends strongly that you regularly
check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products in use should also be
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You can find additional information at:
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Table of contents
1 Preface ................................................................................................................................................... 7
2 What's new? ......................................................................................................................................... 10
3 Installing updates and service packs ..................................................................................................... 11
3.1 Introduction ............................................................................................................................ 11
3.1.1 General .................................................................................................................................. 11
3.1.2 What must necessarily be taken into account? ..................................................................... 12
3.1.3 Differences between maintenance and a software update with the redundant OS
server ..................................................................................................................................... 14
3.2 Checking plant configuration.................................................................................................. 15
3.3 Checking plant status ............................................................................................................. 17
3.3.1 General .................................................................................................................................. 17
3.3.2 Status of PC stations using SIMATIC Shell ........................................................................... 17
3.3.3 Time synchronization ............................................................................................................. 19
3.3.4 Status of OS connections ...................................................................................................... 19
3.3.5 Standard server settings ........................................................................................................ 22
3.3.6 Preferred server settings ........................................................................................................ 24
3.3.7 Redundancy status on the OS server .................................................................................... 26
3.3.8 Client-server connections ...................................................................................................... 29
3.3.9 Archive synchronization of the redundant OS server after a hot restart of the standby
server ..................................................................................................................................... 30
3.3.10 Process control messages ..................................................................................................... 32
3.4 Checking the WinCC channel diagnostics ............................................................................. 32
3.5 Checking the OS functionality after restarting an OS server ................................................. 35
3.6 Deactivating and activating non-redundant OS servers ........................................................ 36
3.7 Deactivating and activating redundant OS servers................................................................ 37
3.8 Additional Information ............................................................................................................ 38
4 Replacing hardware .............................................................................................................................. 39
4.1 Use of new hardware ............................................................................................................. 41
4.2 Deploying new hardware as replacement .............................................................................. 44
4.3 Procedure for replacing hardware.......................................................................................... 45
Compendium Part D Operation and Maintenance (V8.1)

Operating Manual, 01/2015, A5E35031848-AA 4
Preface
5 Firmware update of hardware ................................................................................................................ 48

5.1 Introduction .............................................................................................................................48
5.2 Downloading the firmware ......................................................................................................49
5.3 Updating firmware of a CPU ...................................................................................................49
5.4 Updating firmware of an H system..........................................................................................49
5.4.1 Updating firmware during operation........................................................................................50
5.4.2 Firmware update using S7-400 Flash memory card...............................................................51
5.5 Updating firmware of a communications processor (CP) .......................................................51
5.6 Updating firmware of an interface module (IM) ......................................................................52
5.7 Updating firmware of I/O modules ..........................................................................................53
5.8 Updating firmware of network components ............................................................................54
6 Service and maintenance of SIMATIC PDM .......................................................................................... 55
6.1 General information on importing devices ..............................................................................55
6.2 Device import in SIMATIC PDM V8.2 .....................................................................................56
6.3 Managing device descriptions in the project ...........................................................................57
6.4 Updating SIMATIC PDM .........................................................................................................62
6.5 Updating device descriptions ..................................................................................................65
6.6 Replacing/removing field devices ...........................................................................................66
6.6.1 Scenario 1 - Replacing a device of the same type and with a later version ...........................67
6.6.2 Scenario 2 - Replacing a device with a different type .............................................................73
6.6.3 Case 3 Removing field devices ............................................................................................77
7 AS and OS expansions ......................................................................................................................... 78
7.1 Changes to the AS configuration ............................................................................................78
7.1.1 Changes to the configuration of a standard AS ......................................................................78
7.1.2 Changes to the configuration of an H system .........................................................................82
7.1.3 Changes to the configuration of an ET 200iSP ......................................................................85
7.1.4 Changes to the connection configuration ...............................................................................85
7.2 Program changes ....................................................................................................................87
7.2.1 Checking the logs ...................................................................................................................87
7.2.2 Checking the delta download capability with time stamp comparison ....................................88
7.2.3 Measures for maintaining delta download capability ..............................................................89
7.2.4 Parameter changes.................................................................................................................96
7.2.5 Reading back charts ...............................................................................................................96
7.3 Changes to the safety program or F signal modules ..............................................................97
7.3.1 General ...................................................................................................................................97
7.3.2 Using fail-safe blocks V1_2 or V1_3 .......................................................................................98
7.3.3 Working with F block types in S7 F systems ..........................................................................98
7.3.4 Deleting F_CH_DO F channel drivers .....................................................................................99
7.4 Changes in the OS project ....................................................................................................100

Preface
8 Backing up and restoring data ..............................................................................................................101

8.1 Introduction .......................................................................................................................... 101
8.2 Restore DVDs supplied with bundle PCs ............................................................................ 101
8.3 Rules for creating backups .................................................................................................. 102
8.4 Software for creating backups ............................................................................................. 103
8.5 Creating a backup ................................................................................................................ 103
8.6 Recovery plan ...................................................................................................................... 104
8.7 Storing backups ................................................................................................................... 104

6 Operating Manual, 01/2015, A5E35031848-AA
Preface 1
Subject of the manual
SIMATIC PCS 7, as a distinctly open system, can be flexibly adapted to a wide range of
customer needs. The system software provides the project engineer with a great deal of
freedom in terms of project configuration, as well as in the design of the program and
visualization.
Experience has shown that subsequent modernization or plant expansion work is made
much easier if the project is configured "in conformance with PCS 7" as far as possible right
from the start. This means users must adhere to certain basic rules to ensure that the
provided system functions will offer optimum usability in the future.
This manual serves as a compendium to the product documentation covering SIMATIC PCS
7. The basic tasks for creating and configuring the project are described in the form of
instructions with numerous illustrations.
The compendium directly reflects the recommended method for configuration, which is
based on the results of a great deal of practical experience. The description relates to
working with the project and the parameter settings of the components it contains but not the
application itself.
The compendium contains the following parts:
Configuration guidelines including checklist
Process safety including two checklists
Technical functions with SFC types
Operation and maintenance including checklist
Hardware installation including checklist
Industrial Security
Checklists
You can download the checklist for the SIMATIC PCS 7 compendium part D (V8.1) as a zip
file via the "Info" button on the entries page.
Validity
This documentation is valid for the software packages:
SIMATIC PCS 7 V8.1
SIMATIC PCS 7 documentation

Full PCS 7 documentation is available to you free of charge and in multiple languages in
PDF format at www.siemens.com/pcs7-documentation.

Preface
Compendium Part D "Operation and Maintenance"

Part D describes several runtime scenarios of a plant, for example, maintenance, expansion
and upgrading.
Particular attention is paid to the following topics in this regard:
Planning and implementing PCS 7 updates
Replacing modules as spare parts
Updating firmware and PDM data
Adding hardware and functions
Checklist with important points for preparation and implementation of project changes and
installation of updates.
The relevant checklist can be accessed via the "Info button" on the download page of the
manual.
Additional support
If this manual does not contain the answers to any questions you may have about how to
use the products described, please contact your local Siemens representative.
You can locate your contact at http://www.siemens.com/automation/partner.
You can find a guide to the technical documentation available for individual SIMATIC
products and systems at http://www.siemens.de/simatic-tech-doku-portal.
The online catalog and online ordering system are available at
www.siemens.com/industrymall.
Training center
Siemens offers a number of training courses to familiarize you with the SIMATIC PCS 7
process control system. Contact your regional training center or the main training center in
Nuremberg, 90327, Germany (http://www.sitrain.com).
Technical support
You can contact technical support for all Industry Automation and Drive Technology products
using the Support Request web form http://www.siemens.de/automation/support-request.
More information about our technical support services is available on the Internet at
http://support.automation.siemens.com/WW/view/en/16604318.

Preface
Industry Online Support on the Internet

In addition to our documentation options, our expertise is also available to you online
(http://support.automation.siemens.com).
Here you will find:
Overview of the most important technical information and solutions for PCS 7 under
http://www.siemens.com/industry/onlinesupport/pcs7.
The newsletter that keeps you constantly up-to-date with the latest information about our
products.
The right documents for you via the search facility in our Industry Online Support portal.
A forum in which users and experts from all over the world exchange ideas and
experiences.
Your local contact for Industry Automation and Drive Technology.
Information about local service, repairs, spare parts. The "Services" section offers even
more options.

What's new? 2
The contents of the compendium have been updated in accordance with the new functions
and operator input options of SIMATIC PCS 7 V8.1.
Changes and extensions were made in the following sections in particular:
Installing updates and service packs
Service and maintenance of SIMATIC PDM V8.2

Installing updates and service packs 3
3.1 Introduction
3.1.1 General
One scenario which may arise within a PCS 7 plant is the need to install updates or service
packs safely and effectively.
Updates may be:
PCS 7 updates
PCS 7 service packs
Microsoft updates
Antivirus software updates
Other software updates
Compendium Part D focuses on the preparations and checks which you need to make
before you start to install PCS 7 updates and service packs or maintain PCS 7 plant
sections. The information applies in particular to redundant plant sections which are to be
maintained or upgraded during operation.
Note
You can find practical information and brief instructions for the PCS 7 software update in the
document "Information and brief instructions for updating/upgrading PCS 7 software"
(http://support.automation.siemens.com/WW/view/en/39980937).
The procedure for updating software in the context of a PCS 7 project is described in detail
in the following documents:
"SIMATIC Process Control System PCS 7 Software update without utilization of new
functions" (http://support.automation.siemens.com/WW/view/en/90682681)
"SIMATIC Process Control System PCS 7 Software update with utilization of new
functions" (http://support.automation.siemens.com/WW/view/en/90683053)
"SIMATIC Process Control System PCS 7 Fault-tolerant Process Control Systems"
(http://support.automation.siemens.com/WW/view/en/90682535)

3.1 Introduction
You can find information about Microsoft updates and antivirus software in the following
sources:
FAQ "With what are SIMATIC PCS 7 V8.x, V7.x, V 6.x, V5.x and V4.x compatible?"
FAQ "Which Microsoft Security Patches have been tested for compatibility with SIMATIC
PCS 7?" (http://support.automation.siemens.com/WW/view/en/18490004)
SIMATIC Process Control System PCS 7 Security concept PCS 7 & WinCC (Basic)
SIMATIC Process Control System PCS 7 Trend Micro OfficeScan 11 Configuration
Symantec Endpoint Protection V12.1.4 configuration
Use of Whitelisting with McAfee Application Control in the PCS 7- / WinCC environment
SIMATIC Process Control System PCS 7 Configuration McAfee VirusScan Enterprise 8.8
White Paper (http://support.automation.siemens.com/WW/view/en/66475606)
Whitepaper: "Security Concept PCS 7 and WinCC (Basic)"
3.1.2 What must necessarily be taken into account?

You need to deactivate the OS and restart the PC stations to install a PCS 7 update and
service pack, a Microsoft update or to maintain the OS server and OS client hardware.
Process availability
Operator control and monitoring functions often must continue to run, thus ensuring that the
PCS 7 plant operates safely, while such actions are being performed. The following sections
describe checks, which we recommend you carry out before, during, and after an update or
maintenance work.
If it is necessary to restore the plant to the same state it had before the update or service
pack was installed, we strongly recommend that you back up all computers (including the
ES) and the PCS 7 multi-project or keep the backup available. You can find details on this in
the section titled "Backing up and restoring data" (Page 101).
Make sure that all software products and information required to carry out the update, such
as additional software, libraries, add-ons, information about non-standard functions within
the project, modified system pictures, or other data specific to the plant, etc. are available. All
project-specific settings, such as PC, network, web server and archiving system, should also
be known. You need to verify this information with the plant operator in advance, because
there may have been changes to the PCS 7 plant since its initial installation/most recent
update.

3.1 Introduction
Plant status
You should always evaluate the plant status before you start starting work on OS stations in
Runtime.
Is the OS server system in a redundant status?
Do all clients have a connection to the OS servers?
Only if you can answer "yes" to these two questions can you start the scheduled update.
You should carry out specific intermediate checks while the relevant work is being
performed. You should carry out these checks while updating the PCS 7 project on the ES,
but they should also be performed on the updated OS stations in the plant.
For example, you first install a new PCS 7 service pack on a redundant partner and the
associated OS clients. Then you check whether the plant can be operator-controlled on the
updated stations. If this test is successful, you can continue with the work and update the
remaining OS stations.
After the work has been completed successfully, you must perform a full check of the plant
redundancy status and its operator control and monitoring functionality.
Note
A guide to checking the redundancy status is available in the section titled "Checking the OS
functionality after restarting an OS server" (Page 35).
Coordination of timings
You must make sure that matters are organized such that maintenance work is not carried
out on redundant components simultaneously. Actions of this type must be coordinated so
that they are performed one after the other and they must not overlap.
Also note the following regarding the update sequence of the PCS 7 stations:
Before you start to update the OS stations (Runtime), you must have already updated the ES
itself with a new PCS 7 service pack, for example, as well as the PCS 7 project. As part of
this process, it is essential that you have compiled all AS and OS stations with the new PCS
7 service pack for the entire PCS 7 project. We always recommend that you carry out an OS
simulation or a brief test (for example, download the target system for AS and OS in a testing
environment) before starting work on a running plant.
Note
You can find a summary of the individual check points in the "PCS 7 delta configuration"
checklist that is part of the PCS 7 Compendium Part D.

3.1 Introduction
3.1.3 Differences between maintenance and a software update with the redundant
OS server
Maintenance
In this context, maintenance is considered a task performed when the OS server is
deactivated and in which the OS software version is not changed. This may involve cleaning
the OS server hardware, for example.
When deactivating a redundant OS server, you must not allow all OS clients to switch from
the master server to the standby server at the same time, because this would render the
plant inoperable for the duration of the switchover.
Configuring a preferred server for the OS clients enables you to achieve even distribution
across the master and standby servers. If one of the OS servers is deactivated, only half of
the OS clients will switch to the partner server.
Software update
You must install the same software version on the OS servers and the OS clients connected
to them.
The standby OS server is usually deactivated first and its software updated. Before you
deactivate the standby OS server you must check that the master OS server is fully
functional and a sufficient number of functional OS clients must be connected to that master
OS server.
First update only the OS clients which are interconnected with the standby OS server that
has already been updated or which have defined it as their preferred server. Then update
the OS clients which are interconnected with the master OS server or which have defined it
as their preferred server.
This method is not practical if the maximum number of OS clients must be available for
operator control and monitoring purposes during the software update. In this case, all OS
clients must first be connected to the master server by configuring the preferred server. The
standby server is then deactivated, the OS software updated, and the server started again.
The next step involves deactivating each OS client one after the other, updating the
software, and then connecting each OS client to the standby server by configuring the
preferred server. Once each OS client has been updated, check that its operator control and
monitoring functions are working correctly.
Once all OS clients with their new software version have been connected to the standby
server, the master server will be deactivated and its software updated.

3.2 Checking plant configuration
Once the software has the same version on the redundant OS server and all OS clients, the
OS clients can be distributed between the master and standby servers by configuring the
preferred server.
Note
In order to guarantee the continuous operator control and monitoring capabilities, the
following conditions must be fulfilled:
Before downloading the AS: Operate and monitor the processes through the operator
stations, whose software has not yet been updated.
After downloading the AS: Operate and monitor the processes through the operator
stations, whose software has been updated.

The first step is to check if the OS server to be deactivated is a redundant server pair. If a
redundant OS server is not involved, the plant section will be inoperable for the duration of
the server shutdown. In this case, we recommend you plan to carry out the
maintenance/software update during a regularly scheduled maintenance shutdown of the
plant.
You should be familiar with the plant structure before shutting down an OS server.
Check the following points in the PCS 7 project on the engineering station:
How many OS servers/redundant OS servers are there in the PCS 7 plant?
If uninterrupted plant operation must be ensured during the shutdown of the OS server, at
least one OS server per OS server pair must continue to run in process mode without
interruption.
How many automation systems are there in the PCS 7 project?
Which automation systems are assigned to the which OS server/redundant OS server?
If uninterrupted plant operation must be ensured during the shutdown of the OS server, a
corresponding OS server must be available for each AS.
Is the OS server you want to deactivate a standard server for OS clients?
Does it involve a PCS 7 plant with SIMATIC BATCH?
Is the OS server to be shut down a message server relevant for BATCH?
Is the OS server you want to shut down also a BATCH server?
If so, no batches should be running or started at the time of the OS server shutdown.

Does it involve a PCS 7 plant with SIMATIC Route Control?

Is the OS server you want to shut down also a Route Control server?
If so, no material transport should be running or started at the time of the OS server
shutdown.
Is a higher-level MES system connected to the PCS 7 system?
If so, you need to ensure the MES system will not attempt to access the OS server during
the shutdown period.
Note
Depending on the plant configuration, the additional measures for activating and
deactivating an OS server may vary.
You should consult with the system administrator responsible for SIMATIC BATCH,
SIMATIC Route Control, PH (Process Historian), MES and other systems to define the
measures that need to be introduced. Also refer to the respective product manuals in this
regard.
Note
The system configuration can be checked by the SIMATIC Management Console
(inventory function). You will find further information in the "SIMATIC Process Control
System PCS 7 SIMATIC Management Console (V8.1)"
(http://support.automation.siemens.com/WW/view/en/90683240) operating manual.

3.3 Checking plant status
3.3.1 General
To check the current plant status, we recommend carrying out these tests on the OS server
and the OS client directly, as settings may also have been changed directly on the Runtime
computers.
Certain checks must be performed in the WinCC Explorer, which means it will have to be
accessed. If access to the WinCC Explorer is blocked by OS Runtime, you will have to
terminate OS Runtime mode. In this case, we recommend first carrying out all plant status
checks which can be performed during OS server/OS client Runtime, before terminating that
mode.
If settings need to be changed on the OS server or the OS client directly, you must also
incorporate the changes on the ES. This means there will be no difference between the PCS
7 project on the ES and the data on the Runtime system, plus the changes will not be lost
when the Runtime system is loaded again.
Note
The state monitoring (check for installation readiness) can also be performed with the aid of
SIMATIC Management Console. You will find additional information on this in the "SIMATIC
Process Control System PCS 7 SIMATIC Management Console (V8.1)"
(http://support.automation.siemens.com/WW/view/en/90683240) manual.
3.3.2 Status of PC stations using SIMATIC Shell

The "Simatic Shell" dialog is a component of the PCS 7 OS and is used for central
maintenance and diagnostics of all computers integrated in your client-server system. The
"Simatic Shell" dialog displays all OS client and OS server computers available in the
network. The status of the computers and the loaded OS client and OS server projects can
be determined with SIMATIC Shell.

Procedure
1. Open the Windows Explorer on the ES.
2. Select the folder "My Computer > Simatic Shell" in the tree view.
Note
You can use the shortcut menu, for example, to check the redundant connection to the
partner server on an OS server via the menu command "Redundancy Settings".
Note
You can find more detailed information in the manual titled "SIMATIC Process Control
System PCS 7 - Service Support and Diagnostics"
(http://support.automation.siemens.com/WW/view/en/90682682) and in the WinCC online
help.

3.3.3 Time synchronization

Before deactivating an OS server, you should check whether all computers in the PCS 7
plant are running in synchronism. System messages generated by the OS server are
assigned a time stamp by the OS server. If there is no time synchronization set for a
redundant OS server, for example, it is difficult to chronologically track the system
messages.
Note
The manual titled "SIMATIC Process Control System PCS 7 - Time Synchronization"
(http://support.automation.siemens.com/WW/view/en/90682531) contains more detailed
information on the topic of "time synchronization".
3.3.4 Status of OS connections

The current status of all configured connections can be determined with the "Options >
Status - Connections" function in the WinCC Explorer.

Procedure
1. Open the WinCC Explorer on the OS server. The OS project must be in Runtime on the
server.
2. Select the menu command "Options > Status - Connections".

3. Check the entries in the "Status" column. The "Cleared" entry may indicate an error in the
configuration or hardware.

3.3.5 Standard server settings

Before you deactivate an OS server, check whether it is configured as a standard server.
General information
As a general rule, only a standard server for alarms, the SSM (Split Screen Manager) and
optionally also for user archives is configured for PCS 7.
Standard servers are configured in the "Server Data > Standard Server" menu of the WinCC
Explorer. Such configurations are usually set on the ES and then loaded to the OS client.
Configured standard servers must be checked on the OS client directly, as settings may also
have been changed directly on the OS client. The WinCC Explorer needs to be accessed on
the OS client for this purpose.
The standard server must be checked on every OS client. If deviating settings do arise, the
ES project must be adjusted.
Alarms
If you want to generate operator messages for operations on an OS client, you will have to
specify a standard server for alarms. You cannot configure alarm logging on the OS client
itself. The messages must be archived on an OS server.

SSM (Split Screen Manager)

You must specify a standard server for the SSM component if you want to compile trend
groups or screen compositions on an OS client and store them on the standard server.
If no standard server is configured for the SSM component on the OS client, the compiled
trends are saved locally on this computer. Other OS clients cannot have these trend groups
displayed in the Online Trend Control. The same applies to screen compositions.
When redundancy is configured on an OS server, the data of the trend groups and the
screen compositions are also synchronized on the respective redundant partner server. This
means all compiled trend groups and screen compositions can be called up from all OS
clients when you perform a redundancy switchover.
The configured standard servers will be displayed in the "Server Data" menu in the WinCC
Explorer of the OS client, as shown in the following example.
Example
Loaded server data (package) without standard server
Loaded server data (package) with standard server
Scenario
A PCS 7 plant contains three non-redundant OS servers. The server data from three OS
servers is assigned to an OS client. If a non-redundant OS server has been configured on
the OS client as the standard server for alarms and SSM and this OS server needs to be
deactivated, then:
The OS areas of an OS server not in process mode cannot be operator-controlled.
No operator messages will be generated for the OS areas that can still be operator-
controlled while the server is shut down.
The configured compilations of trends are not available. The same applies to OS servers
still in process mode.
The configured screen compositions are not available. The same applies to OS servers
still in process mode.

You should therefore check if a server is a standard server before deactivating runtime on it.
Deactivation of process mode on the OS server must be timed in such a way that the
functionality it provides will not be missed.
Note
When a redundant OS server is used, the functionality of the standard server will be
maintained only if one computer of the OS server pair is deactivated.
If no standard server is configured for alarms of an OS client, then the OS client will not
generate any operator messages.
3.3.6 Preferred server settings
Function of the preferred server in process mode

If redundant OS servers are used, then the OS client will interconnect with the OS server
which has been configured as the preferred server. If the preferred server fails, the OS client
switches to its partner server. When the failed preferred server returns, the OS client will
switch back to this OS server.
We recommend configuring the preferred server for the OS client on the ES and then loading
the OS client. Because the preferred server can also be configured on the OS client via the
WinCC Explorer, you should check the preferred server directly on the OS client.

Procedure
1. Open the WinCC Explorer on the OS client.
2. Open the "Server Data" shortcut menu.
3. Select the menu command "Configure".
4. Select one of the redundant OS server computers as the preferred server.

3.3.7 Redundancy status on the OS server

The following internal variables of the "Redundancy" group can be checked in the variable
management area on the OS server to determine the redundancy status of the OS server.
The values of the internal variables can be determined in the OS server's WinCC Explorer at
runtime. These are displayed in the "Value" column.
When attempting to deactivate runtime on one of the two redundant servers, a check is
made in the system to see whether there is a redundancy problem and this will be indicated
in the event of an error.

Meaning of the variables
Variable name Meaning

@RM_MASTER The @RM_MASTER variable is set to identify the server com-
puter as the master. The @RM_MASTER variable will be reset if
the server computer is in "standby".
@RM_MASTER_NAME The computer name of the master server is specified in the
@RM_MASTER_NAME variable.
@RM_SERVER_NAME This variable contains the computer name of the OS server.
@RM_OFFLINE_UA_NAME Used for diagnostic purposes, a separate variable is created
with a corresponding archive name for each user archive.
The following system variables can be checked on the OS server to determine the
redundancy status of the OS server.
Meaning of the variables
Variable name Meaning

@LocalMachineName This variable contains the local computer name.
@RedundantServerState The variable shows the redundancy status of this server. Value
= 0 -> Undefined status (starting value); Value = 1 -> Server is
master; Value = 2 -> Server is standby; Value = 3 -> Server
fault; Value = 4 -> Server is standalone (no redundant mode).

Checking the redundancy on the OS client

If packages are loaded on the OS client, a green, yellow, or red button appears in the area
overview for the status of the connected server. You can use this display to check the status
of the connected OS servers. If you click on the button, a window opens in the work space in
which all connected servers are listed.
Visual representation of the redundancy monitoring in the area overview:
On the clients, the status of all the redundant OS server pairs and non-redundant OS servers
downloaded from the packages are displayed in the right-hand part of the area overview:
Green button:
The monitored OS servers are available and are in runtime with the status "OK".
Yellow button:
One server or multiple servers have a problem. The servers are still available for the
clients.
If a server partner is switched off or has an error state and the second server partner also
develops an error state, the second server partner initially remains available for the
connected clients. The second server partner only disconnects the clients if the first server
partner is in an operational state again and has synchronized with the second server partner.
This therefore ensures that the clients can at least connect to this server pair, even if both
server partners have a problem.

Red button:
Not all of the monitored OS servers are in runtime.
Not all of the monitored OS servers have the status "OK".
Not all of the monitored OS servers have a fault-free network connection.
No button:
The process "CCEmergencyWatchRTServer.exe" is missing from the startup list on the OS
client.
No packages are loaded on the OS client.
3.3.8 Client-server connections

When you deactivate an OS server, you should not connect all OS clients to another OS
server at the same time, because this step would render the plant temporarily inoperable.
Therefore, you need to determine the OS server to which the OS clients are currently
connected. As a general rule, you should distribute the OS clients evenly across the
redundant OS servers. You achieve this goal via the preferred server configuration.
Checking the @RM_SERVER_NAME internal OS variable

The @RM_SERVER_NAME internal OS server variable contains the name of the OS server
that provides the process picture to the OS client. This variable can be be visualized in the
process picture, for example, in a text field. When the screen appears you can see from the
text box to which OS server the OS client is currently connected.
Note
You can find further information in the FAQ "On the WinCC client, how do you establish
which server this is connected to?"

3.3.9 Archive synchronization of the redundant OS server after a hot restart of the
standby server
Scenario
Server A is the master server and server B is the standby server. Maintenance work needs
to be performed on the redundant OS server. No preferred server is configured for OS
clients; the OS clients are therefore connected to the master server.
To avoid an unnecessary redundancy switchover of the OS clients, the standby server will
be deactivated first in this case. Once the maintenance work is complete, server B will be
restarted.
A time window of two hours is required for the maintenance work. Within this time window,
the TagLogging and AlarmLogging values have only been archived by server A.
Before you deactivate server A for the required maintenance work, you need to ensure that
archive synchronization has been completed in full.
Note
If server A is deactivated before the archive synchronization is complete, data loss can occur
as a consequence.
The redundancy option of the PCS 7 OS provides a series of system messages. You need to
evaluate the following system messages to determine whether or not archive
synchronization has been successfully completed.
Message num- Message text Meaning

ber
1012208 REDRT: Archive synchroni- This message is generated at the start of the archive
zation starts synchronization by the OS server.
1012209 REDRT: Archive synchroni- This message is generated at the end of the archive
zation ends synchronization by the OS server.

Example
In process mode, open the process control message list with the OS client button shown
below:
The process control messages generated by OS redundancy all start with the string
"REDRT" in the event text. If you configure a user filter with this string, it will facilitate the
search for the relevant messages.
Create a filter with the string "REDRT":
Result
Filtered process control list with messages generated by OS redundancy.
The archive synchronization procedure starts automatically ten minutes after the standby
server has undergone a hot restart.

3.4 Checking the WinCC channel diagnostics
3.3.10 Process control messages

Process control messages are error messages caused, for example, by the failure of a
component or a wire break affecting a connected I/O signal.
Process control messages of the "System, need not be acknowledged" message class are
intended for maintenance personnel. It is the responsibility of maintenance personnel to view
the process control list regularly and resolve any problems that occur.
Note
You can find a list of system messages and a general definition of the measures that need to
be taken in the FAQ "What are the causes of PCS 7 control technology and system
messages and what measures are to be taken to clear them?"
Scenario
A redundant OS server needs to be serviced. The standby server has lost the connection to
the AS. If the master server is deactivated in this situation, the plant can no longer be
operator-controlled because the standby server has not established process communication.
To avoid this situation, you need to check the process control message list before
deactivating an OS server and resolve the causes of critical messages that are still relevant.
It helps here to filter the process control list for the name of the computer you want to
service.

"WinCC Channel Diagnosis" enables WinCC users to create a quick overview of the status
of active connections in runtime. It not only provides status and diagnostic information for
channel units, but it also serves as a user interface for configuring the diagnostic output.
WinCC channel diagnostics can be performed on an OS server or an OS single station in
runtime.
Channel diagnostics offers the following options:

Output of status/statistical information about communication
Text output in a trace file to support the hotline for identifying communication problems.
The diagnostic module can be inserted as an ActiveX control in a process picture or it can
run as a standalone application from the Windows Start menu. Only the status information of
the channels that support diagnostics will be displayed.

Overview of status displays
Icon Description
Channel / connection operational with no restriction
Channel / connection operational with restriction
Channel / no information about connection status available
Channel / connection faulty
Procedure
1. Start the "Channel Diagnosis" WinCC channel diagnostics on the activated OS server
with the Start menu command "SIMATIC > WinCC > Tools > Channel Diagnosis".
Operation of the Start menu via the OS must not be blocked for this procedure to work.
2. The application window for "Channel Diagnosis" opens.
The left section of the "Channels/Connections" tab shows the status information for all
installed channels and their connections.

3. Check the icons next to the "SIMATIC S7 Protocol Suite" channel name and the
connection.
The status of the channel or the connection is correct when a green check mark is
displayed in front of the respective entry. The meaning of the icons are available in the
table "Overview of status displays."
4. If there is no green check mark in front of the name of channel and connection, select the
connection in the left window. Check the entries of the counters "First Error Code" and
"Last Error Code" in the right window. The entries provide information about errors
detected.
The shortcut menu of the value display provides you with direct help.
5. On the "Configuration" tab, select the status and error displays that you want to output to
the log file. To do this, select the "SIMATIC S7 Protocol Suite" channel and configure the
error displays.
You can find a description of this process under the topic "How to configure the trace
function of a channel" in the WinCC online help.
6. Check the channel-specific log file. To do this, open the file at "<Installation
directory>\WinCC\Diagnostics" in a text editor. Check the latest entries with the "ERROR"
flag. You can find a description of this step under the topic "Description of the entries in
the log file" in the WinCC online help.
7. If the error cannot be located even after checking the log file, contact the Customer
Support Team.
Note
You can find more information on the topic of "Channel Diagnosis" in the WinCC online
help.

3.5 Checking the OS functionality after restarting an OS server
3.5 Checking the OS functionality after restarting an OS server

With a client-server system, operator control and monitoring is not usually performed directly
on the OS server. Therefore, the operator control and monitoring functionalities must be
checked with the aid of an OS client.
You need to check the following points in this regard:
Availability of all OS areas
Entries in the process control list
Status of connections
Perform a picture change and estimate the time required to open a picture
Lifebeat monitoring/asset management (maintenance station)
Screen compositions
Trend compilations for archive and online tags
Redundancy status of the redundant OS servers
Distribution of the OS clients to the preferred servers
Time synchronization
You can find further information in the "SIMATIC Process Control System PCS 7
Time Synchronization" (http://support.automation.siemens.com/WW/view/en/90682531)
manual.
Redundancy settings for redundant OS servers

3.6 Deactivating and activating non-redundant OS servers
3.6 Deactivating and activating non-redundant OS servers
Deactivating
If a non-redundant OS server is deactivated, process operation cannot continue with the
corresponding OS clients.
1. Check to determine when the OS server function will not be necessary.
2. Check the configuration of the PCS 7 plant.
3. Check the plant status of the PCS 7 plant.
4. Check that the OS server is functioning correctly with the help of an OS client.
5. Deactivate the runtime of the OS server.
Note
In the case of a server shutdown you can, for example, operate an OS single station
system in parallel to the OS server for emergency operation. The PCS 7 engineering
system does not support synchronization of the OS server and the OS single station
system in the PCS 7 project.
The OS single station system must be fully installed, configured, and licensed for
emergency operation.
Activating
The functionality of the client-server system needs to be checked once the OS server has
been activated. Read the section titled "Checking the OS functionality after restarting an OS
server (Page 35)" for more information.
Procedure
1. Open the OS project on the OS server.
2. Activate Runtime on the OS server.
3. Check that the OS server is operating correctly.

3.7 Deactivating and activating redundant OS servers
3.7 Deactivating and activating redundant OS servers
Deactivating
To safeguard process operation on a permanent basis, you should never deactivate both
computers of a redundant OS server pair at the same time. You must always deactivate the
standby server first.
1. Check the configuration of the PCS 7 plant.
2. Check that the OS clients are configured correctly.
4. Check that the redundant OS server is operating correctly.
5. Deactivate Runtime on the standby OS server.
6. Check that the plant is operating correctly without an available standby OS server.
Activating
When activating redundant servers, it is important to ensure that the first server has been
fully activated before activating the redundancy partner.
No client should be running before the servers are activated for the first time. The OS clients
can then be activated.
The functionality of the client-server system needs to be checked once the OS server has
been activated.
Read the section titled "Checking the OS functionality after restarting an OS server
(Page 35)" for more information.
1. Check that the OS server is configured correctly.
2. Check that the OS clients are configured correctly.
4. Open the WinCC project on the standby OS server.
5. Activate Runtime of the OS server, if an automatic start has not been configured.
6. Check that the OS server and connected OS clients are operating correctly.
7. Check the archive synchronization of the redundant OS server.

3.8 Additional Information
3.8 Additional Information

You can find more detailed information in the following sources:
In the "SIMATIC Process Control System PCS 7 Fault-tolerant Process Control
Systems" (http://support.automation.siemens.com/WW/view/en/90682535) manual
In the "SIMATIC Process Control System PCS 7 Operator Station"
(http://support.automation.siemens.com/WW/view/en/90682677) manual
You usually test the OS on the ES using the "Start OS Simulation" command.
If you have accidentally put the OS server project online on the ES, proceed as described
in the following FAQ to return the OS project to its original state:
"What should you do if the OS server project is taken online by mistake on the ES?"
You can find information on updating redundant OS servers during operation in the
following documents:
In the "SIMATIC Process Control System PCS 7 Fault-tolerant Process Control
Systems" (http://support.automation.siemens.com/WW/view/en/90682535) manual
In the FAQ "On the WinCC client, how can you determine which server it is connected
to?" (http://support.automation.siemens.com/WW/view/en/26412141)
WinCC online help, section "WinCC redundancy"
Manual "WinCC Options Redundancy"

Replacing hardware 4
General information
This section deals with the replacement of modules at a scheduled maintenance interval or
during plant modernization work.
Note
If you have a defective module, please contact your regional Siemens representative so that
the module can be replaced as soon as possible. You can find further information on support
with spare parts under (http://support.automation.siemens.com/DE/view/en/16611927).
The replacement modules must be approved for use with the respective PCS 7 version. The
manual "SIMATIC Process Control System PCS 7 Released Modules"
(http://support.automation.siemens.com/WW/view/en/103151431) and the PCS 7 V8.1
readme file (online) (http://support.automation.siemens.com/WW/view/en/101094704) for
each PCS 7 version provide information about the approval status. Components must
always be replaced with identical models (identical MLFB).
If listed modules are no longer available, successor modules should be installed; these need
to be explicitly compatible as replacements. Information about whether or not a new module
is compatible as a replacement is available on the delivery release, as shown in the figure
below, which uses HART analog modules as an example.

Replacing hardware
There are two scenarios for deploying modules compatible as replacements:

Case 1: With configuration changes
Can the new hardware be operated within the present PCS 7 version with the full range
of functions?
In this case, the new hardware can be configured with additional software components.
This gives users the opportunity to use new functions.
This scenario is described with an example in the section "Use of new hardware
(Page 41)".
Case 2: Without configuration changes
When replacing hardware, does the new hardware have to be used without new
functions?
The following applies: The old hardware component has been configured and the new
hardware component which is compatible as a replacement is then deployed.
This scenario is described with an example in the section titled "Deploying new hardware
as replacement (Page 44)".
Redundancy
If a redundant component fails and a successor module or a new hardware or firmware
version is used, the partner component will also need to be upgraded to the same type. See
the section titled "Procedure for replacing hardware (Page 45)" for more information.
Procedure
You need to determine if scenario 1 is applicable for the PCS 7 version you are using. If this
is not the case, scenario 2 applies automatically. Use the checklist to perform the check for
each type of module according to the section titled "Replacing hardware".
Note
The replacement part scenario (case 2) is always possible, even if new functions (case 1)
could be used but you do not wish to change the configuration.

Replacing hardware
4.1 Use of new hardware
Difference between HUPs and HSPs

For SIMATIC PCS 7 only explicitly approved HUPs may be used (Hardware Upgrade
Packages). HSPs (Hardware Support Packages) may not be used with PCS 7.
The difference between HUPs and HSPs is explained in more detail below.
Definition
HSP Hardware Support Package
Software package installed in HW Config; facilitates the configuration of new hardware.
Note
New HSPs are released together with new STEP 7 versions. Never install a STEP 7 version
which is more recent than the one officially released for the PCS 7 version to use these
HSPs.
HUP Hardware Upgrade Package

Software package in the form of an installation file, which contains one or more HSPs and
the meta information required to automatically generate and connect the corresponding
PCS 7-specific module drivers in the S7 program by means of a wizard.
Note
These module drivers and their proper integration into the S7 program form the basis of
hardware component diagnostics and status information.

Replacing hardware
Monitoring on the system side

The definition specifies that individual HSPs cannot be used with PCS 7 but can only be
used for HUPs approved for PCS 7.
If an HSP is used without accompanying meta information, the module drivers cannot be
generated. as indicated by the message "Module is not supported by the module driver"
(shown in the figure, using an ET 200M module as an example). As a result, no diagnostics
or status messages of the hardware can be processed.

Replacing hardware
Example: Using H-CPU V4.5 in PCS 7 V6.1 SPx

The following updated AS hardware components can be used with PCS 7 V6.1 SP2 in
addition to the AS hardware components listed in the document titled "PCS 7 - Released
Modules" (extract from the PCS 7 V6.1 SP2 "Readme.txt" file):
Product Modules
CPU 41X-? H V4.5 6ES7 412-3HJ14-0AB0, 6ES7 414-4HJ14-0AB0,
6ES7 417-4HT14-0AB0,
CPU 41X-???04 V4.0 / V4.1 6ES7 414-3XJ04-0AB0, 6ES7 416-2XK04-0AB0,
6ES7 416-3XL04-0AB0, 6ES7 417-4XL04-0AB0,
6ES7 414-4HJ04-0AB0, 6ES7 417-4HL04-0AB0,
The "Readme.txt" file contains concrete information about the additional release of H-CPU
V4.5. The HSP and the required meta information will be supplied as software as of PCS 7
V6.1 SP2.
The following overview of the release schedule should clarify this point:
Delivery release date Product Remark

8/15/2005 PCS 7 V6.1 SP1 Replacement-compatible
RSHUDtion
12/18/2006 PCS 7 V7.0 Replacement-compatible
RSHUDtion
10/2/2007 HSP of H-CPU V4.5 for PCS 7 7.0 SP1 Download from Service & Sup-
port portal via entry
,'26609816
1/21/2008 PCS 7 V6.1 SP2 HSP integrated
2/17/2009 PCS 7 V6.1 SP3 HSP integrated
The order of the delivery releases shows that H-CPU V4.5 can only be used with its full
range of functions starting with PCS 7 V6.1 SP2 or V7.0 SP1. The HSP of H-CPU V4.5 was
officially released only for PCS 7 V7.0 SP1. The H-CPU must be operated as a replacement
for PCS 7 V6.1 SP1. We recommend an upgrade to PCS 7 V6.1 SP2.
New functions such as "firmware update in RUN" can only be used because you can now
configure the H-CPU V4.5 in PCS 7.
None of this is possible in PCS 7 V6.1 SP1 or V7.0. The H-CPU V4.5 is used as a
replacement component here (see section (Page 44)).
Redundancy
If an HUP/HSP is used in a PCS 7 project for redundant components, such as H-CPU or IM
153-2, you will have to replace both redundant components during a maintenance interval.

Replacing hardware
4.2 Deploying new hardware as replacement
4.2 Deploying new hardware as replacement

If no successor module has yet been listed in the manual titled "PCS 7 Released Modules"
(http://support.automation.siemens.com/WW/view/en/103151431) and no related information
appears in the PCS 7 Readme (online)
(http://support.automation.siemens.com/WW/view/en/101094704), the successor module
can be used in spare part-compatible operation. The replacement scenario is described in
the corresponding delivery release.
Note
The following always applies when replacing hardware: The old hardware component has
been configured and the new hardware component which is compatible as a replacement is
then deployed.
When a new hardware component is deployed as a replacement, it will not be possible to
use its advanced functions.
Example: Using IM 153-2 BAxx in PCS 7 V6.1 SPx

An IM 153-2 interface module (used for ET 200M, DP/PA link, and Y link) is presented here
as an example.
The "Readme.txt" file for PCS 7 V6.1 SP3 contains the following description with regard to
the IM 153-2BAxx:
"The following updated AS hardware components can be used with PCS 7 V6.1 SP3 in
addition to the AS hardware components listed in the document titled "PCS 7 - Released
Modules" (the listed hardware support packages are integrated).
Product Modules
ET 200M IM 153-2BAx1 * 6GK7 153-2BA01-0XB0;
6GK7 153-2BA81-0XB0
ET 200M IM 153-2BAx2 * 6GK7 153-2BA02-0XB0,
6GK7 153-2BA82-0XB0
* = Only in replacement-compatible operation (the corresponding hardware can only be used

by configuring the predecessor module released for PCS 7 or the previous and released
firmware version)."
This means that the following, new ET 200M functions cannot be used with PCS 7 V6.1 SP2
and SP3 yet but only with PCS 7 V7.0 SP1:
Configuring 12 modules in a single ET 200M
High-precision time stamping with 1 ms
Use of HART primary and secondary variables for 8-channel ET 200M HART module

Replacing hardware
4.3 Procedure for replacing hardware
Summary for IM 153-2BAxx:
Delivery release Product Remark

date
8/15/2005 PCS 7 V6.1 SP1 Replacement-compatible operation
4/26/2006 IM 153-2 (6ES7 153-2BAx1-0XB0) See delivery release (ID 23004099) on
the Service & Support portal
9/11/2007 IM 153-2 (6ES7 153-2BAx2-0XB0) See delivery release (ID 26291781) on
the Service & Support portal
9/27/2007 PCS 7 V7.0 SP1 Configuration possible
Redundancy
If new hardware is used to replace redundant components such as H-CPU or IM 153-2, you
will have to replace both redundant components during a maintenance interval.
Note
If a redundant module is defective, the same module type and firmware version must be
used to ensure that process mode will not be disrupted.
Requirements for replacing hardware during operation

Before you start to replace components in an automation system with a redundant
configuration (for example, CPU, CP, or IM), you must ensure that the H system is in a
completely redundant state.
You can only replace a CPU in the H system, for example, if all stations (e.g. ET 200M) on
the PROFIBUS are connected redundantly, active (power supply), and free of faults.
Also, you can only remove a redundant interface module if the H system and both IMs are in
a redundant state.
NOTICE
Only make changes to a plant during operation if no redundancy faults are present, i.e. the
REDF LED is not lit, and you have ensured that both IMs for all stations connected
redundantly (e.g. ET 200M) are in fault-free mode. Otherwise, process mode may be
disrupted.

Replacing hardware
Procedure
The exact procedure for a specific component is provided in its accompanying manual. The
table below provides information about the relevant components and associated manuals.
Component Manual/section Note

ET 200M interface in a Manual "SIMATIC Distributed I/O You can find possible combinations of bus
non-redundant system Device ET 200M"1), section titled modules, interface modules and configurations
"Service and maintenance" under "New PROFIBUS interface module for ET
200M, DP/PA link and Y link"2).
ET 200M interface in a Manual "SIMATIC Distributed I/O
redundant system Device ET 200M"1), section titled
"Service and maintenance"
Manual "SIMATIC Fault-tolerant
Systems S7-400H"3), section "Failure
and replacement of components during
operation"
ET 200M module Manual "SIMATIC Distributed I/O Please note that the startup time following in-
ET 200M redundant module Device ET 200M"1), section titled stallation of the module is longer for fail-safe
"Service and maintenance" modules than for standard ones.
ET 200M bus module Manual "SIMATIC Distributed I/O Active bus modules can only be installed on an
Device ET 200M"1), section titled IM 1532 if the power supply is interrupted.
"Service and maintenance" You can find possible combinations of bus
modules, interface modules and configurations
under "New PROFIBUS interface module for
ET 200M, DP/PA link and Y link"2).
Connection of DP/PA link and "SIMATIC Bus links DP/PA coupler, You can find possible combinations of bus
Y link active field distributors, DP/PA Link and modules, interface modules and configurations
Y Link"4) manual, section "Service and under "New PROFIBUS interface module for
maintenance" ET 200M, DP/PA link and Y link"2).
ET 200iSP interface Manual "SIMATIC Distributed I/O ET Setting and altering the address may require
ET 200iSP interface in a 200iSP"5), section "Replacing the deletion of the non-volatile parameters on the
redundant system interface module" interface. This is only possible by shutting off
the power supply. This step may not be possible
in a redundant system.
Set the address of the IM 152 on the module in
advance. This way you can avoid having to shut
down the station. The IM will start up with the
correct address.
ET 200iSP module Manual "SIMATIC Distributed I/O ET 200iSP tolerates a single module gap during
ET 200iSP"5), section "Removing and ongoing operation (RUN). Never remove more
inserting electronic modules during than one electronic module during operation.
operation"

Replacing hardware
Component Manual/section Note

PS and CPU of a standard AS Manual "Automation System S7-400
Hardware and Installation"6), section
"Maintenance"
H-CPU of an H system Manual "SIMATIC Fault-tolerant Sys- To swap a CPU, the corresponding power
tems S7-400H"3), section "Failure and supply must be switched off.
CP 443-1 in H system replacement of components during Swapping can be performed with the power
operation" supply switched on.
CP 443-5 in H system To swap an active DP master, the correspond-
ing power supply must be switched off.
1) Manual "SIMATIC Distributed I/O Device ET 200M"

2)Document "New PROFIBUS Interface Modules for ET 200M, DP/PA Link and Y Link"
3)Manual "SIMATIC Fault-tolerant Systems S7-400H"
4)Manual "SIMATIC Bus links DP/PA coupler, active field distributors, DP/PA Link and Y
Link" (http://support.automation.siemens.com/WW/view/en/1142696)
5)Manual "SIMATIC Distributed I/O ET 200iSP"
(http://support.automation.siemens.com/en/view/en/98821323)
6)Manual "Automation System S7-400 Hardware and Installation"
Special considerations when switching to CP443-1 (6GK7 443-1EX20-0XE0,

6GK7 443-1EX30-0XE0)
Discontinuation of CP 443-1 (6GK7443-1EX11-0XE0) as of 10/1/2009
(http://support.automation.siemens.com/DE/view/en/24931461)
What should you watch out for when upgrading from previous modules to the successor
module CP 443-1 (6GK7 443-1EX20-0XE0) or CP 443-1 Advanced (6GK7 443-1GX20-
0XE0)? (http://support.automation.siemens.com/DE/view/en/34894744)

Firmware update of hardware 5
5.1 Introduction
A firmware update may be required or recommended for the following hardware in a PCS 7
plant to correct any faults or implement new functions:
S7-400 CPU
S7-400 CP for Ethernet (CP 443-1) and Profibus (CP 443-5 Ext.)
Interface modules in ET 200 stations, DP/PA link or Y link
HART modules and signal modules for ET 200 (M, iSP, S, pro) stations
S7-300 function and communication modules
SCALANCE
SICLOCK central plant clock
The basic procedure is described in section "Hardware update" of the
"SIMATIC Process Control System PCS 7 Service Support and Diagnostics"
We would strongly recommend that you contact your regional Siemens representative to
discuss module upgrades.
You can locate your respective contact at
(http://www.automation.siemens.com/partner/guiwelcome.asp?lang=en).
Note
Plan your firmware update in such a way that the plant operator control and monitoring
functions remain uninterrupted.
For example, when updating the firmware of a redundant CPU and its CP it is not advisable
to deactivate the connected redundant OS servers at the same time to perform maintenance
on them. Coordinate such actions so they are carried out one after the other.

Firmware update of hardware
5.2 Downloading the firmware
5.2 Downloading the firmware

You can download firmware updates for the various hardware components on the Internet
from Siemens Industry Online Support (http://support.automation.siemens.com).
5.3 Updating firmware of a CPU

For a CPU with firmware V5.0 and higher, or an H-CPU with firmware V4.5 and higher, you
can update the firmware online (over the network) from the engineering station.
For an older CPU you will need an S7-400 Flash memory card and a USB external prommer,
or a PG for programming the memory card.
You can find the requirements which must be met in order to perform the firmware update in
the download entry corresponding to the CPU.
5.4 Updating firmware of an H system

For an H-CPU with firmware V4.5 and higher, you can update the firmware online (over the
network) from the engineering station.
For an older H-CPU based on V2, V3, or V4 firmware, you will need an S7-400 Flash
memory card and a USB external prommer, or a PG for programming the memory card.
You can learn about the requirements for performing a firmware update from the download
area (http://support.automation.siemens.com/WW/view/en/6741018) of the respective CPU
firmware.

5.4 Updating firmware of an H system
5.4.1 Updating firmware during operation

In order to update firmware in RUN, the H-CPU from V4.5 and higher must have been
configured in HW Config (see also the section titled "Deploying new hardware with new
HUP/HSP"). The update can only be performed from one version to the next, for the purpose
of correcting faults (e.g. from V4.5.1 to V4.5.2).
NOTICE
System change
Only make a system change during operation if no redundancy errors are present; i.e. the
REDF LED is not lit, and you have ensured that both IMs for all stations connected
redundantly (e.g. ET 200M) are in error-free operation. Otherwise, process mode may be
disrupted.
Update firmware automatically

To update the firmware of a redundant CPU automatically (simultaneously), proceed as
follows:
1. Select one of the redundant CPUs in the SIMATIC Manager or in HW Config.
2. Execute the menu command "CPU > Update Firmware".
The "Update Firmware" dialog box opens.
3. Select the firmware file which is to be loaded onto the selected CPU and click on the
"Execute" button.
The setup for updating the firmware is started. Using the setup, the firmware update can
be performed on both CPUs automatically.
Update firmware step by step

To update the firmware of a redundant CPU step by step, proceed as follows:
1. Select the current standby CPU in the SIMATIC Manager or in HW Config and set this to
STOP with the menu command "CPU > Operating state".
2. Select this CPU in HW Config and execute the menu command "CPU > Update
Firmware".
The "Update Firmware" dialog box opens.
3. Select the firmware file which is to be loaded onto the selected CPU and click "Execute".
While the firmware is being updated, all indicator LEDs on the CPU will light up (INTF,
EXTF, FRCE, CRST, RUN, STOP). The operating system update is performed and, when
it is complete, the STOP LED on the CPU will flash slowly (clear/reset request on the
system side).
Caution: The self-test will start immediately after the update and may take a few minutes,
depending on the memory configuration. Wait until the CPU switches to the STOP
operating mode.
4. In SIMATIC Manager or HW Config, select the menu command "CPU > Operating Mode
> Switch to CPU 41xH" and select the option button "with modified operating system".

5.5 Updating firmware of a communications processor (CP)
5. Repeat steps 1 to 3 for the other CPU.

6. In SIMATIC Manager, select the menu command "CPU > Operating Mode > Restart the
CPU currently in STOP".
The two CPUs are in "Redundant" operating mode with updated firmware (operating
system).
You will find more detailed information in
the section "Updating firmware in RUN" in the "SIMATIC Process Control System PCS 7
CPU 410-5H Process Automation"
manual "SIMATIC Process Control System PCS 7 Fault-tolerant Process Control Systems"
5.4.2 Firmware update using S7-400 Flash memory card

You can find the requirements for performing the firmware update once again in the
download area (http://support.automation.siemens.com/WW/view/en/6741018) for the
respective CPU firmware.
5.5 Updating firmware of a communications processor (CP)

This section applies to Ethernet CP 443-1, PROFIBUS CP 443-5 Extended, and
PtP CP 341.
The requirements and steps are described in the manual titled "SIMATIC Process Control
System PCS 7 Service Support and Diagnostics" for the respective PCS 7 version.
NOTICE
Only update firmware during operation if no redundancy faults are present, i.e. the REDF
LED is not lit, and you have ensured that both IMs for all stations connected redundantly
(e.g. ET 200M) are in fault-free mode. Otherwise, process mode may be disrupted.

5.6 Updating firmware of an interface module (IM)
5.6 Updating firmware of an interface module (IM)

This section applies to the product series ET 200M, ET 200S, ET 200SP, ET 200iSP, ET
200pro, DP/PA link, and Y link.
Requirements
The requirements and steps needed for updating an interface module are described in the
manual titled "SIMATIC Process Control System PCS 7 Service Support and Diagnostics"
for the respective PCS 7 version.
You can find more information in the following manuals:
ET 200M (http://support.automation.siemens.com/WW/view/en/1142798)
ET 200S (http://support.automation.siemens.com/WW/view/en/19728475)
ET 200SP (http://support.automation.siemens.com/WW/view/en/58649293)
ET 200iSP (http://support.automation.siemens.com/en/view/en/98821323)
ET 200pro (http://support.automation.siemens.com/WW/view/en/21210852)
DP/PA Link and Y Link (http://support.automation.siemens.com/WW/view/en/1142696)
Updating in the standard system

Prior to performing the firmware update, the "Update firmware after downloading" option can
be used to specify the time at which the station needs to be restarted; this enables you to
avoid disruptions to the process.
NOTICE
If the "Update firmware after downloading" box is checked, the IM will restart once the
firmware has been downloaded, which will cause the ET 200 station to fail temporarily.

5.7 Updating firmware of I/O modules
Update in a redundant system

In the case of SIMATIC S7 400H stations with redundant interface modules, you can update
the firmware of the interface modules during operation.
If the update of the active IM is made via PROFIBUS DP, the restart automatically triggers a
switchover between the two IMs. The second IM then needs to be updated too. The update
must be performed separately for each IM. If the ES or the PG is connected to the Profibus
master system directly, with PCS 7 V7.0 SP1 (STEP 7 V5.4 SP3) and higher, as well as IM
153-2BAx1 and IM 153-2BAx2, the two IMs are updated one after the other.
NOTICE
Before you begin the update, make sure that both IMs are in redundant mode.
The PROFIBUS DP cable is plugged in at both ends.
Both IMs are plugged in.
The IMs and modules do not indicate any faults.
Otherwise, the station will briefly fail after the restart instead of switching over.
5.7 Updating firmware of I/O modules
Example: HART modules

A firmware update can be performed via HW Config for the HART modules
6ES7331-7TF01-0AB0 and 6ES7332-8TF01-0AB0.
You can find the requirements and steps in the section titled "Firmware update through
+:Config" in the "ET 200M distributed I/O device HART analog modules"
Example: SM 331 AI 6 x TC
The firmware can be updated via HW Config for electrically isolated analog input module
60331; AI 6 x TC (6ES7331-7PE10-0AB0). See the manual titled "SIMATIC S7-300 S7-300
Automation System Module Data"
(http://support.automation.siemens.com/WW/view/en/8859629) for more details.

5.8 Updating firmware of network components
5.8 Updating firmware of network components

We generally recommend that you update the firmware of network components (switches).
The feasibility of such an update must be checked for each individual plant configuration.
Because the switches of most manufacturers need to be restarted following a firmware
update, you must ensure that this restart will not put safe plant operation at risk.
Example: SCALANCE X-300 and X-400

You will find a description of the firmware update for Scalance X-300 and X-400 in the
"Firmware update" section of the "SIMATIC NET Industrial Ethernet Switches SCALANCE X-
300 SCALANCE X-400 Configuration Manual"

Service and maintenance of SIMATIC PDM 6
6.1 General information on importing devices
Once SIMATIC PDM has been installed on the PCS 7 ES, you will be prompted to import the
device descriptions of the field devices you use to your computer. PDM supports the
following device descriptions:
HCF DD (device description of the HART Communication Foundation)
Electronic Device Description (EDD)
Note
HCF DDs are part of the HCF DD library and can be used in PDM and in handheld
communicators. These device descriptions may only be imported into PDM from the
device catalog supplied.
Every PDM software version is delivered together with a device catalog. Each combination
has been tested and released. The version of the device catalog is listed in the "Readme" of
the PDM version under "Scope of delivery".
Note
The device catalog CD (device library) that ships with the product varies according to the
SIMATIC PDM delivery version; e.g. SIMATIC PDM V8.0 and SIMATIC PDM V8.2.
New device descriptions may have been added or existing ones removed or updated. For
this reason, you should retain the device catalogs used.
The following device descriptions are supplied with the device catalog:
Device descriptions for Siemens field devices
Device descriptions for released HCF (HART Communication Foundation) field devices
Device descriptions for released field devices of the FF (Fieldbus Foundation)
Device descriptions for field devices from third-party manufacturers
Universal device description for HART
Profile device description for PROFIBUS DP/PA field devices
Profile device description for PROFINET field devices

Service and maintenance of SIMATIC PDM
6.2 Device import in SIMATIC PDM V8.2
If your project contains device types for which no device descriptions are provided in the
device catalog supplied, you can import the necessary device descriptions from older
delivery versions of the device catalog.
Note
Only import individual device descriptions from previous delivery versions of the device
catalog and never the entire catalog.
The import of device descriptions of a newer device catalog is only permitted if this device
catalog is released for your SIMATIC PDM version. You can find this information in the
"pdmdevices-Readme" document.
Additional device descriptions can be obtained from other sources and imported in the same
way as the device catalog. Other sources are:
Downloads from manufacturer website
Data carrier supplied with the field device
Save these device descriptions (data) as well. We recommend that you keep a collection of
all device descriptions. Note that you will have to extract devices from external sources prior
to import and that you may have to import them individually.
Use the same PDM software version and uniform device descriptions in every PCS 7 ES.
Follow the steps given above to import device descriptions.
6.2 Device import in SIMATIC PDM V8.2

The Device Integration Manager (DIM) is used for importing device descriptions in PDM
V8.2. This function is started using the menu command "SIMATIC PDM > Device Integration
Manager".
The device integration manager lists all device descriptions contained in a source folder in
the form of a tree topology. Via the menu command "File > Read-in a List of the Integrated
Device Descriptions", a list of the integrated device descriptions is displayed.
Note
In the device integration manager, you can create a printout of the integrated device
descriptions via the menu command "File > Print Device List".
You will find further functions of the Device Integration Manager in the
"SIMATIC Process Control System PCS 7 SIMATIC PDM 8.2"
(http://support.automation.siemens.com/WW/view/en/90682678) operating manual.

6.3 Managing device descriptions in the project

We recommend you document all device types used in the PCS 7 project. You do this for the
device type only and not for every device instance.
Information to be documented:
Tag name
Name of the GSD file (type file)
EDD version
Name of device DDL (DD/EDD name)
DD revision
SW/FW revision of the device
The following information can be documented if desired:
Product name
MLFB/order number of the device
Sensor/actuator type
Communication type
HW revision of the device
Data storage and origin (e.g. Internet)

Example for the FDC 157-0 device (PROFIBUS PA) in PDM V8.2
Once the device has been opened with PDM, you will find the DD version and the software
and hardware revision of the device in the parameter view.
Note
Note that the first time you open a device with SIMATIC PDM, its initial values will be
displayed. These values may differ from the actual values in the device. The "Upload to
PC/PG..." function is used to transfer the device parameters to SIMATIC PDM.
In certain cases, values can be changed by means of local operation on the keypad, for
example. These changes will not be shown in SIMATIC PDM until after "Upload to PC/PG"
has been performed.

Detailed information
To obtain detailed information on the EDD in PDM V8.2, open the object properties via the
"Device" menu in the PDM. In the "Device" tab you will find the following information:
Device-type designation
Device DDL
Order number
Manufacturer
DD_Version (DD_Revision)
Device_Type
Device_Revision

Example table for a device overview list
Device GSD name EDD name DD version DD_Revision SW/FW Com type
revision of
the device
FDC 157-0 SI028131.GSE SIDP_DPPAK.DDL 1.1.14 14 V 1.0.2 PA
SITRANS T3K PA SIEM8090.GSD SIPA__TTK101.DDL 01.768.06- 6 1.32 PA
04
SIPART PS2 SI028079.GSD SIPA_ACP_PS2A_M.DDL 21.768.6- 6 4.00.00 PA
004
You can use the information gathered, for example, to later search through the detailed
summary of the device catalog "ListOfIntegratedDevices" to find the right EDD version for
your device. You can find this list on the device catalog CD in the "Manuals" folder.
Collecting the data has two advantages:
You can compare the EDD versions specified in the "ListOfIntegratedDevices" catalog
with those used in your project.
Then you only have to import the EDD files required to operate your devices.
Example for the list of devices integrated in the device catalog

Please be aware that your project may contain a device type which has different SW/FW
revisions. The EDD version must always match an SW/FW revision of the device. If an
incorrect EDD is assigned, PDM will detect the deviation and communication with the device
will not be established. As a user you will receive a message from PDM stating which device
it expects and which one it has detected during device identification.
The SIPART PS2 has been configured with the EDD for SW revision 5.00.00. The PDM
device identification function detects that the connected device has a deviating SW revision
of 4.00.00. A project-specific device overview makes clear how the EDD versions and the
SW/FW revisions of the device relate to one another.
Device GSD name EDD name DD version DD_Revision Software Com

revi- type
sion/device
SIPART PS2 SI028079.GSD SIPA_ACP_PS2A_M.DDL 21.768.6- 6 4.00.00 PA
004
SIPART PS2 SI028079.GSD SIPA_ACP_PS2A_P.DDL 21.769.1- 7 5.00.00 PA
009

6.4 Updating SIMATIC PDM
Applications
For an update of the PCS 7 ES, the SIMATIC PDM version released for this PCS 7 ES and
the associated device catalog should be installed. You will find further information in the
"PCS 7 Readme" (http://support.automation.siemens.com/WW/view/en/101094704).
Note
Please note the installation requirements when using a more recent PDM version. You can
find more detailed information in the "PDM Readme" ("pdmbase-readme") on your SIMATIC
PDM CD.
1. case:
The project is upgraded to a later PCS 7 version. You need to reinstall the master ES.
2. case:
The project needs to be edited on a different ES. You need to update the installation to
implement the same software version.
Requirement
If the required device descriptions are missing from the PCS 7 ES, it may not be possible to
edit the devices using PDM in the PCS 7 project. If this is the case, check the PDM
installation and verify that all necessary device descriptions have been imported; if they have
not, the error message shown below will appear when the project or HW Config is opened.
HW Config will be opened as read-only in this case. Individual device descriptions will be
missing in most cases.

Procedure
1. Install the PDM version released for the PCS 7 ES and import the device catalog
associated with it (import all devices).
2. Import additional device descriptions which were not imported in the previous step as part
of the PDM device catalog in the same or an updated version.
3. Optional: import individual devices from older PDM device catalogs.
Caution: Selectively import only the missing device descriptions and not the entire
catalog.
4. Open the process device plant view in SIMATIC Manager. Sort the devices to list those
with no description file. You can display the "Devices" column in SIMATIC Manager under
"Options > Settings > Columns > Process Device Plant View".
If no device description has been assigned to a configured device, its symbol will be
displayed in gray. The device description (EDD) file is not installed in this example. You
receive the following message when you double-click on this device:
You can use the Device Integration Manager to display the available and missing device
descriptions in your projects.
Note
A PCS 7 project can contain information about device descriptions which are no longer
used in the project. In this case, you need to carry out a "Save with reorganization" for the
project.

Check device descriptions

The Device Integration Manger of PDM V8.2 enables you to filter out the device descriptions
that have been integrated as well as those that are missing. You can also integrate
unavailable or updated device descriptions (for example, from the library of device
descriptions (Device Library), from a download from the vendor website or from a data
medium supplied with the devices).
Note
You can find information about the the device description library "SIMATIC PDM Device
Library 1#2014" in the entry http://support.automation.siemens.com/WW/view/en/92561933.
The entry http://support.automation.siemens.com/WW/view/en/92561357 provides the library
for download.
To check the device descriptions, open the "Device Integration Manager" (Start > Device
Integration Manager).
Select the menu command "File > List of integrated device descriptions" to display an
overview of all integrated device descriptions.
Select the menu command "File > List of used device descriptions" and the integrated and
non-integrated (black circle) device descriptions are displayed once you have selected a
project.

6.5 Updating device descriptions
6.5 Updating device descriptions

Device manufacturers occasionally offer updates of device descriptions for existing devices.
These device descriptions often contain new functionalities, in which case you can install
them subsequently and transfer them to the existing configuration.
Note
In certain cases, it may be that new device descriptions of older software versions of PDM
may not be supported.
The device manufacturer will inform you if a new device description is only supported as of a
particular PDM software version.
Example
Using the example of the SIPART PS2PA positioner 5.00.00, you can see which additional
features a new EDD version provides.
Versions of SIMATIC PDM Revision Additional features

and device catalogs
PDM V6.0 SP5 with device 7
catalog 01/2009
PDM V6.0 SP5 HF5 with 08/21/08 Quick Start Wizard
device catalog 01/2011 Graphical user guidance through the initializa-
tion process
Partial Stroke Test Wizard
Graphical user guidance through the initializa-
tion and parameterization process of the partial
stroke test
Note
The additional features are available once the SIPART PS2 EDD version 1/21/2008 (not
included in device catalog 01/2009) has been imported.

6.6 Replacing/removing field devices

The following applications are considered for HART and PA devices:
Scenario 1 - Replacing a device of the same type and with a later version (Page 67)
Scenario 2 - Replacing a device with a different type (Page 73)
Case 3 Removing field devices (Page 77)
Scenario 4 Replacement of FF devices
You can find information on replacing FF devices in the manuals "SIMATIC Process
Control System PCS 7 FOUNDATION Fieldbus" and "SIMATIC Process Control System
PCS 7 Help for SIMATIC PDM".
We recommend that you back up the parameter set before replacing or removing PDM
devices. To do this, click on a device in the process device plant view of the SIMATIC
Manager with the right mouse button. In the shortcut menu, click on "SIMATIC PDM >
Export...". You can use the backed up device parameters during a later parameterization
process, e.g. when replacing with another device type.
Exporting the change log

The "Change Log" and "Value Comparison" functions are available as of version PDM V8.0
SP2. You will find information in the "Process Control System PCS 7 Help for SIMATIC
PDM (V8.2)" (http://support.automation.siemens.com/WW/view/en/90682678) operating
manual.

6.6.1 Scenario 1 - Replacing a device of the same type and with a later version
HART device (PDM V8.2) procedure

In this example, the Siemens SIPART PS2 positioner version C1 is replaced with version
4.00.00. The device is configured with the name "Compend" in HW Config.

1. Open the process device plant view in SIMATIC Manager.

2. Right-click the "Compend" device and select "SIMATIC PDM > Device selection
(Reassign)" to open the PDM assignment dialog.

3. Select the EDD for Siemens SIPART PS2 Positioner V4.00.00.

The device path is displayed in the window title bar. The selected device type is shown
on a blue background.
Note
Please note that replacing the SIPART PS2 HART positioner FW C1 with the FW 4.00.00
version necessitates a parameter check and an initialization.
The "Download to devices..." function transfers the parameters from SIMATIC PDM to the
device.

PA device (PDM V8.2) procedure

In this example, the Siemens SITRANS LR250 level radar revision 2 is replaced with revision
3. The device is configured with the name LR250_Compend in HW Config.

1. Open the process device plant view in SIMATIC Manager.

2. Right-click the "LR250_Compend" device and select "SIMATIC PDM > Device selection
(Reassign)".

3. Select the EDD SITRANS LR250 device revision 3.

The device path is displayed in the window title bar. The selected device type is shown
on a blue background.
Note
Please note that the reassignment requires a parameter check.
device.

6.6.2 Scenario 2 - Replacing a device with a different type
HART device (PDM V8.2) procedure

In this example, a SAMSON positioner is replaced with a Siemens SIPART PS2 positioner.
1. Open the device in the PDM and select "File > Object properties...".
2. Back up all project-specific information and settings. You will need this information for
configuring and assigning parameters for the new device type.
3. Close the PDM.
4. Switch to the process device plant view of the SIMATIC Manager to back up the
parameter set.
5. Select the device "Replace" (SAMSON positioner) and select "SIMATIC PDM > Export ..."
in the shortcut menu.

6. Perform the export with the following options:
7. Make the assignment of the new device type. The procedure is described in the section
titled "Scenario 1 - Replacing a device of the same type and with a later version
(Page 67)".
Note
Please note that replacing the device type requires a reassignment of parameters and an
initialization.
device.

PA device (PDM V8.2) procedure

In this example, a Siemens SITRANS LR250 level radar is replaced with a Siemens
SITRANS LR260 level radar.
1. In HW Config, select "Object Properties" from the shortcut menu of the LR250.
2. Back up all project-specific information and settings from the "General" and "Assign
Parameters" tabs. You will need this information for configuring and assigning parameters
for the new device type.
3. Make a backup of the symbol table (E address).
4. Switch to the process device plant view to back up the LR250 parameter set.
5. Select the device "LR250_Compend" and select "SIMATIC PDM > Export ..." in the
shortcut menu.

The export dialog is opened. Using the export dialog, you can back up the device
parameters and diagnostics and document manager information.

6. Delete the SITRANS LR250 in HW Config. This deletion of the device type is required
because the LR250 and LR260 have different GSD files. The associated PDM object is
automatically deleted with it.
7. Configure the new device type (here an LR260) in HW Config using the backed up
property information (e.g. settings, addresses).
8. Perform the assignment of parameters of the LR260 in the PDM. In so doing, take note of
the procedure for the configuration and parameter assignment of field devices described
in "PCS 7 Compendium Part A" (www.siemens.com/pcs7-documentation). You can also
find further information in the section titled "Changing the AS configuration" (Page 78).
6.6.3 Case 3 Removing field devices

Before removing a field device, the entire parameter assignment should be exported.
To back up the parameter set of a PDM object, switch to the process device plant view of the
SIMATIC Manager. Select the device and select "SIMATIC PDM > Export ..." in the shortcut
menu.
Note
As long as a PDM object is in the PDM database, one PDM tag of the associated license is
used. Devices which are no longer used and which have been backed up must be deleted to
release these PDM tags.
Procedure in PDM V8.2

1. Switch to HW Config and remove the field device (HART, PA, FF, DP).
Further steps are not necessary, because the associated PDM object is automatically
deleted in the process device plant view.
You should therefore take note of the recommended procedure for backing up device
parameters which is described in the section "Case 2 Replacing a device with another
type" (Page 73) using the "PA device in PDM V8.2 example".

AS and OS expansions 7
7.1 Changes to the AS configuration
General information
Some plants need to be expanded or modified during operation. This step may be due to the
complexity of the automated process or the high cost associated with restarting.
In PCS 7, changes can be made on a standard AS and on an H system during operation.
The differences between the more flexible H system and a standard AS will be explained in
the following subsections.
The abbreviation CiR (Configuration in RUN) is also used to refer to changes to the
hardware configuration during operation in PCS 7.
7.1.1 Changes to the configuration of a standard AS

You can find the basics, configuration, and application of CiR with a standard AS in the
manual "SIMATIC Process Control System PCS 7 Engineering System"
(http://support.automation.siemens.com/WW/view/en/90663380). The most important points
are summarized below.
For information on CiR, also refer to the "SIMATIC STEP7 V5.5 Modifying the System during
Operation via CiR" (http://support.automation.siemens.com/WW/view/en/45531308) manual.
Principle
Any changes made to the configuration of a standard AS only relate to the distributed
PROFIBUS I/Os and are implemented via the configuration of "CiR objects" and "CiR
modules", which function as placeholders for future I/O expansions in HW Config.
These placeholders can only be activated for the first time in HW Config and subsequent
changes to properties can only be loaded by stopping the AS.
Therefore, the size of the placeholders should be set prior to commissioning the plant to
ensure there is sufficient space for the planned expansions until the next scheduled AS
STOP.

AS and OS expansions
Every PROFIBUS I/O expansion made during operation reduces the set size incrementally.
At the next scheduled AS STOP the placeholder size can be set according to new targets, as
long as it will not violate the system limits for the CPU and PROFIBUS.
Project phase Steps Loading capaci- Frequency

ty
Engineering phase Design of the configuration including activation Via STOP Only required once
of CiR capability and setting the CiR reserve
according to the expansions planned until the
next downtime.
Ongoing operation Adding new stations/modules using the In RUN As often as desired until
CiR reserve CiR reserve is exhausted
Reassignment of parameters for existing
stations/modules
Maintenance downtime Resetting of CiR reserve according to the Via STOP Required after every
expansions planned until the next downtime. change to the CiR re-
serve
Note
The changes to the configuration for a standard AS are only available after the "Enable CiR"
option is set in HW Config for a respective DP master system and after the configuration has
been loaded in STOP operating mode.
Application field
Typical cases of configuration changes on a standard AS include:
Adding a DP slave or PA slave with the next highest bus address.
Adding a module to the first free slot at the end of a modular station, e.g. ET 200M.
Reassigning parameters for modules within a modular station, e.g. ET 200M (based on
the functions of the module in use).
Removing a DP slave or PA slave with the next highest bus address.
Removing the last configured module in a modular station, e.g. the ET 200M.
You can find an overview of all supported configuration changes in the manual titled
"SIMATIC Process Control System PCS 7 Engineering System"

Requirements for using the "Enable CiR" option

Use of an S7-400 CPU or an S7-400 H-CPU in single-station mode, each as of
firmware V3.1
Internal DP interface of the CPU or CP 443-5 Extended (as of firmware version V5.0)
The DP master must be configured in the DPV1 operating mode.
ET 200M: IM 153 (as of 6ES7153-2BA00-0XA00)
You also need to equip the ET 200M with active bus elements and ensure sufficient
space for the planned expansion. You may not connect the ET 200M as a DPV0 slave via
the GSD file.
ET 200iSP: IM 152 (as of 6ES7152-1AA00-0AB0)
You also need to provide sufficient space for the planned expansion and equip the
ET 200iSP with additional terminal modules and reserve modules.
DP/PA link: IM 153 (as of 6ES7153-2BA00-0XA00)
Recommendations for the properties of a CiR object

Take note of the size of the process image set in your CPU properties because, like all CPU
parameters, it can only be changed by an AS STOP. The future address lengths reserved in
the CiR objects must be within the process image size for inputs/outputs.
Preconfigured values of the CiR objects:
On the DP master system: 15 slaves, 1220 input and output bytes
On the PA master system: 6 slaves, 80 input and output bytes
Important rules for working with CiR

Use Ctrl+Alt+F (menu command "Station > Check CiR Capability") to check if the
currently open configuration can be loaded via "Download station configuration in RUN
mode" prior to making a change in HW Config. This consistency check is also performed
automatically before the download is carried out.
If a distributed station has an orange background color, this color indicates that the
station has been added or can be removed via CiR.
New slaves are dragged and dropped to the CiR object of the DP master system and not
directly to the master system.
New modules for ET 200M/ET 200isP are dragged and dropped to the CiR module of the
station.

Use the "Save and Compile" function only after successfully downloading the
configuration changes. If you cannot perform the download for some reason, you can
reverse your configuration changes by closing HW Config.
Download each configured change to the AS individually using "Download station

configuration in RUN mode". You can use such "small" changes to shorten the CiR
synchronization time to a few milliseconds. The new I/O is registered in the AS during the
CiR synchronization time. The entire processing cycle is interrupted.
After each HW Config delta download, the charts need to be updated (including the
"Generate module drivers" option). The PCS 7 driver blocks are then automatically
adapted to the modified I/O.
Note
The CiR function only supports addition or deletion for F I/Os. You can find further
information in the section titled "Configuration in Run (CiR)" in the "SIMATIC Industrial
Software S7 F/FH Systems Configuring and Programming"
(http://support.automation.siemens.com/DE/view/en/2201072) manual.
Important restrictions for delta configuration

A new DP/PA slave must be assigned a bus address higher than all addresses which
have already been configured.
New modules in the ET 200M are inserted and fastened into the next available configured
slot.
All free module slots at the end of an ET 200iSP station must have already had non-
configured reserve modules allocated to them and may only be replaced individually, one
after the other, as the entire ET 200iSP station will enter STOP mode if it has two or more
free slots. A new module is then plugged into the configured slot in place of the first
reserve module.
Changing of I/Os and slave addresses is not possible.
Note
You can find special considerations for using an ET 200iSP on a standard AS described
in the section titled "Configuration changes in RUN" in the "SIMATIC Distributed I/O
ET 200iSP" (http://support.automation.siemens.com/en/view/en/98821323) manual.

7.1.2 Changes to the configuration of an H system

The basics, configuration and application of configuration changes in RUN for an H system
are described in the following manuals:
Manual "SIMATIC Process Control System PCS 7 Fault-tolerant Process Control
Systems" (http://support.automation.siemens.com/WW/view/en/90682535)
Manual SIMATIC Fault-tolerant Systems S7-400H
The most important points are summarized below.
Principle
In contrast to a standard AS, the configuration of an H system is changed not via CiR
objects, but by means of a master/standby switchover with the modified configuration. This
means that many of the restrictions described in the previous section do not apply here. This
means changes in HW Config can be downloaded during operation without previously
activating a function.
Application field
Typical cases of configuration changes on an H system:
Adding distributed stations on the PROFIBUS DP or PROFIBUS PA with any bus
address.
Adding more modules within ET 200M at any free slots.
Reassigning parameters for modules within the ET 200M or ET 200isP (based on the
capabilities of the module in use).
Assigning a different process image partition to a module.
Additional cases for an H system:

Removing existing distributed PROFIBUS stations with any bus address.
Removing existing modules within the ET 200M stations with PROFIBUS connection.
Adding central modules (e.g. additional CPs for Ethernet or PROFIBUS).
Changing certain CPU parameters marked in blue (e.g. local data requirements, max.
communication resources or cyclic interrupt cycle).
Note
You can either add or remove modules during a hardware change. If you want to rebuild
your H system by removing a module type and inserting a new type in its place, you need
to perform two hardware changes one after the other.

Requirements
ET 200M, DP/PA link, and Y link should always be mounted with an active backplane bus
and fully equipped with bus modules, because the bus modules cannot be plugged in or
pulled out during operation.
ET 200iSP is to be equipped with additional terminal modules and fitted with reserve
modules on the free slots, because the terminal modules cannot be plugged in or pulled
out during operation.
Bus cables for PROFIBUS DP and PROFIBUS PA should be provided with active bus
terminating elements at both ends so that the cables are properly terminated even during
the rebuilding period.
PROFIBUS PA bus systems should be built with components from the SplitConnect
product series (see interactive catalog CA01) and active field distributors (AFD, AFDiS
and AFS) so that the lines do not have to be split.
Restrictions
Which parameters cannot be changed during operation of an H system (selection for typical
PCS 7 projects)?
CPU: Activation of process image partition
CPU: Size of maximum local data requirements
Setting for time synchronization
Transmission rate to the DP master systems
Settings on the Ethernet CP and PROFIBUS CP
Changes to the I/O addresses

Checking the plant status

The following requirements must be met prior to making the changes:
The H system is in "Redundant" system mode.
All redundant DP slaves are ready for the upcoming master/standby switchover; in other
words, no redundancy errors are pending on the H system or other errors on the interface
module.
Note
If a fault is pending on an interface module, the master/standby switchover will cause the
system to indicate a station failure of the DP slave concerned when the configuration is
downloaded in RUN.
As of PCS 7 V7.0 SP2, related problems with the signal modules concerned are resolved
automatically as soon as the configuration change is active.
With older PCS 7 versions, the ACC input must first be set on the MOD_D1 driver blocks
concerned to ensure that these problems will be resolved.
All changes must be downloaded via HW Config using "Download station configuration in
RUN mode". The "Compile and download objects" function in SIMATIC Manager cannot
be used for this purpose.
Procedure
As of PCS 7 V6.1 SP1, the required tasks are performed automatically for the most part via
the dialog that appears after you have selected the "Download station configuration in RUN
mode" function in HW Config.

Use the "Save and Compile" function only after successfully downloading the configuration
changes. If you cannot perform the download for some reason or if the H system no longer
goes into the "RUN Redundant" state, you can reverse your configuration changes by
closing HW Config.
7.1.3 Changes to the configuration of an ET 200iSP

You can find information on performing maintenance on the ET 200iSP in zone 1, zone 2,
zone 21 or zone 22 in the "SIMATIC Distributed I/O ET 200iSP"
(http://support.automation.siemens.com/en/view/en/98821323) manual.
7.1.4 Changes to the connection configuration

Before you make changes in NetPro and download them to one or more ASs during
operation, check the status color of all the stations in the multiproject.
Station color white: Fault-free and compiled
Station color orange: Changes not yet compiled
Station color red: Inconsistent connections
Start to make your planned changes only when all stations have been compiled without
faults. You can view a description of the connection configuration in NetPro by pressing F1
to access online help.

Adding a new connection
Deleting a connection
Once a connection has been deleted, you need to highlight the corresponding station and
run the "Download Connections and Gateways" function. This downloads the entire
connection configuration to the AS.
This function can also be performed when the CPU is in the RUN(P) operating mode. Check
the effects on the process in advance and change the charts associated with the connection
prior to the deletion.
Note
Downloading the network configuration using the "Selected Station", "Selected Station and
Partner Station", and " Stations on the Subnet" menu commands can only be performed
when the AS is in STOP.

7.2 Program changes
7.2 Program changes

This section provides guidelines for making program changes to a standard process.
Additional regulations and procedural guidelines apply to F/FH systems in safety mode;
these are described in the section titled "Changes to the safety program or F signal modules"
(Page 97).
After you have completed compilation without any faults, you can download the user
program to test and run it on the target system. After you have compiled but not yet
downloaded the program, SIMATIC Manager will display an additional symbol at the lower
left corner of the closed chart folder in the component view.
The basics for program changes, especially the rules regarding maintaining delta download
capability, are described in the section titled "Download" in the "SIMATIC Process Control
System PCS 7 CFC for SIMATIC S7" (http://support.automation.siemens.com/WW/view/en/)
manual.
Requirements
You can download program changes when the CPU is in RUN-P mode. It is generally
possible to download changes if the following conditions are met:
At least one complete download has been performed successfully.
The download is performed with the program structure used most recently.
As soon as delta download capability is lost, the "Delta Download" selection is grayed out
and only a complete download can be performed.
7.2.1 Checking the logs

The first task is to check the logs for the chart folder in the plant, for example, by calling the
menu command "Options > Logs" in the CFC editor. Save all the available logs separately as
text files to be able to compare them later.

7.2 Program changes
7.2.2 Checking the delta download capability with time stamp comparison
Select the menu command "CPU > Compare" in the CFC editor to check the project status
before each download procedure.
PCS 7 provides the following three time stamps:
As can be seen in the screenshot, the online program that you have downloaded to the CPU
is only identical to the offline program, in other words, the chart folder and the compiled
blocks in the block folder, if the last two time stamps match exactly and are more recent than
the "Last download-relevant change" time stamp.
In all other cases, care needs to be given to the running process:
If the last download-relevant change is more recent than the last compilation, changes
made in the project have not been compiled.
If the last compilation is more recent than the compilation of the loaded program, the
compiled changes in the project have not been download to the CPU.

7.2 Program changes
7.2.3 Measures for maintaining delta download capability

The following section describes the actions and guidelines you have to observe to continue
downloading changes in RUN.
Generating reference data
Note
The SIMATIC Manager menu command "Options > Reference Data > Generate" cannot be
used in PCS 7, because it would require a complete download with the CPU in STOP.
The "Options > Chart Reference Data" function is provided in the CFC editor for PCS 7 to
display reference information about the chart folder.

7.2 Program changes
Range of DB and FC numbers

The range of DB and FC numbers can be neither compressed nor modified; otherwise, a
complete download with the CPU in STOP will be required.

7.2 Program changes
Changing block types

If you need to change a block type already in use, remember that interface changes will
require a complete download of the AS. Such changes are:
Adding inputs/outputs
Making a block capable of signaling
Changing initial values
As an alternative, you should create reserve variables from the start when you generate a
block. For more information, please refer to the following FAQ:
What should you watch out for when defining the program blocks to ensure that the CPU
does not go into "STOP" status during downloading whenever its interfaces have to be
changed again in the future?
Type updating in RUN (TCiR, Type Change in RUN)

In connection with the CPU 410-5H process automation (from firmware V8.1) and PCS 7
version V8.1 ,a type update is supported in the RUN operating state. This makes it possible
to update the instances and download them to the CPU in RUN mode after changing an
interface at the block types.
Note
You will find additional information on the subject of "Type updating in Run" in the "SIMATIC
Process Control System PCS 7 CFC for SIMATIC S7"
(http://support.automation.siemens.com/WW/view/en/) manual in the section titled "Type
updating with a CPU 410-5H PA" and in the Industry Online support portal in the entry
"Process optimization with the controller SIMATIC PCS 7 CPU 410-H"

7.2 Program changes
Downloading to PLCSIM or a test CPU

You want to test your program changes in advance in PLCSIM or on a test CPU.
If you use "Changes only" mode for this download, the delta download capability of the plant
CPU will be lost due to the different time stamps.
You can maintain delta download capability by selecting "To test CPU (entire program)"
mode for the download.
Archiving
Make sure you archive the latest project version after every download. Otherwise, in some
circumstance it may not be possible to perform a delta download with a retrieved project due
to time stamps that have changed over time.

7.2 Program changes
Auto-archiving after successful download

As of PCS 7 version V8.1, the auto-archiving function is available in the "Download to target
system" dialog box. Archiving is performed automatically after downloading by setting the
"Archive project after successful download" option. The option can only be activated if a
version project was selected via the "Browse for Version Project..." button. Archiving is
performed automatically using Version Trail by activating the "Archive project after
successful download" option. Archiving is started once the "S7 Download" dialog box is
closed and the download was completed successfully. Version Trail is opened for this
purpose.
Note
The "Archive project after successful download" option requires that the Version Trail options
package is installed on the ES.
Selective download
The "Selective download" function can be used to download one or more modified CFCs or
SFCs. You can use selective downloading of individual charts to specifically select which
configured changes should be transferred to the target system and enabled. This makes it
possible, for example, to configure multiple units on a CPU at one time, because the
changes to a specific unit can be compiled, downloaded, and tested. Selective download is
not possible under the following conditions:
A complete download is required
A complete compilation is required
Status message for TCiR is displayed (a type adjustment has been initiated)

7.2 Program changes
Selecting the charts

A dialog box displays all charts that can be selectively downloaded. Select the charts that
you want to download in this dialog box. Dependent charts are also automatically selected.
The charts that are not selected but affected by the changes are not transferred as well.
System charts with the prefix "@" are not displayed but are automatically transferred as well
if they are affected by the changes.
Note
Dependent charts arise due to one of the following conditions:
Change to an SFC type: All charts that contain an instance of this SFC type are
dependent and are also downloaded when the SFC type is downloaded.
A dependent chart is a chart that contains at least one block which is in the same runtime
group as a block of the chart to be downloaded.
CAUTION
Before downloading
Make sure that no dangerous system states can arise before downloading. If you have
changed multiple charts with cross-chart interconnections and do not then transfer all
charts to the AS together using "Selective downloading", damage could occur due to
inconsistent states.
Note
You will find further information on the subject of "Selective Downloading" in the in the
section "How to download modified charts to the CPU individually" of the"Process Control
System PCS 7 Engineering System (V8.1)"
(http://support.automation.siemens.com/WW/view/de/90663380) manual and in the
"Downloading individual charts selectively" section of the "Process Control System PCS 7
CFC for SIMATIC S7 (V8.1)" (http://support.automation.siemens.com/WW/view/en/) function
manual.

7.2 Program changes
Chart-based insertion of blocks in runtime groups

To use the "Selective Download" function, it is recommended to enable the "Chart-based
insertion" option in the "Properties Chart Folder" dialog.
With the "chart-based insertion" option activated, an appropriate runtime group is
automatically created in the OB 100 when instantiating blocks with startup characteristics. All
block instances in a chart that have startup characteristics are integrated in the cyclic
runtime groups and in the runtime group assigned to this chart in OB 100.
With PCS 7 projects created from version V8.1 onwards, the "chart-based insertion" option is
activated automatically in the properties of the chart folder.
For an upgraded project that was created with a version prior to V8.1, this option only works
on newly created charts after the option has been enabled. The existing charts and their
configuration are not affected by this activation.
To activate this function select the relevant chart folder and select the "Object Properties >
Advanced" shortcut menu.
Inserting the new blocks of a chart in the runtime group of this chart reduces the number of
dependent charts, which would also need to be included in the selective download.
Aborting the "Complete Download" function

If a complete download is aborted, it will no longer be possible to perform an online delta
download. The online delta download is available again only when a complete download has
been successfully performed.

7.2 Program changes
Aborting the "Delta Download" function

A delta download can be repeated after aborting a prior delta download, in contrast, whereby
only the missing components will be copied.
7.2.4 Parameter changes

You can find a general description on monitoring and changing block interfaces and
parameters in the section titled "Testing user programs" in the "SIMATIC Process Control
System PCS 7 CFC for SIMATIC S7" (http://support.automation.siemens.com/WW/view/en/)
manual.
Parameter changes can be made via test mode in the CFC editor or in the process object
view.
However, you can only change the values of non-interconnected inputs of an FB instance;
outputs and interconnected inputs can only be monitored. In general, inputs/outputs of FC
instances cannot be changed, because FCs do not have instance DBs.
7.2.5 Reading back charts

The parameters of all CFC charts contained in the chart folder of the active chart whose AS
data was changed, for example via OS operations, can be saved in the configuration and
read back. This also applies to limits and controller settings, for example.
A general description of how parameters are read back is included in the manual titled
"SIMATIC Process Control System PCS 7 CFC for SIMATIC S7"
(http://support.automation.siemens.com/WW/view/en/).
Note
As of PCS 7 V8.0, there is the option of reading back charts cyclically and automatically.

7.3 Changes to the safety program or F signal modules
7.3.1 General
There are other regulations and procedural guidelines for F/FH systems in safety mode in
addition to those described in the section titled "Program changes" (Page 87).
Requirements
Qualified personnel who hold the necessary authorizations and qualifications to
commission and/or maintain the SIMATIC F system, as well as devices and systems
associated with PIC protection functions, in accordance with the safety engineering
requirements of the manufacturer and the TV (German Technical Inspectorate).
Modifications to the safety-instrumented system must be carefully planned, tested, and
approved prior to implementation.
You must ensure that the safety integrity level required of the system is maintained during
and after the modifications.
Note
You can find more information in IEC 61511-1.
Changing the safety program

You can make changes to the safety program either offline or online. Depending on the type
of change in question, it may be possible to make it during operation; if not, an F startup or
CPU cold or warm restart will be required.
Note
You can find more information in the following manuals:
Making and downloading changes in safety mode:
Manual "Industrial Software S7 F/FH Systems Configuring and Programming"
(http://support.automation.siemens.com/WW/view/en/2201072) in section
"Changing the safety program".
Safety mode, changes, change tracking and acceptance:
Manual "PCS 7 Compendium - Part B - Process Safety", section "Changes, tracking
changes, and acceptance"
You can find FAQs relating to S7 F/FH systems under
(http://support.automation.siemens.com/WW/view/en/13711209/133000).
The following sections contain a range of use cases which require a particular procedure.

7.3.2 Using fail-safe blocks V1_2 or V1_3
Inserting a new F_CH_AI channel driver in a redundant configuration

If fail-safe analog input modules are operated in a redundant configuration, in certain
circumstances programming a new process tag with a new F_CH_AI channel driver and then
performing a delta download can lead to a shutdown of the safety program in the F-CPU.
To prevent this response from occurring, follow the procedure described in the FAQs.
Redundant F AI modules without MTA
Redundant F AI modules using MTA
Creating or moving F sequence groups

Certain blocks of S7 F systems are automatically moved to the first or last sequence group
within their shutdown group to optimize the F program response times during compilation.
If an F sequence group is placed before the first or after the last F sequence group, a delta
download may lead to passivation of F I/Os or of AS-AS communication.
To prevent this response from occurring, follow the procedure described in this FAQ:
What do you need to take into account when creating or moving F sequence groups and
using the F library "Fail-safe blocks (V1_2)" or "Fail-safe blocks (V1_1)"?
7.3.3 Working with F block types in S7 F systems
General information
The creation of F block types is described in section "Creating F block types" in the
manual "Industrial Software S7 F/FH Systems Configuring and Programming"
You should always copy F block types from the master data library or your F block type
project. The PAR_IDs of the inputs/outputs of your original F block type must be in their
original state.
Use F process tag types with F block types for your project and enter them in your master
data library. Copy CFCs with F block types from the master data library.
To copy a CFC with F block types, all PAR_IDs need to be reset in the copy. Use the
program provided in the FAQ below to do this. Alternatively, copy the CFC to your F block
type project, reset the PAR_ID information there, and copy the chart from the F block type
project at a later time.

Note
You can find further information in the FAQ "What do you need to take into account when
working with F block types?" (http://support.automation.siemens.com/DE/view/en/24931461).
Special considerations for large projects

Every input/output parameter of an F block contains a PAR_ID. If the total number of
PAR_IDs in the safety program (total of all block inputs and outputs) exceeds the limit of
65,535 and F block types are being used, the collective signature of the safety program in
the footer on the printout may differ from that contained in the program information section.
After a delta download of the safety program it may no longer be possible to activate safety
mode.
Check the number of PAR_IDs in the safety program of the AS, using the program provided
in this FAQ, and implement the measures described therein, if necessary.
FAQ "What do you need to take note of in large projects if F block types are used?"
7.3.4 Deleting F_CH_DO F channel drivers
Deleting F_CH_DO F channel drivers (applies to F library fail-safe blocks smaller than V1.3)
If you only delete individual F_CH_DO F channel drivers for an F I/O with outputs, which
have multiple F_CH_DO F channel drivers placed on them, the safety program may trigger
an F STOP immediately after safety mode is activated once the delta download has been
performed.
You can restart the safety program straightaway following the F STOP, for example, by using
the "RESTART" input on the F_SHUTDN block.

7.4 Changes in the OS project
How do I prevent this behavior?

Passivate the F channel drivers which are no longer required by assigning the parameter "1"
to the "PASS_ON" input, instead of deleting them.
Note
You can find further information in the FAQ "What do you need to take into account when
deleting F_CH_DO F channel drivers and using the F library "Fail-safe blocks (V1_2)" or
"Fail-safe blocks (V1_1)?" (http://support.automation.siemens.com/WW/view/en/26623656).
7.4 Changes in the OS project

The options for updating an operator station during operation, either with a delta download or
with a series of complete downloads of a redundant OS, have already been described in the
section titled "Changing projects in process mode" of the PCS 7 Compendium Part A.
You can find information on the basics in the "SIMATIC Process Control System PCS 7
Operator Station" (http://support.automation.siemens.com/WW/view/en/90682677) manual.

Backing up and restoring data 8
8.1 Introduction
A backup is used to safeguard data. There are two types of backup in the SIMATIC PCS 7
environment:
The project backup
The system backup
This section deals with the system backup.
System backups are made so that an operating state can be restored following a failure of a
storage medium or the replacement of defective parts.
Note
You can find further information in the "Data backup" section of the "SIMATIC Process
Control System PCS 7 Service Support and Diagnostics"
8.2 Restore DVDs supplied with bundle PCs

The SIMATIC PCS 7 PC bundles are based on the SIMATIC IPCs. The operating system
and the PCS 7 software are preinstalled on the base devices.
The supplied Restore DVDs enable you to quickly restore the factory state if needed or
perform a new installation for other purposes. These so-called Ax DVDs are also provided
with the pre-configured bundles.
Note
In the query dialog of Ax DVD, you have the option of selecting an operating system without
installing PCS 7 or with PCS 7 installation (e.g. OS server). The installation of the operating
system is adapted for use with PCS 7.
Note
These DVDs were specifically assigned to an individual computer by the operating system
license and cannot be used anywhere else.
The DVDs cannot be ordered separately, nor can they be replaced if lost.

Backing up and restoring data
8.3 Rules for creating backups
8.3 Rules for creating backups

If you do not install your computer using the Restore DVDs, the first backup will depend on
your administrative needs.
Basically, there are two recommended methods for performing the backup:
Creating a backup after full installation of all required software (including SIMATIC
software), its service packs and updates, and all the system-related settings
Creating a basic image after installing the operating system with all required settings
A second image is then created after the SIMATIC software has been installed, along
with its service packs and updates.
Note
Backup strategy
Make a backup of the PCS 7 station before installing any update.
To keep the system backup up-to-date with the most recent version, a new backup
should be made each time the software changes. In general, it is a good idea to create
backups on a regular basis.
Backups can also be made at specified intervals when there are frequent changes. The
system administrator needs to decide which method is appropriate.
Requirements
To restore the system from a backup, you need to use hardware identical to that in use at
the time of the backup. The hardware in use and its installation position should always be
recorded for this purpose.
If the computer is no longer physically present, because it has been destroyed in a fire,
for example, and you do not have another identical model, you should expect to
experience problems when restoring the system from a backup. In the worst case
scenario, a new installation will be required.
License keys cannot and may not be included in the backup.
Important: Record the following settings of the hard disk(s):
Hard disk type (ATA vs. SATA)
Hard disk size / partition size, quantity and sequence of the partitions
Formatting of the hard disk or partition
Record the settings in the PC BIOS setup, e.g.:
SATA configuration (AHCI, RAID or IDE modes)
Settings of "onboard" devices (e.g. LAN)
The last point should be a matter of course in creating full documentation for a plant.
Namely, information such as the computer name, IP addresses, number of network
adapters, operating system, installed service packs, installed software, etc.

8.4 Software for creating backups
8.4 Software for creating backups

In general, the software for creating a backup or image must be compatible with the
operating system in use.
For SIMATIC PCS 7 PC bundles, the "SIMATIC Image Creator" software for image creation
is recommended.
CAUTION
In principle, you can use any type of backup software. Despite extensive testing, however,
there is no way to fully exclude the possibility that the functioning of a SIMATIC PCS 7
system may be disrupted or hindered by additional third-party software not explicitly
approved for SIMATIC PCS 7.
You must check whether the "SIMATIC Image Creator" used is compatible with the existing
device.
Microsoft also offers a backup utility (ntbackup.exe) in its operating systems. The system
administrator can use it as an additional backup tool. You can find it under "System Tools" of
the operating system.
8.5 Creating a backup

The basic procedure for a system backup is as follows:
1. Move the license keys and authorizations to another medium (partition, USB drive, etc.)
before creating the backup.
2. Follow the instructions of the manufacturer of the backup/image software when making a
backup.
3. Copy the license keys and authorizations back once the backup has been successfully
completed.

8.6 Recovery plan
8.6 Recovery plan

There is a great variety of backup/image tools available. No matter which tool you choose,
make sure you design a recovery plan that will help you restore a defective computer step by
step. This recovery plan should be performed regularly on test computers for practice. A
stressful situation can occur if a relevant computer fails due to a hardware fault. The
downtime can also be minimized in such a situation if you have adequate training for
performing a restore.
Note
You should create and regularly test a recovery plan in your own interest.
8.7 Storing backups

We recommend backing up to several media, such as DVDs, to external or separate hard
disks and USB sticks.
External hard disks are a practical alternative to meeting the high-capacity requirements of a
system backup. Spatial and topological separation is recommended to protect backups.


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Compendium Part D Preface 1

Installing updates and

Valid for PCS 7 V8.1

Siemens AG A5E35031848-AA Copyright Siemens AG 2015.

Siemens AG A5E35031848-AA Copyright Siemens AG 2015.

Compendium Part D Operation and Maintenance (V8.1)

5 Firmware update of hardware ................................................................................................................ 48

Compendium Part D Operation and Maintenance (V8.1)

8 Backing up and restoring data ..............................................................................................................101

Compendium Part D Operation and Maintenance (V8.1)

SIMATIC PCS 7 documentation

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D "Operation and Maintenance"

Compendium Part D Operation and Maintenance (V8.1)

Industry Online Support on the Internet

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

3.1.2 What must necessarily be taken into account?

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

3.2 Checking plant configuration

Compendium Part D Operation and Maintenance (V8.1)

Does it involve a PCS 7 plant with SIMATIC Route Control?

Compendium Part D Operation and Maintenance (V8.1)

3.3 Checking plant status

3.3.2 Status of PC stations using SIMATIC Shell

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

3.3.3 Time synchronization

3.3.4 Status of OS connections

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

Compendium Part D Operation and Maintenance (V8.1)

3.3.5 Standard server settings

Compendium Part D Operation and Maintenance (V8.1)

SSM (Split Screen Manager)

Loaded server data (package) without standard server

Loaded server data (package) with standard server

Compendium Part D Operation and Maintenance (V8.1)

3.3.6 Preferred server settings

Function of the preferred server in process mode

Compendium Part D Operation and Maintenance (V8.1)

3. Select the menu command "Configure".

4. Select one of the redundant OS server computers as the preferred server.

Compendium Part D Operation and Maintenance (V8.1)

3.3.7 Redundancy status on the OS server

Compendium Part D Operation and Maintenance (V8.1)

Meaning of the variables

Variable name Meaning

Meaning of the variables

Variable name Meaning

Compendium Part D Operation and Maintenance (V8.1)

Checking the redundancy on the OS client

Visual representation of the redundancy monitoring in the area overview:

Compendium Part D Operation and Maintenance (V8.1)

3.3.8 Client-server connections

Checking the @RM_SERVER_NAME internal OS variable