ProTool TP170 Backup: ProSave Restore and Back Transfer Guide

Overview: ProTool TP170 Backup and Recovery Constraints

The SIMATIC TP170 mono (catalog family 6AV6 545-0xA15-2AX0) is a 5.7" monochrome (4 blue shades) panel from the OP/TP 170 family, configurable with Siemens ProTool/Pro V6.0 and also editable from WinCC Flexible 2004 / 2005 / 2007 / 2008 SP3. The device has no on-board non-volatile project storage for the engineering source; the runtime image that resides in flash can be transferred back to the engineering station only when Back transfer (Rückübertragung) has been enabled before the original download. The resulting *.pdl / *.bin or compressed archive is runtime-only: it can be restored to the same panel type and same firmware revision but cannot be opened or edited in ProTool or WinCC Flexible.

This article documents the only supported recovery path using ProSave (the backup/restore utility shipped with ProTool and WinCC Flexible) and addresses the common scenario where a plant (for example a water-treatment skid controlled by an S7-300 or S7-200 with a TP170 mono) ships without any PLC or HMI backup.

TP170 Mono Hardware and Catalog Reference

The mono variants share the same ProTool/Pro runtime image format and the same ProSave backup container. A backup of a TP170A mono cannot be restored to a TP170B mono and vice-versa; the panel type and the firmware revision (e.g. Bootloader 1.x, FW 4.x) are part of the compressed project envelope. Cross-restoration will fail with Error 2005 / panel type mismatch.

Prerequisites

1. Engineering station: A Windows XP / Windows 7 (32-bit) PC with either ProTool/Pro V6.0 SP3 or WinCC Flexible 2008 SP3 installed. WinCC Flexible 2008 SP3 is a valid substitute because it includes the TP170 device description, the ProSave utility, and the Transfer menu used for back transfer.
2. ProSave: Available at Start > SIMATIC > ProSave. It is installed automatically with ProTool/Pro and with WinCC Flexible. The same Prosave.exe binary is used; only the path and version differ.
3. PC-PPI / PC-MPI / USB-PPI cable: A Siemens 6ES7 901-3CB30-0XA0 (RS232 PPI/MPI) or the USB version 6ES7 901-3DB30-0XA0. For TP170B the service USB may be used as a serial substitute. Set the PC adapter MPI address to 0 and the panel address to 1 (defaults).
4. MPI/PROFIBUS parameters: Default baud rate on the TP170 mono is 187.5 kbit/s; the panel must be configured for the same bus profile, highest station address typically 15.
5. Power on panel: Apply 24 VDC and let the boot phase complete. The TP170 mono shows Transfer mode automatically when started without a valid configuration, or when Enable Back Transfer is set.
6. Original project (if available): Even though the TP170 cannot be edited from a back transfer, the recovered file must match the target firmware. Verify the panel boot loader and firmware under Start Center > Info > System.

Back Transfer (Rückübertragung) Concept

Back transfer is the directional counterpart to Download. When enabled in the ProTool/Pro project (or in WinCC Flexible under Project > Transfer > Settings > Back transfer), the runtime image stored in the panel's flash is flagged as "back-readable". After that flag is set, the operator can initiate a back transfer from the panel menu (Transfer > Back transfer on newer firmware, or Start Center > Transfer on TP170) and the file is sent back over the MPI/PROFIBUS connection to the engineering station, where ProSave writes it to *.psb or *.bin format.

Key constraints:

• Back transfer is a one-way read of the runtime image; variables, alarms, and screens are extracted but the source *.pdl project file is not recovered.
• The recovered file cannot be opened, edited or printed in ProTool or WinCC Flexible. It is a binary envelope suitable only for restoration to a same-type panel.
• If back transfer was not enabled before the original download, the file on the panel is protected and ProSave will return Error 1302 "Back transfer not allowed" or similar, depending on the firmware generation.
• Back transfer requires that the panel and PC are connected via MPI/PROFIBUS (or USB service on TP170B) and that no transfer is currently running.

Step-by-Step: Enabling Back Transfer in the Project (for Future Downloads)

This procedure is for engineers who still have the source *.pdl project and want to ensure back transfer is possible later. It must be performed before every download.

1. Open the project in ProTool/Pro V6.0 SP3 or WinCC Flexible 2008 SP3.
2. Navigate to File > Transfer > Transfer Settings (ProTool) or Project > Transfer > Settings (WinCC Flexible).
3. Select the panel TP170 mono.
4. Activate the checkbox "Enable Back Transfer" (German: Rückübertragung aktivieren).
5. Set the access password if one is required by the plant standard (8 characters, alphanumeric). Without a password the back transfer is unrestricted once initiated from the panel.
6. Click OK and recompile: Project > Compiler > All.
7. Download to the panel via MPI/PROFIBUS. The new image, flagged for back transfer, replaces the previous one.

Step-by-Step: Performing the Back Transfer from the TP170

1. Connect the PC adapter to the TP170's MPI/PROFIBUS port and to the PC.
2. Start ProSave on the PC (Start > SIMATIC > ProSave).
3. Under Device type, select TP170 mono (or TP170A mono / TP170B mono depending on the exact variant).
4. Set Connection to Serial / MPI and configure the PC adapter (COM port, baud 187.5 kbit/s, MPI address 0).
5. Click File > Back Transfer (in older ProSave versions: Backup > Read from device).
6. On the TP170, enter Transfer mode from the Start Center and confirm Back Transfer. The panel will display Waiting for transfer.
7. ProSave will report the panel type, firmware, and the file size. Confirm the destination path (default \Program Files\Siemens\ProTool\Backup\<timestamp>.psb).
8. Click Start. Progress is shown in the status bar. Typical duration: 1-4 minutes for a small-to-medium TP170 project.
9. When ProSave reports Transfer completed successfully, close the dialog. The *.psb file is now on the PC.

Step-by-Step: Restoring the Backup to a Replacement TP170

1. Verify the replacement panel is identical type (TP170A mono → TP170A mono, not TP170B) and runs the same firmware revision as recorded in the back-up file's Properties.
2. Connect MPI/PROFIBUS and start ProSave.
3. Select File > Restore > to device.
4. Browse to the *.psb / *.bin file.
5. Click Start Restore. ProSave will check the panel type and firmware before writing. If the firmware is older, ProSave will offer a Firmware Update step first.
6. Once restoration completes, ProSave may prompt for a panel restart. Confirm; the panel reboots into the recovered project.
7. Verify by cycling through the screens and checking that all tags update against the live PLC.

WinCC Flexible 2008 SP3 as the Configuration Front-End

WinCC Flexible 2008 SP3 can be used to configure a TP170 mono (the device was re-classified as a "Compact Panels" generation and retained backward compatibility). It can also be used only to perform the back transfer and restore operations through its bundled ProSave. What WinCC Flexible cannot do:

• Open or edit the recovered *.psb file as a project.
• Convert a TP170 mono back-up into a TP170 comfort/panel project.
• Migrate the runtime into TIA Portal without a full source project — the migration path requires the *.pdl source, which is recovered only by reading from the panel before the back-transfer flag was disabled.

If the goal is to migrate to TIA Portal (e.g. to a KTP700 Basic or TP700 Comfort), the only safe approach is to obtain the original *.pdl source from the system integrator or rebuild the project from the PLC tag list. Migrating from a runtime *.psb back-up is not supported by Siemens and will fail at the importer with "no source available".

ProSave Parameter Reference

Common Error Codes and Their Meaning

Troubleshooting Matrix

Alternative Recovery Path When Back Transfer Is Disabled

If the panel was originally downloaded with the Back transfer flag disabled, ProSave cannot recover the runtime image. The remaining options, in order of preference, are:

1. PLC tag export: Connect to the S7 PLC with STEP 7 (or TIA Portal with the S7-300/S7-200 add-on) and export the symbol table. Variables used by the HMI can be reconstructed from this list.
2. Screen capture via ProTool runtime: If the panel is still running, navigate through every screen and capture with a camera. Useful as a reference but not editable.
3. Original integrator: Contact the OEM/system integrator and request the *.pdl source. This is the cleanest recovery path.
4. Reverse engineering: The ProTool *.pdl format is partially documented. Third-party tools can extract text strings, screen layouts and tag references, but the output requires manual reconstruction in ProTool or WinCC Flexible. This is not an officially supported path and may breach license terms.

Verification After Restore

After a successful restore, perform the following checks before signing off:

1. Tag test: Trigger a known PLC input (e.g. start pump) and verify the corresponding HMI button/state updates within one scan cycle.
2. Alarm test: Force a configured alarm in the PLC; verify it appears in the TP170 alarm view and clears on acknowledgement.
3. Recipe / parameter test: If the project uses recipes, write one to the panel and confirm the values land at the PLC.
4. Trend test: Verify the trend archive is logging and that historical data is readable.
5. Communication diagnostics: Open Info > System > Communication on the TP170 and confirm MPI "connection OK" with the configured partner (PLC).
6. Re-enable back transfer: Immediately after verification, enable Back transfer again (see step-by-step above) so that the next event of plant loss does not repeat the situation.

Field-Proven Caveats

• TP170A and TP170B use different flash file systems. A TP170B backup will not restore onto a TP170A and ProSave will reject it at the panel-type check.
• MPI address conflicts on the bus will silently abort the back transfer at the "connection establishment" step. If multiple stations share the bus, isolate the TP170 on a dedicated cable for the duration of the operation.
• Some TP170 panels have a write-protection switch on the rear (S1 on TP170B). The switch must be in the unlocked position; otherwise ProSave will return error 3000 ("Flash write error").
• The 24 VDC supply must be stable during the entire restore. A drop below 21 V mid-write can leave the panel in a non-bootable state requiring a full firmware re-load.
• ProSave does not verify that the PLC program is intact. Always keep an independent PLC backup (PG archive in STEP 7, or *.s7p source) in addition to the HMI backup.
• Document the firmware version of every TP170 in the plant. Future replacement panels must be flashed to the same version before restoring a back-up taken with a different version.

Recommended Backup Policy for ProTool TP170 Installations

1. Always keep three copies of every ProTool project: PG source, engineering-station back-up, and an offline copy on the plant server.
2. Always enable Back transfer on every TP170 download so a back-up can be read even if the source is lost.
3. Perform a ProSave back-up annually and after every program change. Store the file with a timestamp and the firmware revision.
4. Keep a record of the MPI addresses, panel catalog numbers, and firmware versions of every panel on site.
5. When decommissioning a TP170, perform a final back-up before disconnecting power; flash content is volatile when the unit is stored unpowered for extended periods.

FAQ