Resolving WinCC Runtime pdata.fwc Version Mismatch in TIA Portal

Problem Overview

When a TIA Portal project compiled with V15 or V15.1 is loaded onto a runtime station that has WinCC Runtime V16 (or later) installed, the HMI runtime aborts at startup. The error message identifies the configuration database pdata.fwc as incompatible: the file carries a version stamp of 15.0.0.0 (written by the TIA V15.1 compiler), but the installed WinCC Runtime reports its internal version as 16.0.0.0.

The same class of error can also appear when a project created in TIA V15.1 is opened and recompiled on a machine that has TIA V16 installed, or when a virtual machine hosts both TIA Portal versions side-by-side and the wrong runtime resolves the compiled configuration.

Typical affected environment:

• Engineering station: TIA Portal V15.1 with WinCC Comfort/Advanced/Professional or WinCC Unified PC
• Target hardware: SIMATIC IPC477E (Multitouch, 15"/19"/22") with preinstalled Windows 10 IoT Enterprise and WinCC Runtime V16
• Failure mode: Runtime process terminates before any screen is displayed; the Windows event log records a configuration format error

Affected Versions and Components

The version mismatch is governed by the TIA Portal / WinCC compatibility matrix published by Siemens. The relevant rule is that a TIA Portal major version (V15, V15.1, V16, V16 Update 1, V17, V18, V19) can compile configurations only for runtime versions whose major number matches the engineering tool.

Components involved in the failure path:

• pdata.fwc – compiled HMI configuration database. Located in the project runtime folder (e.g. \Project\IM\HMI\<device>\ for WinCC Comfort/Advanced) or in the WinCC Unified PC project output directory.
• WinCC Runtime (RT) V16 – runtime services CCAlgCon.exe, CCExplorer.exe, CCLoad.exe (WinCC Professional) and their Unified counterparts.
• SIMATIC IPC477E – 19" multitouch panel PC. Image releases ship with a specific WinCC Runtime version preinstalled. The version is recorded in the device image manifest and may differ between orders placed in different quarters.
• HSP (Hardware Support Packages) – Siemens-distributed updates that extend a TIA Portal version with new device descriptions and, in some cases, new runtime compatibility shims.

Root Cause Analysis

The pdata.fwc file is a binary, version-tagged configuration database generated by the TIA Portal compiler when you perform a "Compile" or "Compile and download" operation on an HMI device. The file contains:

• Screen definitions (graphical layout, animations, script bindings)
• Tag database (pointers to PLC variables, internal tags, limits)
• Alarm and logging configuration
• Recipe structures and scheduler definitions
• User administration and audit trail configuration
• Runtime version stamp – a 4-byte header field that the runtime checks before loading the file

The runtime version stamp is set by the compiler to match the major version of the TIA Portal used at compile time. When the WinCC Runtime loader initializes, it compares the stamp inside pdata.fwc against its own internal version. If the two values do not match, the loader refuses to start and logs an error that names the file and the two competing version numbers.

Three conditions produce this error:

1. Mismatched compiler vs. runtime major version. A V15.1-compiled project is loaded on a runtime station with V16 installed. This is the most common case on the IPC477E image.
2. Side-by-side TIA Portal installations. A VM hosts TIA V15.1 and V16. If the V15.1 project is opened and compiled, the resulting pdata.fwc carries the V15 stamp regardless of which runtime is later installed on the target.
3. Unintended upgrade of the runtime during system maintenance. A Windows update or a SIMATIC software update bundle installs a newer WinCC Runtime on top of an older one, changing the major version on the panel PC.

Diagnostic Procedures

Before applying a fix, confirm that the failure is in fact a version mismatch and not a corrupted configuration file or a missing dependency.

Step 1 – Read the runtime error

On the IPC477E, open the Windows Event Viewer (eventvwr.msc) and inspect Windows Logs → Application. Look for a source of CCRuntime or WinCC. The event message identifies the file (pdata.fwc), the configuration version (e.g. 15.0.0.0), and the installed runtime version (e.g. 16.0.0.0).

Step 2 – Confirm the installed runtime version

Open the "Installed Software" applet (appwiz.cpl) and look for entries starting with SIMATIC WinCC Runtime. The version is appended, e.g. SIMATIC WinCC Runtime V16.0 Update 1. The matching build number is also written to the registry under:

Step 3 – Confirm the compiled configuration version

On the engineering PC, navigate to the project output directory of the HMI device. Open pdata.fwc with a hex editor (e.g. HxD) and inspect the first 32 bytes. Bytes 8–11 contain the version stamp as a little-endian 32-bit integer. A value of 0F 00 00 00 = 15, 10 00 00 00 = 16.

Step 4 – Check for side-by-side installations

On a VM with multiple TIA Portal versions, open the project in each version and recompile. Only the TIA version used at compile time determines the version stamp in pdata.fwc. The TIA version that last opened and saved the project determines the project file format (.ap16 vs. .ap15_1), which is independent.

Solution Path A – Remove the Higher-Major WinCC Runtime

This is the fastest path and is appropriate when the runtime station image was delivered with a newer RT than the engineering project requires, and you do not need the newer features of V16.

Prerequisites

• Local administrator account on the IPC477E
• Recovery image or backup of the panel, in case rollback is needed
• No concurrent engineering operations targeting the panel

Step-by-step

1. On the IPC477E, log in as a user with administrative rights.
2. Open Control Panel → Programs and Features (or appwiz.cpl).
3. Sort by publisher and locate all entries under Siemens AG whose name starts with SIMATIC WinCC Runtime and whose version is V16 (or higher than the project's compile-time major version).
4. Right-click the highest-version entry and select Uninstall. Follow the Siemens uninstaller prompts.
5. Repeat for any matching V16 service packs, updates, or HSP-installed components (e.g. SIMATIC WinCC Runtime V16.0 Update 1).
6. Reboot the panel.
7. Open appwiz.cpl again and verify that the remaining WinCC Runtime entries match the project's TIA version (e.g. V15.1).
8. Transfer the project to the panel from TIA V15.1 and start the runtime.

Solution Path B – Upgrade the Project to TIA V16

This is the long-term correct path: it preserves the newer runtime, allows installation of additional software packages such as Energy Suite, and aligns the engineering tool with the runtime.

Prerequisites

• TIA Portal V16 (or later) installed on the engineering station, with a valid license
• The project backup before migration
• All Hardware Support Packages (HSP) needed for the IPC477E and any I/O in the project
• Any optional packages used in the project: WinCC Energy Suite, ProDiag, GRAPH, SCL, etc.

Step-by-step project upgrade

1. Open the project in TIA Portal V16 via Project → Open and accept the upgrade prompt. TIA V16 can read .ap15_1 projects and will convert them in place, writing the result as .ap16.
2. Wait for the upgrade wizard to complete its compatibility scan. Note any warnings about device descriptions, library references, or program blocks.
3. Open Options → Support Packages and install any HSP required for the IPC477E and the I/O used in the project. The V16 HSP for the IPC477E may not be installed by default.
4. If the project uses Energy Suite: install the Energy Suite add-in for TIA V16 from the Siemens support portal and re-insert the Energy Suite objects. The V15.1 Energy Suite objects are not forward-compatible and must be re-licensed.
5. Open the HMI device configuration (IPC477E). In the device properties, expand Runtime settings and confirm that Runtime version is set to V16.0.0.0. If the menu only offers V15.x, the corresponding HSP is missing – return to step 3.
6. Recompile the HMI: right-click the HMI device → Compile → Software (rebuild all). The new pdata.fwc will carry the V16 stamp.
7. Re-download the full project to the IPC477E.

Order of installation on a clean IPC477E image

Hardware Support Packages (HSP) – Detailed Procedure

HSPs are ZIP files distributed by Siemens that extend the TIA Portal device catalog and may enable compatibility with runtime versions newer than the engineering tool's major release. For the IPC477E specifically, the relevant HSP must be installed in every TIA Portal instance that is supposed to open or compile a project for that panel.

1. Download the latest IPC477E HSP from the Siemens Industry Online Support portal. The file is named HSPxxxx_IPC477E_Vxx.zip or similar.
2. Close all TIA Portal instances.
3. Open TIA Portal → Options → Support Packages → Install. Point at the downloaded ZIP.
4. Restart TIA Portal.
5. Verify the package under Options → Support Packages → Installed support packages.
6. Re-open the project. The HMI device catalog should now show the IPC477E under the latest available firmware/runtime combo.

Energy Suite Considerations

The WinCC Energy Suite is an optional add-in that allows measurement and evaluation of energy data on the HMI. It is delivered as a separately installable package with its own version number. Common causes of "cannot open Energy Suite project in V16" are:

• Energy Suite V15.1 is installed, but the project was opened in TIA V16 – uninstall the V15.1 Energy Suite and install the V16 version.
• The Energy Suite license is tied to a specific major TIA version – re-authorize the license on the V16 installation.
• Energy Suite objects (energy programs, energy tags) generated under V15.1 are present in the project – TIA V16 will warn that these will not be loaded. Re-generate them with the V16 tool.

Verifying the Fix

After applying either solution, perform the following checks before declaring the system healthy.

Version check

1. On the panel: open appwiz.cpl and note the installed WinCC Runtime version.
2. On the engineering station: open the compiled pdata.fwc in a hex editor and read the version stamp.
3. Confirm both numbers match.

Runtime startup check

1. Restart the HMI runtime from the panel desktop shortcut or via TIA's "Go online → Start runtime" command.
2. The startup splash should reach 100% without an error dialog.
3. The first configured screen should appear within 10–30 seconds.

Tag and alarm check

1. Open the HMI tag simulation (if enabled) or trigger a known PLC value.
2. Confirm the value is visible in the runtime screen.
3. Trigger a configured alarm and confirm it appears in the alarm view.

Event log review

1. Open Event Viewer on the panel and confirm no CCRuntime errors are recorded for the current boot session.

Preventive Measures and Best Practices

• One TIA Portal version per engineering VM. Avoid side-by-side installations of TIA V15.1 and V16 on the same engineering station. If unavoidable, segregate the projects into separate workspaces and recompile after every version switch.
• Lock the runtime version on the panel. Use the Siemens Software Update Tool or the panel's UAC-controlled installation policy to prevent automatic WinCC Runtime upgrades during Windows updates.
• Document the engineering toolchain. Record the TIA Portal version, HSP list, and add-ins (Energy Suite, ProDiag) used for each commissioned project. The information is needed to reproduce the compile environment.
• Use the TIA Compatibility Tool. Before any major version change, consult the Siemens TIA Compatibility Tool to verify the supported upgrade path for the IPC477E and any other devices in the project.
• Pin the runtime in the project. In the HMI device configuration → Runtime settings, set the runtime version explicitly rather than relying on "latest installed".
• Maintain a recovery image. Before touching the panel's runtime, capture a full image with the Siemens SIMATIC Image Creator or a third-party disk imager. Recovery from a corrupted image is faster than re-installing the OS and all add-ins.

Edge Cases and Field Notes

Case 1 – Mixed-version panel fleet. A site has 12 IPC477E panels, half on V15.1 images, half on V16. Engineering must be done in TIA V15.1, compiled, and then individually recompiled (or kept at the matching runtime) per panel. Use SIMATIC Automation Tool to script the bulk transfer.

Case 2 – Plant-wide upgrade. The runtime station is on V16, but a new V17 feature is required. The supported path is TIA V17 (with the V17 HSP for the IPC477E) on the engineering side, recompile the project, and deploy. TIA V15.1 cannot target V17 directly.

Case 3 – Read-only project file. The compiled pdata.fwc was delivered on a read-only network share and cannot be regenerated. The only option is to bring the panel runtime back to the engineering version. The image may need to be re-flashed.

Case 4 – WinCC Unified vs. Comfort/Advanced. WinCC Unified PC has a different configuration file format and is not subject to the same pdata.fwc version rule. If the project is migrated from Comfort/Advanced to Unified, the legacy pdata.fwc is not used and the version mismatch is moot.

Case 5 – TIA Project Server. When using a multi-user project on a TIA Project Server, the server's installed TIA version determines the compile behavior. All clients must run a TIA version that matches the server, otherwise the resulting pdata.fwc will carry the version of the last client that compiled the HMI.

References to Official Documentation

• SIMATIC IPC477E operating instructions (Siemens Industry Online Support)
• TIA Portal V16 installation and upgrade guide
• WinCC V16 compatibility tool entries
• SIMATIC HMI Panel PCs product page
• WinCC Energy Suite V16 manual
• Hardware Support Packages installation guide

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