Restoring Siemens HMI from WinCC Flexible 2008 Project File

Problem Overview

When a Siemens HMI panel (for example an MP 277, TP 177, or OP 277) boots into its Control Panel and an operator selects Backup/Restore > Restore, the device looks for a *.psb archive on the attached storage medium (CF card, SD card, or USB stick depending on the panel class). If only the engineering project file (the editable .hmi / .flex project compiled from SIMATIC WinCC flexible 2008) is available, the restore menu shows no selectable backup, or the operator receives the prompt "Insert backup medium". A common field symptom reported by service engineers is the compatibility error "The image version is not compatible with the device version" during a back-transfer attempt from the panel, which then prevents a round-trip download of the same project.

This article documents the correct procedure to recover a panel when only the WinCC flexible engineering source is available, explains the role of the PROSave utility, and details the OS update path used to clear the compatibility error.

Why the Panel Asks for a .psb File

The .psb (Panel Storage Backup) container is the proprietary compressed image that PROSave writes when executing a Backup operation from the panel side. It contains:

• The runtime image (firmware + project) currently active on the panel.
• Recipe data, alarm logs, and user administration exports.
• Panel-specific parameters (Ethernet address, MPI/PROFIBUS node, brightness, calibration).

The WinCC flexible engineering project file does not contain any of this runtime state. It contains only the project source compiled against a specific panel image version. Therefore, a direct Restore from .psb is only possible if a backup was previously generated. When no .psb exists, the only viable recovery is to re-compile and download the engineering project to the panel, then immediately generate a new .psb through PROSave for future use.

Affected Products and Versions

Prerequisites

1. Programming device with WinCC flexible 2008 SP5 installed (SP3 or SP4 also acceptable; SP5 recommended for the latest device description packs). Confirm in Help > About that the build number is at least K06.01.05.00_01.04.
2. The compiled or source .hmi / .flex project matching the target panel's article number.
3. A PROSave license included with the WinCC flexible install (full image, not runtime-only).
4. An appropriate transfer cable:
   • RS-232 null-modem (6ES7 901-1BF00-0XA0) for OP 73 / OP 77 series.
   • MPI/PROFIB USB adapter (6GK1 571-1BA00-0AA0) or Ethernet crossover for Ethernet-capable panels.
   • Ethernet RJ-45 patch for TP/MP panels with integrated PROFINET.
5. If the source project is a TIA Portal migration target, the TIA Portal Project View > Transfer menu is used instead of WinCC flexible — see the TIA Portal section below.

Step-by-Step Recovery Procedure

Step 1 — Verify the Project Targets the Panel

Open the project in WinCC flexible 2008 and select Project > Device > Change Device Type to confirm the target article number matches the physical panel. Mismatches cause the compatibility error during transfer. Re-save the project after any device change.

Step 2 — Configure the PG/PC Interface

Open Start > SIMATIC > PG/PC Interface and set the access point S7ONLINE to the correct adapter (for example TCP/IP > Intel NIC). For MPI/PROFIBUS use PC Adapter (MPI) or PC Adapter (PROFIBUS) with the correct baud rate (typically 1.5 Mbps for TP/MP panels).

Step 3 — Place the Panel in Transfer Mode

On the panel itself, navigate to Control Panel > Transfer and enable Wait for transfer. The panel will display "Transfer mode active". If the Control Panel is inaccessible because the runtime is locked, hold the Hold key during power-up until the loader appears (panel-specific), then access the loader.

Step 4 — Transfer the Project from Engineering to Panel

In WinCC flexible 2008 select Project > Transfer > Transfer to Device (shortcut Ctrl-T). Configure the connection parameters (panel IP or MPI address), tick "Overwrite existing project", and click Transfer. The compile log will report events such as:

[Transfer]  Open connection to 192.168.0.10
[Transfer]  Device type: MP 277 8" Touch
[Transfer]  Image version on device: V12.00.00
[Transfer]  Image version required: V12.00.00
[Transfer]  Transfer started
[Transfer]  100 %  (2.4 MB / 2.4 MB)
[Transfer]  Restart device

If a compatibility error appears (for example "Image 13.00.00 is not compatible with the panel. Required: 12.00.00"), proceed to the OS update step before re-transferring.

Step 5 — Generate a .psb Restore File with PROSave

After the panel reboots and the new project is running:

1. Launch PROSave from the Start menu.
2. Select Panel type matching the device (MP 277 8" Touch, TP 177 4", etc.).
3. Choose the Connection (Ethernet, MPI, USB, or serial) and set the address.
4. Click Backup, browse to the storage path, and provide a filename such as MP277_2024-05-12.psb.
5. Enable Compress and confirm. The backup completes in 30–90 seconds depending on log volume.

Copy the resulting .psb to a CF/SD/USB medium and store it with the project documentation. This file is now suitable for the panel's Restore menu.

Resolving the Compatibility Error (OS Update)

The most common reason a back-transfer or a download fails with a compatibility error is that the panel's runtime image version does not match the version WinCC flexible 2008 expects for the device article number. WinCC flexible 2008 was released with a fixed device-description set; later panel firmware revisions add features that older engineering tools cannot recognize.

Method A — Update the Panel OS via PROSave

1. Download the appropriate Panel Image from the Siemens Industry Online Support portal. Search for the article number (for example 6AV6 644-1AB05-0AX0) and select Downloads > HMI Software > Panel Images. Typical image files use the naming scheme MP377_V12_Upd3.zip.
2. Extract the zip to a folder; the image carries an extension such as .img or is bundled as a .fwf package.
3. Open PROSave, connect to the panel, and select OS Update.
4. Browse to the extracted image and confirm. The panel will reboot, flash the image, and reboot again. Total downtime is typically 3–6 minutes.
5. After the OS update, re-attempt the transfer from Step 4.

Method B — Use a Compatible Engineering Build

If an OS update is not permissible in a validated environment, install the matching version of WinCC flexible (for example WinCC flexible 2008 SP4 HF7 for early MP 277 firmware). The build can be selected during install via the Setup > Language Selection > Components dialog. Confirm the Service Pack in Help > About > Installed Software.

TIA Portal Migration Path

Projects that have been migrated to TIA Portal (V13 SP1 or later) follow a slightly different procedure because PROSave is replaced by the integrated Online & Diagnostics functions. To transfer a migrated project to a Comfort Panel or a legacy panel still running CE:

1. Open the project in TIA Portal and select the HMI device in the project tree.
2. Choose Online > HMI Device Maintenance > OS Update if the image needs to be refreshed first.
3. Choose Online > Download to Device. The selection dialog includes the same Ethernet/MPI/PROFIBUS adapters as WinCC flexible.
4. Confirm the Overwrite prompt and wait for the progress bar to complete.
5. Use Online > HMI Device Maintenance > Backup to write the equivalent of a .psb file (TIA Portal writes a .hmi.backup archive).

Verification Checklist

Troubleshooting Matrix

Best Practices for Future Restores

• Automate PROSave backups through a scheduled Windows task calling Prosave.exe /backup /panel=MP277 /conn=Ethernet /addr=192.168.0.10 /file=D:\Backup\MP277_%date%.psb. The CLI flags are documented in the PROSave help (/?).
• Maintain a project-archive structure: \<plant>\<line>\<panel>\Engineering\, \Backups\, \OS-Images\. This ensures every engineering revision has a matching .psb and panel image.
• Tag every .psb with the engineering revision hash: MP277_Rev3.4_2024-05-12.psb.
• Use a dedicated Service Stick (Siemens 6AV6 671-1XY00-0AX0 or compatible industrial-grade USB) for restore operations. Consumer USB drives can cause write errors on the panel loader.
• After any OS update, regenerate the .psb immediately and store it alongside the project tree.

Key Field Notes

• Transfer does not equal Restore. The panel's Restore menu operates exclusively on .psb containers produced by PROSave or by the panel's own Backup menu. The engineering project is delivered through WinCC flexible or TIA Portal Transfer, not through the Restore menu.
• Back-transfer is engineering → panel only. The legacy term back-transfer in WinCC flexible refers to uploading from the panel back into the engineering tool to refresh the project source. It cannot be used to push a project onto the panel when the target image version is incompatible.
• Licensing is per image. A panel licensed for Sm@rtAccess will retain that license across OS updates provided the destination medium is the same. Swapping the CF card requires the license key to be re-applied via PROSave.
• Time sync. Some WinCC flexible projects assume the panel clock is NTP-synced. After a restore, verify Control Panel > Date/Time or the PLC tag driving $SystemTime.