S7-200 SMART SR40 Upload Failure: Resolving the “feature.dvp” PLC Type Not Found Error

1. Problem Description

When attempting to upload a project from a Siemens SIMATIC S7-200 SMART CPU (typical case: the SR40, order number 6ES7288-1SR40-0AA0), STEP 7 Micro/WIN aborts the transfer and reports the message:

No program blocks (OB/main, SBR, INT), data blocks (DB), or system blocks (SB) are transferred to the PC. The project remains empty or the previous on-disk copy is left untouched.

Symptoms typically observed by the user:

• The Upload action in Micro/WIN produces the error dialog and aborts.
• The communication channel establishes (green “Connected” indicator) but read/write of project files fails.
• The Read/Write CPU dialog does not display the connected CPU type in the device list.
• The same PC may communicate with classic S7-200 CPUs (CPU 222, 224, 224XP, 226) using the same software installation, while the SMART CPU is invisible.
• Reinstalling the editor, replacing the project file, or switching communication drivers does not clear the error.

2. Root Cause Analysis

The feature.dvp file is the encrypted, version-tagged project container that the Micro/WIN family uses to identify a CPU's catalog number and firmware version. The error message is generated when the PC-side editor cannot find a matching entry in its internal feature database for the catalog/firmware combination reported by the connected CPU.

There are three production branches in the S7-200 world, and each has its own feature database:

When the PC runs the legacy Micro/WIN V4.0 SP9 and connects to an S7-200 SMART CPU, the editor cannot find a matching entry in its feature.dvp index. The error is therefore not a PLC fault, a cable fault, or a corrupted project file — it is a software-family mismatch.

2.1 Why the error wording is misleading

The phrase “not found in feature.dvp file” suggests a corrupted project file on the local disk. In reality, the local file is irrelevant: the error is generated by a lookup against the editor's internal catalog/firmware database when the connected CPU's identity is reported. Reinstalling the editor, replacing project files, or switching to a different PC will not fix the problem until the correct editor family is used.

2.2 Two editors, two databases, one PC

Legacy Micro/WIN V4.0 and Micro/WIN SMART install into separate program directories and use independent registry keys. They can coexist on the same Windows workstation. Project files are not interchangeable: a *.mwp file belongs to the legacy editor, and a *.smart file belongs to Micro/WIN SMART. Opening a SMART project in the legacy editor will be rejected and may corrupt the file if the user accepts the “convert to generic project” prompt.

3. Affected Products, Catalog Numbers, and Versions

4. Resolution: Use the Correct Software Family

The fix is to install STEP 7 Micro/WIN SMART. The two editors are independent products and may coexist on the same PC.

4.1 Step 1 — Confirm the CPU family

From the side label of the SR40, read the order number. If it begins with 6ES7288-1, the device is part of the SMART family and requires Micro/WIN SMART. Numbers beginning with 6ES7210-2, 6ES7212-2, 6ES7214-2, or 6ES7216-2 indicate the classic S7-200 line and require Micro/WIN V4.0 SP9.

4.2 Step 2 — Install STEP 7 Micro/WIN SMART

1. Download the installer from the official Siemens support portal or use the installation DVD (MLFB 6ES7288-0FA02-0YA0 for V2.7). Older V2.x releases (V2.5) may still be found on the legacy DVD 6ES7288-0FA01-0YA0.
2. Run the installer as Administrator. The package contains the editor, the SMART communication driver stack, and the feature database that knows how to decode S7-200 SMART catalog numbers and firmware versions.
3. Restart Windows when prompted. The Micro/WIN SMART background service (Siemens TCP/IP Auto) is registered during install and must be running for Find CPU to discover devices on the local subnet.
4. Activate the license. Micro/WIN SMART is a 21-day trial if no license is applied. Licenses are available as standalone USB key (red Siemens USB stick) or floating licenses bound to a license server. The Micro/WIN SMART license is independent of any TIA Portal or STEP 7 V5.x license on the same PC.

4.3 Step 3 — Configure the Ethernet interface

1. Set the PC Ethernet adapter to a static IP in the same subnet as the SR40. The factory default IP of a SMART CPU is 192.168.2.1; assign the PC 192.168.2.100 / 255.255.255.0 if you have not changed the CPU.
2. In Micro/WIN SMART, open the Communications dialog (left navigation pane) and click the Ethernet interface card.
3. Click Find CPU. Micro/WIN SMART broadcasts on the local subnet via UDP and lists every SMART CPU it can reach. The list shows IP, MAC, and the catalog order number.
4. Select the SR40 and click OK. The active project is now bound to that CPU catalog and firmware version.

4.4 Step 4 — Upload the program

1. From the File menu, choose Upload or click the Upload arrow on the toolbar.
2. Confirm the upload dialog. The editor reads the project blocks (main, SBRs, INTs, DBs) and rebuilds a feature.dvp that matches the connected CPU.
3. Save the uploaded project immediately as a new *.smart file. The default Project1.smart name should be replaced with a descriptive filename that includes the CPU and firmware version.

5. Verification Procedure

After upload completes, verify the following to confirm a healthy system:

• CPU type field at the top of the project tree reads “CPU SR40” with the actual order number (6ES7288-1SR40-0AA0) and firmware version.
• Program block tree contains all expected subroutines, interrupts, and data blocks. Compare block count to the original project documentation.
• System block matches the installed hardware: input filter times, output forces, retention areas, RS-485 port configuration, and any PROFINET device name.
• Disconnecting and reconnecting the Ethernet cable while in RUN does not corrupt the uploaded program. Cycle power and confirm retention behaves as configured.
• Download a known-good small program (for example, a single SM0.0-driven Q0.0 toggle) to the CPU to prove bidirectional write capability.
• Open the Web Server of the CPU (default port 80) to confirm the CPU is responding. Default credentials are admin/admin; change before deploying to a production network.

6. Troubleshooting Matrix

7. License and Coexistence Notes

STEP 7 Micro/WIN SMART, STEP 7 Micro/WIN V4.0, STEP 7 V5.x (SIMATIC Manager), and TIA Portal are independent software products with independent licensing. Installing Micro/WIN SMART does not consume or invalidate TIA Portal licenses, and the reverse is also true. Both legacy and SMART editors can be installed on the same Windows workstation.

For a plant that mixes classic S7-200 and S7-200 SMART CPUs, keep both editors installed. Configure file associations as follows:

• *.mwp → legacy Micro/WIN V4.0 SP9
• *.smart → Micro/WIN SMART

Do not attempt to open a *.smart project in the legacy editor. The legacy editor rejects the file format and may attempt to roll it back to a generic project, which can produce a corrupted file if the user accepts the prompt without reading it.

8. Connectivity Reference: SR40 Onboard Ethernet

9. Feature Database Mechanics (Why the Error Exists)

Every CPU family entry in the editor's feature database is a tuple of (MLFB order number, firmware major.minor, hardware revision). The editor computes this tuple from the project file or from a live CPU's identification reply and looks it up in the database. If the lookup fails, the editor cannot perform any operation that depends on knowing the catalog number, including upload.

The lookup also drives several downstream behaviors:

• Instruction set. The available STL and LAD instructions differ across CPU families. A block written for a classic CPU may not compile on a SMART CPU even when both feature databases recognize both.
• Address range dropdowns. The editor populates I, Q, M, V, AI, AQ ranges based on the feature entry; an unrecognized catalog produces empty dropdowns.
• PROFINET wizard. The PROFINET device-name and module configuration are gated by the entry; a missing entry disables the PROFINET wizard and any PROFINET IO download.
• Web server templates. Pages such as “Module Information” reference the catalog and firmware to render the correct device tree.

For the SR40 specifically, Micro/WIN SMART V2.6+ recognizes firmware 2.0 through 2.6 of the 6ES7288-1SR40-0AA0. Newer firmware revisions are added in subsequent editor updates. Siemens typically ships an editor update within a few weeks of a major firmware release; users with very recent firmware should check the support portal for the latest editor build.

10. Quick Diagnostic Flow

1. Is the connected CPU's order number visible in Micro/WIN's “Read/Write CPU” device list? If yes, the feature database recognizes the catalog and upload should succeed; investigate the communication channel rather than the software family.
2. Does the order number start with 6ES7288? If yes, the CPU is S7-200 SMART; install Micro/WIN SMART.
3. Does the order number start with 6ES721x? If yes, the CPU is classic S7-200; use legacy Micro/WIN V4.0 SP9.
4. After installing Micro/WIN SMART, can the editor find the CPU via “Find CPU” on the Ethernet interface? If no, the issue is network connectivity (subnet, firewall, cable) rather than software.
5. Does the editor find the CPU but upload still fails with the feature.dvp message? The Micro/WIN SMART version is older than the CPU firmware; upgrade the editor to the latest release.
6. Does the editor find the CPU and upload succeed? Save the project and document the firmware version in the filename.

11. Best Practices for S7-200 SMART Program Management

1. Always upload to a freshly named *.smart file, not over an existing project. This keeps a clean audit trail of what was actually on the CPU at the time of upload.
2. Document the CPU firmware version in the project name (for example, Line3_Conveyor_2025-08_FW2.6.smart).
3. Configure the CPU's web server with a strong, non-default password before deploying to a production network. The default admin / admin is a security risk on any plant network.
4. Enable the CPU's read protection (four-level password) for any machine shipped to a third party. The four passwords can be set independently: read, write, PLC-to-PC upload, and function-block access.
5. Maintain a backup of the library of SMART subroutine templates in a version-controlled directory. The editor does not include a built-in version-control client; external Git or SVN is recommended.
6. When commissioning, record the IP address, subnet, gateway, and PROFINET device name in the project file's documentation block.
7. Keep a copy of the Micro/WIN SMART install media (DVD or ISO) for each firmware generation. A CPU running firmware 2.6 may not upload with an editor that supports only V1.x.
8. Use the PROFINET device-name reset to factory if the CPU was previously configured for a different controller. A mismatched PROFINET name prevents IO startup and may produce confusing diagnostic indicators.

12. When to Escalate to Siemens Support

Escalate to Siemens regional support (or to the official Siemens Industry Online Support portal) when:

• The SR40 firmware is newer than the latest Micro/WIN SMART release and the editor does not list the catalog number even after a clean install.
• The CPU is locked with an unknown password and password reset is required. Siemens support can authorize a reset procedure with proof of ownership; without authorization, a forgotten password is not recoverable.
• Communications establish but the editor reports a hardware defect — for example, a corrupted firmware signature, a non-recoverable STOP/FAULT condition that survives a power cycle, or an SF (system fault) LED that does not clear after firmware download.
• The Micro/WIN SMART license key is lost, damaged, or the license server is unreachable.
• PROFINET IO devices fail to come up after configuration and the diagnostics indicate a GSD file or catalog mismatch that cannot be resolved from the editor.

For users in regions where Siemens maintains dedicated S7-200 SMART support teams, the regional support entry point is the appropriate contact for hardware fault and licensing questions. The general Siemens Industry Online Support portal covers firmware updates, knowledge base articles, and the official SIMATIC forum.

13. Related CPU Notes (Same Feature Database)

The S7-200 SMART family shares a feature database across the lineup, so the same correction (install Micro/WIN SMART) applies to every catalog number. Specific models worth noting:

All S7-200 SMART catalog numbers require the same Micro/WIN SMART editor. There is no per-model feature database in legacy Micro/WIN.

14. SR40 Quick Specs (For Field Reference)

15. Common SR40-Specific Edge Cases

• SM0.0 vs SM0.1 in first scan. SR40 firmware V2.0+ supports the standard Siemens SM bits; if the uploaded program references SM0.0 (always-on) and the CPU stays in STOP after download, check the compile log for any instruction set warnings specific to V1 firmware.
• PROFINET device name persistence. PROFINET device name is stored separately from the project; uploading a project that previously used a different name does not auto-rename. Clear the name in the PROFINET wizard if a name conflict prevents IO startup.
• Web server disabled by project. Some legacy V1 projects disable the web server in System Block. Enable it from System Block → Security → Web Server before assuming the CPU is unreachable over HTTP.
• RS-485 freeport collision. If a freeport user program drives the RS-485 port and the port is misconfigured (e.g., wrong parity), the CPU may enter STOP after power cycle. Upload via Ethernet to recover.

16. Preventive Measures for Engineering Teams

1. Standardize on one editor version per plant site. Document the Micro/WIN SMART build number in a plant master document.
2. Maintain a CPU firmware matrix that maps each installed SR40 to its firmware version and the editor version known to upload it.
3. Disable the energy-saving features on engineering-station Ethernet adapters. This is a recurring source of intermittent disconnects during long upload or monitor sessions.
4. Configure Windows Firewall rules to allow Micro/WIN SMART on the engineering VLAN. Block the same ports on the plant VLAN to limit the web server attack surface.
5. Use dedicated PROFINET device names that embed the asset tag (for example, plc-sr40-line3) so that replacement CPUs are easy to identify and configure.

17. FAQ