Siemens OP17 ProSave Restore Failure: Root Causes and Recovery

1. Problem Overview

The Siemens SIMATIC OP17 is a text-based operator panel from the early generation of SIMATIC HMI devices (pre-MP/Multi Panel era). It is configured with ProTool / ProTool/Pro and is normally maintained (backup, restore, OS update) using ProSave over serial, MPI, or PROFIBUS. A recurring field failure on the OP17 family looks like this:

1. The replacement panel is the same order number (MLFB) as the original.
2. ProSave completes a "Restore" without an error and reports "Transfer OK".
3. Immediately after reboot the panel still displays "Ready for Transfer" / "Connecting to host..." and refuses to start the project.
4. The original ProTool *.pdb / *.tpd project recompiles cleanly and downloads without error, but the panel still returns to the transfer state on every power cycle.

This is not a download protocol fault and it is not a PLC connection fault. The PLC does not need to be re-touched. The fault is on the panel side, specifically in the relationship between the panel's firmware/loader version, the ProSave version, and the hardware revision of the OP17 unit.

2. OP17 Hardware Variants and Identification

There are three OP17 variants still encountered in field service. They differ in PLC interface and tag count, and they are not mutually compatible in the ProSave restore sense:

Confirm the variant before doing anything else. The variant is printed on the rear rating plate and is also reported by ProSave on the "Device / Panel" tab. Cross-check with the original panel's ProTool project header: Project > Properties > Target system. A mismatch between OP17-PP and OP17-DP is a guaranteed restore failure and is the most common reason "the same order number" still does not behave the same.

2.1 Reading the Loader / OS Version

The loader is the small bootloader that runs before the project image. It is what ProSave touches during restore. Two panels with the same MLFB can have different loader versions, and ProSave binds the project image to a loader family.

1. Power the panel off.
2. Hold the F1 + F4 keys (or, on some units, the cursor-up + ENTER keys) during power-on to enter the loader menu.
3. Read the line labeled Loader Vx.yy and Image Vx.yy.

Common values observed in the field:

• Loader V1.03 / Image V1.03 (older production)
• Loader V1.04 / Image V1.04 (current production)
• Loader V1.05 / Image V1.05 (rare, late OP17 batches)

3. ProSave Tool Compatibility Matrix

ProSave is not a single tool. Each major version is bound to a panel OS family. The OP17 belongs to the text-display family (legacy), not the Graphics family. Using the wrong ProSave is the most common cause of the "backup file is from a newer loader version, cannot supply conversion" error reported on the forum thread.

ProSave V7.4.4 in particular is documented by Siemens as for "text-based Displays with operating system version 5.2 or higher". An OP17 with loader V1.x does not satisfy this, even though the panel appears in the device list of newer ProSave. The "Restore" function will appear to run, but the resulting image is invalid for the older loader and the panel reverts to "Ready for Transfer" on the next boot.

4. Root Cause Analysis

The OP17 "ready for transfer after restore" failure has four distinct root causes, in order of frequency observed in field service:

4.1 Hardware Revision Mismatch (most common)

Siemens may ship the same MLFB with different internal hardware revisions, each of which requires a slightly different firmware image. The ProSave backup captured from hardware rev. A is not byte-compatible with rev. B. The panel accepts the image, the checksum is correct for the file, but on boot the loader detects the hardware revision tag in the image and refuses to execute it. The loader then falls back to its transfer screen. Siemens support will, in this case, correctly state that "the order number is the same, but the hardware is different".

4.2 ProSave Version Mismatch

ProSave V7.4.4 is too new for OP17 loader V1.x. The backup format is different (newer image header, compressed tag tables), and the loader cannot decode it. Symptoms: "Error: the backup file is from a newer loader version, cannot supply conversion".

4.3 ProTool Project Image Exceeds Loader Image Size

4.4 Corrupted Loader (rare)

If the panel has been power-cycled during a previous failed restore, the loader itself can be damaged. The panel will only show "Ready for Transfer" and will not respond to ProTool compile/transfer. An OS update (loader re-flash) via ProSave is required. The OP17 supports OS update, but the procedure differs from OP7/OP15/OP17/OP27 family tools.

5. Diagnostic Procedure

Run this sequence on the bench before going to the machine. It takes about 10 minutes and identifies root cause 4.1–4.4 unambiguously.

1. Identify variant. Read MLFB on the rating plate. Confirm OP17-PP / OP17-DP / OP17-12DP. Record it.
2. Read loader version. Boot to loader menu (F1+F4 on power-up). Record Loader Vx.yy and Image Vx.yy.
3. Identify ProSave version on the service PC. Start > ProSave > Help > About. If it is V7.2 or newer and the panel loader is < 2.0, you have the wrong ProSave. Stop here and obtain ProSave V2.x or the legacy V1.1.
4. Identify ProTool version. Open the original project, Help > About. The ProTool version must match the panel generation. ProTool/Pro V6.0 SP3 or V6.0 SP4 is the typical correct tool for OP17.
5. Connect and read device info. In ProSave, File > Select > OP17-DP (or PP/12DP), set the MPI/PROFIBUS address (default 1, default MPI 187.5 kbps), then File > Read Online > Device Identification. If the loader version reported by ProSave differs from the menu, trust ProSave — the menu can lag.
6. Attempt restore from the suspect backup (the file copied off the old panel). Watch the ProSave log window. Look for the strings in the error code table below.

6. Recovery Procedure A — Original ProTool Source Available

This is the clean path. The user has the original *.pdb / *.tpd project (the same one referenced in the field report as "original protool project").

6.1 Prerequisites

• ProTool/Pro V6.0 SP3 or V6.0 SP4 installed on the engineering PC.
• ProSave V2.x (or V1.1) installed — same directory tree as ProTool or standalone.
• RS-232 null-modem cable (for OP17-PP) or MPI cable (PC-Adapter USB or CP 5611) for OP17-DP / OP17-12DP.
• The PLC side does not need to be present; bench-test the panel on the desk first.

6.2 Step-by-Step

1. Open the project in ProTool/Pro. Project > Target System: confirm OP17-DP (or whatever variant).
2. Save under a new file name (File > Save As). Naming the file the same as the original is a known source of "ghost" bugs; a fresh name forces a clean rebuild.
3. Compile (File > Compile > All). The compile must finish with 0 errors, 0 warnings. If there are warnings about image size, the project is at the boundary — note this for verification.
4. Transfer settings (File > Transfer > Settings). For OP17-DP set channel = PROFIBUS, baud = 1.5 Mbps, panel address = 1, PC address = 0. For OP17-PP set channel = PPI / serial, baud = 9600 or 19200 to match the PLC.
5. Start ProSave (standalone or File > Transfer > Start ProSave).
6. Select the panel type matching the rating plate. Do not select "TP170" or "OP27" — the panel will accept the connection then reject the image.
7. Restore: File > Restore > select the compiled *.pdb (or the ProSave backup *.psb). Watch the log.
8. Wait for "Transfer OK". Do not power off the panel during the next 30 seconds — the loader is writing the image to flash.
9. Power cycle the panel. The panel should boot to the first screen of the project, not "Ready for Transfer".

6.3 If "Ready for Transfer" Persists

The compile succeeded and the transfer log was clean. This means root cause 4.1 (hardware revision) is active. The project is fine; the panel is the problem. Two options:

• Order a panel with the same hardware rev. When you call Siemens support, ask not just for the MLFB but for the hardware revision (FS:xx or HW:xx field on the rating plate or in the ProSave device ID string). Without a matching hardware rev, no ProTool source will run on the unit.
• Use a donor panel of the same rev. If a spare or sister-machine panel is available, swap with that. Same MLFB + same rev = guaranteed restore.

7. Recovery Procedure B — No Source Project Available

This is the harder case. The user has only a ProSave *.psb backup of the old panel. It cannot be restored onto the new panel because of the hardware-revision and ProSave-version mismatches above. The fallback is to reconstruct the project in ProTool.

7.1 Capture the Visible Behaviour

1. Power the dead/original panel one more time and photograph every screen (text panels are 2- or 4-line x 20 char; this is tractable).
2. Capture the alarm log contents if the panel still responds to a print or ProSave read.
3. Capture the tag list by reading the ProTool project from the panel via ProSave (Read Online > Project) if the old panel still partially boots.
4. Read the PLC tag database from STEP 7 / MicroWin and match it to the screens.

7.2 Rebuild in ProTool

1. Open ProTool/Pro, create a new project, target = OP17-DP (or matching variant).
2. Define the PLC connection (MPI/PROFIBUS address, baud, slot of the S7 CPU).
3. Define the tags from the captured PLC database.
4. Recreate the screens one by one. For OP17-12DP you have 4 lines; for OP17-DP you have 2 lines — text is precious, use it carefully.
5. Define messages, recipes, and password levels exactly as captured.
6. Compile and transfer per Section 6.2.

8. ProSave Error Code Reference

9. OS Update Constraints on OP17

Unlike OP7/OP15/OP17-DP/OP27 in the Graphics family, the OP17's "OS update" via ProSave is not the same procedure as on newer panels. The OP17 does not support "Reset to factory settings" as a standalone loader command — that menu path is for the OP7/OP17 graphics siblings. On the OP17, a loader re-flash must be done with the legacy ProSave (V1.1 or V2.x) and the matching *.upd image file from the original ProTool installation media.

9.1 Procedure (legacy ProSave)

1. Power the panel off.
2. Hold the loader keys (F1+F4) on power-up to enter the loader menu.
3. Connect ProSave V1.1 or V2.x via MPI/PPI to the panel.
4. Select the OP17 variant.
5. File > OS-Update, point to the OP17 OS image file shipped with the ProTool CD (for example op17_v104.upd).
6. Confirm. The loader erases the flash, writes the new image, and reboots.
7. Re-transfer the project afterwards.

10. Spare-Panel Sizing and Procurement

Use the following checklist at procurement time. This avoids the original-thread scenario of "bought a panel, transfer works, panel still does not start".

11. Verification and Commissioning

After the restore, run this checklist before returning the panel to production. Each step is a separate verification gate; do not skip.

1. Boot verification. Power off, power on. The panel must reach its first project screen within 8–12 s, not the transfer screen.
2. PLC communication. From the panel, navigate to a screen that displays a known PLC tag (e.g. a counter or motor running bit). Verify the value updates live.
3. Alarm log. Trigger a known alarm from the PLC. Verify it appears in the panel's alarm list with the correct timestamp.
4. Write-back test. Use a screen with setpoint entry. Change a value, press ENTER, verify the new value is written to the PLC (read it back from STEP 7).
5. Power-cycle resilience. Power off the panel, wait 10 s, power on. The project must start without re-download.
6. ProSave round-trip. From the now-working panel, take a fresh ProSave backup. Store it in the project archive. This is your next "spare for the spare".

12. Prevention and Long-Term Practice

Three practices prevent the OP17 "ready for transfer" failure from recurring.

1. Keep the ProTool source under version control. ProTool projects (especially pre-STEP 7 V5.x) are notorious for being lost when the engineering PC is decommissioned. Store *.pdb, *.tpd, and the compiled *.psb in the same folder as the STEP 7 / MicroWin project. The ProTool source is the only thing that can be recompiled against any hardware rev.

2. Buy spare panels from the same production batch. When commissioning a new line, order the HMI in pairs and record the rating plate data of both. A spare bought years later can have a different hardware rev even with the same MLFB. If you must buy later, ask the Siemens distributor for the current production date code and compare.

3. Match tool versions to panel family. Use ProTool/Pro V6.0 SP3 or SP4 for OP17. Use ProSave V2.x (or legacy V1.1) for backup/restore and OS update. Do not assume the latest ProSave will work; it is for text panels with OS 5.2+ which excludes the OP17 loader V1.x family. Siemens has documented the OP17 as a mature, non-evolving product; new tools do not gain OP17 compatibility, they lose it.

For related Siemens operator-panel troubleshooting on newer hardware, see the OP7/OP15/OP17/OP27 family tools that ship with ProTool/Pro V6.0 and the ProSave V7.4 service tool for text displays at the official Siemens Industry Online Support portal.

Frequently Asked Questions