Siemens TP177A HMI: Migrating from ProTool to WinCC Flexible

Siemens TP177A HMI Configuration: Migrating from ProTool to WinCC Flexible

The SIMATIC TP177A is a 5.7-inch monochrome or color touch-panel HMI introduced by Siemens as the direct successor to the TP170A. Like the TP170A, it is a compact operator panel designed for small-to-medium machine applications, but it ships with a newer runtime firmware, a different communication co-processor, and a fundamentally different Engineering System (ES) requirement. Whereas the TP170A was configured with the legacy ProTool/Pro (or ProTool V6.0) toolset, the TP177A series exclusively accepts projects authored in SIMATIC WinCC Flexible (and later, TIA Portal WinCC). This single change is the root cause of the most common TP177A migration problem: an integrator who already owns a working ProTool configuration for a TP170A cannot simply open that project on a TP177A, even when the panel replacement is otherwise pin- and footprint-compatible.

This article documents the engineering workflow for converting a ProTool project so that it runs unmodified on a TP177A, the WinCC Flexible ES versions and Service Packs that support the panel, the firmware image that must be loaded on the device, the communication parameters that need to be re-validated, and the field-proven verification steps for confirming a successful migration.

1. Overview: TP177A HMI Panel Architecture

The TP177A sits in the Siemens 170-line / 177-line operator panel hierarchy and shares the 198 × 142 mm cutout of the TP170A family. Mechanically, the panel is a drop-in replacement. Logically, however, the runtime image in flash is a WinCC Flexible RT, which is incompatible with ProTool-generated .pdb / .ssp projects. The runtime boots into a Start Center on cold start, presents a small set of diagnostic pages, and either continues to the last project or enters the Transfer state when instructed by ProSave.

1.1 Panel Family Context

• TP170A / OP170 – ProTool generation, 5.7", mono or STN color, MPI/PROFIBUS, last firmware 1.x and 2.x
• TP177A / OP177A – First WinCC Flexible generation, 5.7", 320×240, mono or STN color, MPI/PROFIBUS DP, runtime image ≥ V1.0.0
• TP177B / OP177B – 4" or 6" color, PROFIBUS and PROFINET, 64k colors, WinCC Flexible 2005 SP1+
• KTP177 – Compact successor with key/touch combination
• TP/OP 277 – 6" widescreen and larger, 64k colors, WinCC Flexible 2007+

2. ProTool vs. WinCC Flexible: Compatibility Matrix

The compatibility boundary between ProTool and WinCC Flexible is defined by the runtime image stored in flash on the HMI. ProTool builds a binary project that targets the ProTool runtime (RT) component, while WinCC Flexible compiles a different binary (internal name: AR-DB / Active Runtime Database) that targets the WinCC Flexible runtime. The TP177A flash holds only the WinCC Flexible RT, so ProTool-compiled projects will be rejected at transfer time with an "image version" or "project invalid" error.

"Converter only" means WinCC Flexible ships with a ProTool converter that can import a .pdb / .ssp project, but the target must be a WinCC Flexible 2004-compatible panel, which does not include the TP177A. The earliest WinCC Flexible version that can author a TP177A project is WinCC Flexible 2005 SP1 (HF7 or later); the recommended engineering baseline is WinCC Flexible 2008 SP2 or 2008 SP3 because they include the most recent TP177A Hotfixes.

2.1 ProTool Upgrade Path to WinCC Flexible

Siemens provides an upgrade path that lets a customer with a valid ProTool license acquire WinCC Flexible at a reduced cost. The order code for the PowerPack from ProTool to WinCC Flexible Compact is 6AV6613-1AA51-3CA0 (ProTool 6.x to WinCC Flexible 2005/2007), and PowerPack to WinCC Flexible Standard/Advanced follows similar 6AV6-1A codes that depend on the source license. The official upgrade entry point in the Siemens Industry Online Support (SIOS) portal is documented under entry ID 26169252. This page is the canonical reference for license migration, supported Service Packs, and any toolbox add-ons (e.g., Audit, Sm@rtAccess) that may need to be re-keyed.

3. Prerequisites for Migrating to WinCC Flexible

Before any project conversion is attempted, confirm that the engineering workstation and the panel both meet the runtime and ES requirements listed below. Skipping these checks is the most common reason for a converter failure or a non-bootable panel image after transfer.

3.1 Engineering Workstation Requirements

3.2 License Model

WinCC Flexible 2005/2007/2008 uses the legacy license key mechanism. A yellow parallel key or a USB dongle is bound to the Flex host ID and is required for ES compilation. In modern deployments (WinCC Flexible 2008 SP3 and later on Windows 7/10), the Automation License Manager (ALM) can migrate the yellow key into a soft container. A TP177A project compiles without a license in demo mode for evaluation, but cannot be transferred to the panel after a 14-day grace period without a valid license.

3.3 Required Service Packs and Hotfixes

• WinCC Flexible 2005 SP1 + Hotfix 7 (HF7) – first build that supports TP177A as a target device
• WinCC Flexible 2005 SP1 + Hotfix 9 (HF9) – recommended for stability and corrected ProTool converter
• WinCC Flexible 2007 SP1 – adds recipes, Sm@rtAccess support, improved ProTool converter
• WinCC Flexible 2008 SP2/SP3 – latest released line; recommended baseline for any new TP177A migration because it incorporates the most recent runtime fixes for MPI/PROFIBUS, screen flicker, and password handling

Each ES Service Pack bundles its own ProTool Converter that knows the current target device list. Do not attempt to convert a project with an older converter and then open it in a newer ES; the converter writes internal schema version tags that may be incompatible.

3.4 Panel Image and Firmware

The TP177A ships from the factory with a WinCC Flexible 2005 SP1 RT image. If the panel has been updated at any point, the image must match the ES that compiled the project – the panel will refuse a project compiled against a newer RT image than what is currently installed. If a mismatch occurs, Siemens ships a ProSave-based image update utility that overwrites the panel flash with a new image file (e.g., TP177A_V1_0_3.img for image V1.0.3). Image files are bundled in the corresponding WinCC Flexible installation under ...\WinCC Flexible\HMI\Images or downloaded from the SIOS portal entry for the panel.

4. Converting ProTool Projects for TP177A

The WinCC Flexible ProTool Converter is invoked from the ES start center: File → Open → Convert ProTool Project. The converter reads the source .pdb or .ssp file, creates a WinCC Flexible project with the same screens, tags, alarms, recipes, and scripts, and prompts the user to choose a target device.

4.1 Pre-Conversion Checklist

1. Open the original project in ProTool V6.0 SP2 or SP3 and execute a project-wide Consistency Check (File → Consistency Check). Resolve all warnings and errors before conversion.
2. Make a backup of the original .pdb / .ssp and any ProTool ProAgent extensions.
3. Export the tag database to a CSV (ProTool: Tags → Export) for reference; this is helpful for re-mapping after conversion.
4. Capture screenshots of every screen and the event-log layout if any non-standard fonts or graphics were used. ProTool's default Symbol Library 1.0 is partially replaced in WinCC Flexible; the converter will substitute missing vector graphics with placeholders.
5. Inventory the optional ProTool Pro add-ons used in the project (e.g., ProAgent for S7-Diagnostics, Recipes with PDM, or any custom ActiveX controls). The converter maps ProAgent diagnostics to WinCC Flexible 2005+ diagnostics screens automatically, but custom OLE/OCX objects require re-implementation.

4.2 Running the Converter

1. Start WinCC Flexible ES with administrative privileges.
2. Choose File → Open → Convert ProTool Project.
3. Browse to the .pdb / .ssp source.
4. The converter dialog shows the detected source device (e.g., TP170A mono or TP170A color) and asks for a target device. Select TP177A mono or TP177A color as appropriate.
5. Click Convert. A conversion log is written to %TEMP%\WcFlex_Convert.log.
6. The converted project opens in the WinCC Flexible ES; review the Compile → All output and resolve any conversion warnings.

4.3 Common Conversion Pitfalls

5. Configuring Communication on TP177A

The TP177A exposes the same 9-pin D-sub MPI/PROFIBUS connector as the TP170A and supports the same baud rates (187.5 kbit/s default MPI, 1.5 Mbit/s PROFIBUS DP). The transfer protocol for project download is ProSave over MPI/PROFIBUS, or alternatively over Ethernet on TP177A variants equipped with the optional Ethernet module.

5.1 Default MPI Settings

5.2 Configuring a Connection in WinCC Flexible

1. In the project tree, open Communication → Connections.
2. Double-click Connections; the connection editor opens.
3. Click New and select SIMATIC S7 300/400 as the communication driver. The TP177A can connect to S7-200 (via MPI/EM 277), S7-300, S7-400, ET 200S, and LOGO! controllers.
4. Set the Station address to the PLC's MPI/PROFIBUS address.
5. Set the Panel address to the panel's MPI address (default 1).
6. Set the bus profile and baud rate. If the PLC is on a PROFIBUS segment that runs at 1.5 Mbit/s, match the baud rate on the panel side.
7. Click OK and run a Connect → Online → Accessible Nodes test from the ES to verify that the panel can see the PLC.

5.3 S7-200 Connection via EM 277

Although ProTool projects on TP170A frequently target S7-200 (CPU 22x) over the PPI/MPI interface, the TP177A communicates with S7-200 only via an EM 277 PROFIBUS module. The EM 277 must be configured with a unique PROFIBUS address (e.g., 2) and the WinCC Flexible connection driver SIMATIC S7 200 (EM 277) selected. Direct PPI communication is not supported on TP177A.

6. Step-by-Step Commissioning Procedure

Use the following procedure for a clean commissioning of a TP177A with a converted ProTool project.

6.1 Pre-Commissioning

1. Verify mechanical mounting (cutout 198 × 142 mm for 5.7" panels; 5 mm tolerance).
2. Verify 24 VDC supply at 0.5 A minimum (TP177A typical 0.4 A, inrush 1.0 A for 100 ms).
3. Verify chassis ground is bonded to cabinet ground at a single point.
4. Confirm the MPI/PROFIBUS cable is terminated at both ends (terminator on, 220 Ω on the last node).

6.2 Image and Project Transfer

1. Connect the PC to the TP177A via MPI cable (6ES7 901-0BF00-0AA0 or equivalent) or PC-Adapter USB A2 (6GK1571-1AA00).
2. Start ProSave (bundled with WinCC Flexible: Start → SIMATIC → ProSave).
3. Select Device type: TP177A, Connection: MPI, Station address: 1.
4. Click Restore → Image and load the TP177A image file from the WinCC Flexible install directory. Skip this step if the image version already matches the ES.
5. After image restore (panel reboots), click Transfer → Project in ProSave and select the compiled *.fwx file (or transfer from WinCC Flexible via Project → Transfer → Transfer).
6. Wait for the transfer progress bar to complete; the panel reboots into the new project.

6.3 Online Verification

1. On the panel, navigate to Main → Settings → OP Properties → Diagnostics → Event Log. Verify that no transfer-time errors are present.
2. From the ES, choose Project → Connect → Online. Confirm a live link to the panel.
3. Open Tools → Tag Simulator in the ES (or use a STEP 7 watch table) and force a few tags. Verify the value updates on the panel screen.
4. Trigger an alarm class test by writing a bit that activates a configured alarm; verify the alarm banner and alarm view render correctly.
5. Test the recipe transfer: write a recipe dataset from the panel, restart the panel, and verify the dataset is persistent in flash.

7. Transfer and Runtime Verification

The TP177A runtime provides a small set of built-in diagnostic screens accessible from the Start Center (default screen on cold boot with no project). These are useful for field verification and are not visible when a project is running.

7.1 Start Center Diagnostic Pages

• Settings – Touch calibration, brightness, contrast, transfer mode, time/date
• OP Properties – Device name, image version, project version, available flash
• Event Log – System messages, transfer errors, runtime warnings
• Info / About – Copyright, license, runtime build number

7.2 Runtime Information via WinCC Flexible Online

When the panel is online with the ES, the following diagnostic data is available:

8. Troubleshooting Common Migration Issues

8.1 Error Codes in Event Log

The TP177A writes numeric event codes to the event log. A representative subset:

9. Specifications and Variant Comparison

10. Firmware and ES (Engineering System) Compatibility

The TP177A runtime image and the WinCC Flexible ES Service Pack are tightly coupled. The following table documents the supported combinations. Always run the ES Service Pack at or above the image version on the panel.

For the SIOS entry that contains TP177A firmware images and version notes, refer to entry 26169252. Newer TP177A panels ship with image V1.0.6 and run any project compiled in WinCC Flexible 2005 SP1 HF7 or later.

11. Long-Term Maintenance and Support Considerations

The TP177A is in the spare-parts phase of its lifecycle. Spares are available via the standard spare-parts channel (typical 10-year availability after phase-out), and image and ES downloads remain accessible on the SIOS portal. The TP177A is, however, no longer sold as a new product – the recommended replacement is the SIMATIC HMI KTP700 Basic or KTP700 Comfort, both of which are configured in TIA Portal. If you are maintaining a fleet that includes TP177A panels, plan a migration roadmap:

1. Catalog every TP177A installation with its current image version and ES Service Pack level.
2. Centralize all converted .ssp / .fwx files in a version-controlled repository.
3. Maintain at least one Windows 7 / Windows 10 32-bit ES workstation with WinCC Flexible 2008 SP3 and the matching ProTool converter installed; this is the lowest-cost path for ongoing editing of TP177A projects.
4. Pre-stage at least one ProSave installer per site for image restoration.

12. Frequently Asked Questions (FAQ)