TP1900 Comfort HMI Replacement: Backup, Restore, and Firmware

TP1900 Comfort HMI Replacement: Backup, Restore, and Firmware

1. Overview

This procedure covers the field replacement of a Siemens SIMATIC HMI TP1900 Comfort panel (order number 6AV2124-0UC02-0AX0) when the display fails (for example, a white screen at power-up) and the panel must be swapped for an equivalent spare. The engineer must capture a valid project backup from the existing panel, install that project on the replacement panel through either the SD card slot (X50) or an Ethernet connection via ProSave, configure a fresh IP address, and verify runtime, alarms, and tag communication before returning the machine to production.

The TP1900 Comfort is a 19-inch widescreen TFT touch panel in the SIMATIC HMI Comfort family. It runs projects compiled with WinCC Comfort (TIA Portal V13 or later) and stores runtime, configuration, and the optional runtime license on internal flash, an external SD card (slot X50), or a USB storage device. Replacement is a routine maintenance event, but the restored panel must be commissioned against the exact project, firmware revision, and network parameters of the failed unit to avoid controller tag, alarm, or recipe faults.

2. Identifying the TP1900 Comfort Panel

Confirm the panel you are about to install is electrically and mechanically identical to the failed unit. The MLFB on the rating plate (rear of device) must match the existing project's target device, otherwise TIA Portal will refuse to compile and ProSave may refuse to restore.

Verify the new panel in SiePortal before commissioning:

SIMATIC HMI TP1900 Comfort product page (Siemens SiePortal)

Record both the old panel's project firmware (for example, V13.0.1.0) and the new panel's image firmware (for example, V13.00.01.09_03.01). A mismatch is acceptable if both images support the WinCC Comfort project revision present in the backup; if not, you must update or downgrade the panel image prior to restore.

3. Prerequisites

1. Backup file: a valid *.brk, *.psf backup, or full panel image generated from the original panel by ProSave or the Control Panel > Backup menu.
2. SD card: FAT32 formatted, 4 GB to 32 GB SDHC recommended. SDXC cards above 32 GB are not supported by the Comfort Panels' restore menu; format as FAT32 on the engineering PC, not in a camera.
3. Engineering PC (Field PG or equivalent): TIA Portal / WinCC Comfort installed with the SP and updates matching the project, plus ProSave (bundled with TIA Portal / WinCC).
4. Ethernet cable: standard Cat 5/6 patch for PROFINET / Ethernet port on TP1900 to the Field PG (direct or via switch).
5. License key / license stick: if the panel uses a runtime license that is not stored inside the backup, have the original license stick ready to reinsert into the new panel.
6. Original project file (optional but recommended): the TIA Portal source project for re-compilation if a fresh image is required.

4. Pre-Replacement: Capturing a Valid Backup from the Existing Panel

If the failed panel is still responsive (white screen may indicate backlight or display fault while the controller and runtime continue running), you have two reliable backup paths. Pick the one that matches the panel's condition.

4.1 Method A — Control Panel backup on the device

1. Power the panel ON; wait for Windows CE / Embedded Compact shell to load.
2. Open Control Panel > Service & Commissioning > Backup / Restore.
3. Select Backup, choose destination (Internal Flash or External Storage), and start the backup.
4. Confirm a file of the form <PanelName>_<date>.brk appears at the destination. Copy it to a USB stick or extract the SD card before panel removal.

4.2 Method B — ProSave backup over Ethernet

1. Connect the Field PG to the TP1900 PROFINET port directly or via the same subnet.
2. Start ProSave. In General, select Device type: TP1900 Comfort, Connection: Ethernet, IP/PC IP: enter the panel's current IP.
3. Open the Backup tab. Select a destination path on the PG (this is your recovery file).
4. Click Start. ProSave authenticates with operator password (default 100 for admin, but site-defined), pulls the runtime image and stores it as a single archive (*.brk or *.psf depending on options selected).

5. SIMATIC Service Concept: Direct vs. Indirect Service Mode

The Siemens Service Concept for SIMATIC Panels defines two service modes. Select the right mode before attempting any restore; otherwise the panel may report no restore file even when the correct file is present.

• Service Mode (Direct) – the panel is connected directly to one engineering PC via Ethernet or USB. The PC has full read/write access to the panel's file system for service operations.
• Service Mode (Indirect) – the panel is integrated into a running PROFINET network; access is restricted to authorized users with the operator password. Use this in live plants.

Refer to the official Service Concept document for full procedural detail:

SIMATIC Panels Service Concept (v1.0, Siemens Industry Online Support)

6. Memory Card Restore via Slot X50

The SD card slot X50 accepts a FAT32 SD/SDHC card containing the project backup produced in step 4. This is the fastest restore path when the field PG is unavailable.

6.1 Prepare the SD card

1. Insert the SD card into a Windows PC with a card reader.
2. Back up any existing content. Format as FAT32 (right-click > Format, file system FAT32, allocation unit size default).
3. Copy the backup file (*.brk or *.psf) to the root of the card. Do not place it in a subfolder unless the restore menu explicitly browses subfolders (most do not).
4. Eject cleanly from Windows.

6.2 Restore on the new TP1900

1. Confirm the new TP1900 is powered OFF. Insert the SD card into X50, contacts down, until it latches.
2. Apply 24 V DC to the panel. The boot loader will detect the card and offer Restore from external storage.
3. Alternatively, after boot, navigate to Control Panel > Service & Commissioning > Backup / Restore > Restore. Select the storage location (External Storage / Card X50) and the panel will list compatible backup files matching its device type.
4. Select the file and confirm with the operator password (default 100 if not changed).
5. The panel reboots and starts the restored project.

7. Ethernet Restore via ProSave

When the SD card restore is unavailable, restore the panel over the engineering network.

7.1 Direct connection (point-to-point)

1. Connect the Field PG's Ethernet port directly to the TP1900 PROFINET port using a patch cable.
2. Set the PG IP to the panel's current subnet (for example, PG: 192.168.0.10 / 24, panel: 192.168.0.20 / 24).
3. Power the new TP1900 and accept any retry DHCP prompt at first boot.

7.2 ProSave restore

1. Launch ProSave on the PG.
2. Set Device type to TP1900 Comfort, Connection to Ethernet, and enter the panel's IP address.
3. Switch to the Restore tab. Tick Restore from file and select the *.brk / *.psf backup.
4. Choose options: Include runtime, Recipe data, Logs as the engineering policy requires.
5. Click Start. ProSave pushes the project; the panel reboots when complete.

8. Configuring the IP Address

A restore operation restores the project configuration, but the panel's network identity depends on where that IP was originally stored:

• If the IP is part of the WinCC project (compiled into the runtime), the restored project automatically sets the panel's IP — no further action required.
• If the IP was manually configured in the Control Panel at commissioning and is not part of the project file, the new panel starts with the factory default IP and you must set it manually.

8.1 Manual IP configuration

1. Open Control Panel > Network & Internet on the new panel.
2. Open the PROFINET adapter (LAN1) and select Use the following IPv4 address.
3. Enter IP, Subnet, and Default gateway. Touch Apply, then OK.
4. Reboot the panel for PROFINET services to bind to the new IP.

8.2 Verification

1. From the Field PG, ping the panel: ping <panel-IP>
2. Open TIA Portal > Online > Accessible devices; the panel must appear with its configured IP.

9. Firmware Compatibility and Image Updates

Comfort Panel firmware (image) versions are independent of WinCC project revisions. A project compiled with V13.0.1.0 will run on a panel whose image is V13.00.01.09_03.01 provided the WinCC runtime version (image build) is equal to or higher than the version that generated the project.

If the replacement image is older than required, run a WinCC image update using ProSave > Update OS with a service pack image. If it is newer, no action is required.

10. Why the Backup File Does Not Appear in the Restore Menu

A frequently reported symptom during panel replacement is: The panel powers on with the SD card inserted in X50, but the restore menu shows no backup file. The most common causes, ordered by likelihood, are:

When in doubt, bypass the SD card path entirely and restore over Ethernet with ProSave (section 7). ProSave does not depend on the panel's restore UI and will display explicit error messages for any incompatibility it encounters.

11. Verification and Commissioning

After restore and IP configuration, verify the panel end-to-end before returning the machine to production:

1. Boot state: panel completes startup without Watchdog reset, Image error, or Missing license dialogs.
2. License: if a runtime license is required and was not part of the backup, insert the original license USB stick; confirm the License dialog reports valid.
3. Connectivity: ping from the controller programming tool returns the panel IP; Accessible devices in TIA Portal lists the panel.
4. HMI tags: from TIA Portal, open HMI tags > Online; values from the PLC should update cyclically. A dashed-out value indicates the connection is not established.
5. Alarms: acknowledge a test alarm and verify the alarm view updates.
6. Recipe / data persistence: write a test recipe and reboot; confirm the value restores from internal flash or the SD card.
7. Touch calibration: open a screen, touch each corner of the active area; cursor accuracy should be within ±2 mm.
8. Time synchronization: confirm the panel clock is correct or correct via PLC time master.

12. Field Notes and Best Practices

• Always burn a complete image (ProSave > Image) to the engineering PC before removing a failed panel. The image is the only artifact guaranteed to capture license, runtime, Windows CE, and project in one.
• Store backups with a naming convention that includes the panel name, MLFB, firmware revision, and date — for example, TP1900_OP10_6AV2124-0UC02-0AX0_V13.00.01.09_03.01_2024-08-12.brk.
• Document the configured IP and PROFINET device name before panel removal; without these values, restoring the panel involves re-reading the PLC project rather than blind reuse.
• Keep spare SD cards in industrial grade (not consumer) variants; consumer cards fail in panel environments where vibration and temperature are common.
• Use a panel image rather than a project restore when the firmware of the replacement differs significantly from the failed panel. The image can be combined with a newer project later.

13. FAQ