Overview
The TIA Portal "Upload device as new station (hardware and software)" function reverses the standard download workflow by reconstructing a complete project from a target CPU. Unlike the legacy "Upload to PG" feature in STEP 7 V5, this menu item in TIA Portal captures not only the block container but also the central/expansion rack configuration, distributed I/O assignment, comments, and symbol tables.
This is the recommended procedure when:
- The original TIA Portal project archive is unavailable or corrupted.
- The CPU was commissioned by a third party and no source file was handed over.
- A backup project must be regenerated before a firmware update or major rework.
- Documentation has drifted from the actual deployed configuration and must be re-baselined.
Supported Devices and Firmware Prerequisites
| CPU Family | Min. TIA Portal (Load Source) | Min. TIA Portal (Target Upload) | Hardware Configuration | Blocks | Comments / Symbols |
|---|---|---|---|---|---|
| S7-1500 / ET 200 CPU | V13 (FW ≥ 1.6 for full restore) | V13+ | Yes (central + distributed) | Yes (all block types) | Yes |
| S7-1200 | V13 | V13+ (same or newer) | Central only | Yes | Yes (V4.x firmware or higher) |
| S7-300 | V13 SP1+ (must have been loaded via TIA) | V13 SP1+ | Central rack only | Yes | Partial (depends on FW) |
| S7-400 | V13+ (TIA-loaded only) | V13+ | Central rack + EXP | Yes | Yes |
| ET 200SP / ET 200MP CPU | V14+ | V14+ | Full station incl. base units | Yes | Yes |
Prerequisites
- Compatible TIA Portal installation. The TIA Portal version used for upload must support the CPU's firmware family. Use the latest available Service Pack for the highest fidelity of uploaded project data.
- Online connection to the CPU. Either PROFINET (TCP/IP, port 102) or PROFIBUS (DP) using the PC adapter or CP. Verify connectivity via "Online > Accessible nodes" before attempting upload.
- Empty / target project. A new project must already be opened. The wizard does not overwrite an existing station; it creates a new station inside the open project.
- PG/PC read/write access rights. The "Upload device as new station" function operates with the CPU's online interface security settings. If a password is configured in the CPU protection properties, the matching password must be known.
- No running process-sensitive blocks. Although the function only reads, briefly consider whether a STOP transition is needed if the CPU is in RUN and interlocks may react to the project being reopened in the editor.
Step-by-Step Upload Procedure
Step 1 - Verify Online Connectivity
- Open the project tree in TIA Portal.
- Expand "Online access" in the project navigation.
- Select the network adapter bound to the subnet of the target CPU (e.g., "Realtek PCIe GbE Family Controller [TCP/IP]").
- Double-click "Update accessible nodes". The CPU should appear with its IP address, MAC address, and device name.
- Ping the CPU via "Online > Accessible nodes > [CPU] > Ping" if needed.
Step 2 - Prepare Target Project
- Launch TIA Portal and open an existing project or use "Create new project".
- From the portal view, select "Devices & networks".
- Do not create any device manually; the upload wizard populates the device automatically.
Step 3 - Initiate Upload
- In the menu bar, select Online.
- Choose Upload device as new station (hardware and software).
- The "Upload preview" dialog opens. TIA Portal queries the target device and displays the detected module type, firmware version, and rack position.
- If multiple accessible devices are found, select the correct target by IP address / device name.
- Confirm with Upload.
Step 4 - Wait for Transfer to Complete
Typical durations:
| Program Size | Approx. Transfer Time (PROFINET 100 Mbit/s) |
|---|---|
| < 500 KB blocks, < 16 modules | 30 s - 1 min |
| 1 - 5 MB blocks, 30 - 60 modules | 2 - 5 min |
| > 10 MB blocks, > 100 modules incl. distributed I/O | 5 - 15 min |
The status bar shows progress as blocks, HWCN, system data, and symbolic information are pulled sequentially.
Step 5 - Verify the Reconstructed Station
- The new station appears in the project tree under the configured device name.
- Expand "PLC_1 > Program blocks" to confirm OB, FB, FC, DB, and UDT/UDB are present.
- Open "PLC tags" and "PLC data types" to verify symbolic information.
- Open "Device configuration" and confirm the rack layout, module order, and slot configuration match the physical hardware.
- For distributed I/O, confirm the PROFINET / PROFIBUS device list under "Devices & networks" was reconstructed with the actual topology.
What Is and Is Not Uploaded
| Project Element | Uploaded? | Notes |
|---|---|---|
| CPU configuration (properties, web server, OPC UA, time) | Yes | Includes IP, PROFINET device name, diagnostics settings |
| Central rack layout (PS, CPU, IM, SM) | Yes | Module order and slot assignments reconstructed |
| Distributed I/O (PROFINET / PROFIBUS) | Yes | Device names and IP addresses reconstructed |
| Blocks (OB / FB / FC / DB / UDT) | Yes | Both compiled and source-relevant metadata |
| PLC tags / symbol table | Yes | Including multi-language comments if available |
| Watch / force tables | No | Must be recreated manually |
| Global libraries | No | Master copies in libraries are not on the CPU |
| HMI connections / HMI tags | No (if HMI is separate) | Only HMI variables used inside PLC tags are visible |
| Safety program (F-CPU) | Partial | F-blocks present but signature / collective signature may require re-signature |
| PLC user constants | Yes | Constants and attributes |
| Trace recordings | No | Trace configuration uploaded, live recordings lost |
S7-300 Upload Caveats
The "Upload device as new station" function works on S7-300 only when the controller was originally loaded from a TIA Portal project. If the CPU's runtime image was loaded using STEP 7 V5 (SIMATIC Manager), the upload returns an error or reconstructs an empty station. To recover such a CPU:
- Locate the original STEP 7 V5 project archive.
- Migrate the project using TIA Portal "Project > Migrate project".
- Perform a comparative compile and download to re-baseline the CPU.
If a TIA V13 SP1 (or newer) project was the source, the upload reconstructs the S7-300 hardware configuration for the central rack only. Distributed I/O on PROFIBUS DP master systems is included but may lack diagnostic address details; verify against the physical installation.
Verification Checklist
- Compile. Trigger a full project compile (Project tree > right-click station > Compile > Software (rebuild all blocks)). Zero errors expected.
- Compare offline / online. Use "Online > Compare offline/online" to confirm the uploaded project matches the current runtime exactly. Resolve any differences before modifying.
- Cross-check I/O. Open the device configuration and confirm slot 1-31 order, module order numbers, and firmware versions match the installed hardware.
- Audit DB initial values. Uploaded DBs contain the snapshot values from the last download, not runtime values. Confirm whether current process state is meaningful before any cold restart.
- Re-signature safety program. For F-CPUs, verify the F-collective signature and run the "Safety acceptance test" again.
Troubleshooting Matrix
| Symptom | Likely Root Cause | Remediation |
|---|---|---|
| Menu item greyed out | Project not opened, or no project selected | Open a project first; the menu item requires an active project context |
| No devices listed in upload dialog | PG/PC interface not bound to correct subnet | Configure the correct network adapter in "Online access"; disable firewalls blocking UDP port 34964 / TCP 102 |
| Upload starts but errors after a few seconds | CPU protection password configured | Enter the protection password in "Online & Diagnostics > Protection" or temporarily clear the password on the CPU |
| Station uploaded but blocks empty | CPU loaded from STEP 7 V5 originally | Upload is not possible in this case; migrate the V5 project via "Project > Migrate project" |
| Hardware configuration reconstructed but rack incomplete | Firmware mismatch between upload TIA and loaded CPU | Use a TIA Portal version equal to or newer than the project version originally used to load the CPU |
| Comments / symbols missing after upload | CPU firmware too old or loaded without comment package | Update CPU firmware to a version that stores comment packages; re-download project with "Include comments" enabled |
| Error "The device cannot be uploaded" | CPU in protective read-only mode (know-how protection) | Temporarily disable know-how protection for the upload, then re-enable |
| Distributed I/O devices missing | PROFINET topology not yet committed to CPU | Reconnect each I/O device, assign PROFINET name, then re-attempt upload |
Best Practices for Reconstructed Projects
- Immediately archive the reconstructed project with the standard "Project > Archive" command; do not rely on the unsaved project file.
- Change nothing in the project without first running "Compare offline/online" and recording the baseline.
- Annotate the upload date in the project properties or in a project comment for audit traceability.
- If multiple CPUs of the same type exist, label each upload with its serial number to avoid confusion.
- Re-sign any encrypted / know-how-protected blocks after the upload, because the source-protected blocks are read-only and cannot be edited until reloaded.
Security and Access Considerations
The upload function respects all CPU access protection levels defined in the device configuration. If the CPU is configured with "Full access (no protection)", the upload proceeds without prompt. At "Read access" level, the upload is permitted but a write-back download will be blocked unless the level is lowered. At "HMI access" or "No access" the upload dialog prompts for the configured password. Always record the protection level before clearing any password on a production CPU.
FAQ
Which TIA Portal version introduced "Upload device as new station (hardware and software)"?
The function was introduced in TIA Portal V13 for S7-1500 CPUs (firmware 1.6 or higher). S7-1200, S7-300, and S7-400 support was added incrementally through V13 SP1 and later service packs.
Can I upload an S7-300 that was loaded with STEP 7 V5 / SIMATIC Manager?
No. The function only reconstructs a station whose runtime image was generated by TIA Portal. For S7-300 CPUs loaded with STEP 7 V5, you must keep the original V5 project or migrate it via "Project > Migrate project" before editing.
Does the upload preserve PLC comments and symbol tables?
Yes, provided the CPU firmware supports the comment package and the original download included the "Comments" option. S7-1500 firmware 2.0 or higher and S7-1200 firmware 4.x or higher fully retain symbolic and comment information.
What happens to the CPU's safety program during upload?
F-blocks and the F-signature are uploaded, but the safety acceptance test must be repeated and the F-collective signature re-validated before any subsequent download to a safety-relevant CPU. Use a separate workstation with the F-safety editor enabled.
How long does the upload take for a typical S7-1500 station?
For a mid-sized configuration with 1 - 5 MB of blocks and 30 - 60 modules, expect 2 to 5 minutes over PROFINET at 100 Mbit/s. Larger stations with extensive distributed I/O and trace recordings may require 10 - 15 minutes.