WinCC Flexible 2008 Project Deployment on Industrial PC Runtime

Overview: Why a .fwx File Will Not Execute on a Bare Industrial PC

Siemens WinCC Flexible 2008 compiles a configuration project into a single runtime container with the extension .fwx. This file is not a standalone Windows executable (.exe) and cannot be launched by double-clicking on a generic industrial PC. The .fwx must be interpreted by WinCC Flexible Runtime (WinCC flexible RT), which is a separately licensed runtime product supplied by Siemens. The configuration engineering tool, the runtime loader, and the runtime itself are three distinct software components, and the runtime host is responsible for opening the project, allocating tag databases, and driving the configured screens, alarms, and recipes.

This design choice has direct consequences when a project originally created in WinCC Flexible 2008 must run on a third-party industrial PC such as a Lauer PCS, EPC, or similar panel-PC. The hardware may be perfectly capable, but the runtime engine is missing. A Lauer industrial PC that ships with a plain Windows CE or Windows XP Embedded image, or with no Siemens runtime preinstalled, will not open a .fwx file even if the file is copied into the file system.

This article documents the field-proven deployment path: install the appropriate WinCC Flexible Runtime variant on the target IPC, transfer the compiled .fwx container using either ProSave, Ethernet, USB, or a CompactFlash card, and configure the RT to autostart the project on power-up. Memory and storage constraints of legacy Lauer hardware (often 128 MB or less) are addressed with concrete optimization steps.

Prerequisites Before You Begin

Verify the following items exist on the engineering workstation and on the target industrial PC before attempting any transfer.

1. Engineering PC with WinCC Flexible 2008 SP2 or later installed and a working license (floating or local). The source *.hmi project must compile cleanly; the compilation produces the .fwx container in the project directory.
2. WinCC Flexible Runtime license matching the target runtime architecture: WinCC flexible RT for Windows XP/Windows 7, or WinCC flexible RT for Windows CE / Windows Embedded CE 6.0. The CE build is required when the Lauer IPC boots Windows CE; the x86 build is required when the IPC boots Windows XP Embedded or a full Windows variant. The two are not interchangeable.
3. Target industrial PC with sufficient free program memory. A bare Windows CE image typically exposes only the on-board flash minus the OS footprint; a 128 MB Lauer panel will have 30-60 MB of usable storage after CE loads, which is the dominant constraint on a CE build.
4. Connection path between the engineering PC and the Lauer IPC: serial (RS-232 null-modem, typically COM1), Ethernet (TCP/IP via hub or crossover), USB client, or removable media (CompactFlash, USB stick, SD card).
5. ProSave utility installed on the engineering PC. ProSave is the official Siemens transfer and backup tool and is shipped with WinCC Flexible 2008 on the same media, or can be installed standalone.

Understanding the WinCC Flexible Project Lifecycle

The relationship between the engineering tool, the compiled project, and the runtime host is summarized in the table below. Each artifact has a fixed role and a fixed file extension.

The key fact for migration is that no exporter in WinCC flexible 2008 can produce a standalone .exe. The runtime container must be opened by a host that carries the WinCC flexible RT engine. This is by design: the runtime engine is the licensed product, not the project.

Selecting the Correct Runtime Variant for the Lauer IPC

Lauer industrial PCs were commonly delivered in three operating-system configurations. Each one requires a specific WinCC flexible RT build, and the licensing is keyed to the panel type. Identify the configuration before you request a license or order media.

Step-by-Step Deployment Procedure

Step 1: Compile and Validate the .fwx on the Engineering PC

1. Open the project in WinCC flexible 2008.
2. Select Project → Compiler → Compile and Check Consistency. Resolve every warning; warnings frequently become hard faults on the runtime.
3. Select Project → Compiler → Generate Runtime Files. The compiled .fwx is written to the project folder, normally under \<ProjectName>\<PanelName>\<PanelName>.fwx.
4. Note the panel type embedded in the project header (for example, TP 177B 6" PN/DP). The runtime host must match this device type, or the .fwx will refuse to open with error 1901 - incompatible project.

Step 2: Choose a Transfer Channel

Select the channel that best matches the physical interfaces on the Lauer IPC and on the engineering PC.

Step 3: Install WinCC Flexible Runtime on the Lauer IPC

1. Insert the WinCC flexible RT installation media into the Lauer IPC, or map a network share containing the install set.
2. Run setup.exe from the install media and follow the wizard. Select the install path that matches the device type embedded in your project (for example, TP 177B 6"). Mismatching the install path to the panel type will allow the install to complete but will block the project from loading.
3. Enter the runtime license key (transferred automatically via Automation License Manager, or entered manually if the IPC has no network access).
4. Reboot the IPC when prompted. On Windows CE the reboot is mandatory; on Windows XP Embedded it is recommended.

Step 4: Transfer the .fwx via ProSave

1. Launch ProSave on the engineering PC.
2. In the Device type field, select the same panel that the project was compiled for.
3. Select the connection type (Ethernet / Serial / USB) and configure the address (IP, COM port, or USB device ID).
4. Click File → Transfer → Transfer to Device, then select the .fwx file produced in Step 1.
5. ProSave will prompt for a transfer mode:
   • Overwrite – replaces the existing project (use during commissioning).
   • Update – preserves the runtime configuration; updates only project contents (use during normal operation).
6. Wait for the confirmation dialog. A successful transfer shows a CRC match and the runtime version on the target.

Step 5: Configure Autostart on the Lauer IPC

1. On the IPC, open the WinCC flexible RT loader (the entry-point executable created during RT install).
2. In Settings → Project, browse to the transferred .fwx file. The loader remembers the last project; setting it explicitly avoids ambiguity after power cycles.
3. Enable Autostart with project and Autostart with delay if the IPC must wait for network services or for a field-bus connection to come up before opening the project.
4. Save the loader configuration. On Windows CE the settings are stored in the registry under HKEY_LOCAL_MACHINE\SOFTWARE\Siemens\WinCC flexible RT\Loader. On Windows XP Embedded they are stored in C:\Program Files\Siemens\WinCC flexible RT\loader.ini.

Step 6: Verify Project Startup

1. Power-cycle the Lauer IPC.
2. Confirm the loader launches the project automatically. The configured start screen should appear within 5-15 seconds on CE, 10-30 seconds on XP Embedded.
3. Press the configured start button or use the configured hotkey to exit the runtime and reach the CE control panel. The control panel access confirms the runtime is loaded as a layer above the OS rather than replacing it.

Memory and Storage Optimization for Constrained Lauer Hardware

When the IPC exposes 128 MB or less, several engineering and configuration choices have an outsized effect on the runtime footprint.

Project-Side Reduction

• Replace bitmap backgrounds with solid colors or with simple geometric shapes. A single full-screen 800x600 24-bit BMP can consume 1.4 MB of loaded memory; ten such bitmaps will not fit on a 128 MB panel.
• Avoid VB scripts where C-style tag arithmetic suffices. The VB script interpreter in the CE build is large.
• Cap the number of languages in the project text library. Each language doubles the size of the text database.
• Disable the Sm@rtAccess, Sm@rtService, and OPC server options in the project properties if they are not used. Each adds a runtime module.

OS-Side Reduction

• Remove the .NET Compact Framework component from the CE image if the project does not use VB scripts.
• Disable the CE shell (Explorer.exe replacement) and use a custom shell that launches the runtime directly. This recovers 8-15 MB of working set.
• Move the registry hive to persistent storage and disable hibernation. The hibernation file on a 128 MB panel can consume up to 40 MB of free space.

Verification: Free Memory Check

On the CE control panel, open System → Memory. The runtime requires:

Troubleshooting Matrix: Common Deployment Errors

Alternative Paths When WinCC Flexible Runtime Cannot Be Installed

If the Lauer hardware cannot host a WinCC flexible RT build — for example, the IPC is locked to a non-Windows RTOS, or the OS image is read-only and the integrator cannot re-image — the following options exist.

1. Reverse-compile to .fwd and migrate to TIA Portal. In WinCC flexible 2008 ES, open the source .hmi project and use Project → Migration → Reverse Compile. The resulting .fwd can be ported into TIA Portal V13 or later using the WinCC migration tool, which produces a Comfort Panel or WinCC Runtime Advanced project that runs on modern Siemens hardware. This path is the official modernization route offered by Siemens when a legacy panel must be replaced.
2. Replace the Lauer hardware with a current Siemens IPC or Comfort Panel. Modern Siemens IFP panels ship with WinCC RT preinstalled and licensed, eliminating the deployment procedure described above.
3. Use a generic SCADA on the Lauer IPC. If a partial rewrite is acceptable, a vendor-neutral SCADA package (Ignition, WinCC on PC, or Movicon) can be installed on Windows XP Embedded or Windows 7, and the .fwx logic re-implemented as tags and screens. This is the most expensive option but the most flexible.

Long-Term Migration Strategy: From WinCC Flexible to TIA Portal

WinCC flexible 2008 is in the late phase of its product lifecycle. New engineering work is being concentrated in TIA Portal, which unifies PLC, HMI, and drive configuration in a single tool. For a plant with multiple WinCC flexible 2008 projects, a structured migration plan reduces risk and cost.

1. Inventory every .hmi / .fwd source in the plant. Group projects by source panel type.
2. Reverse-compile each project to a .fwd file while the engineering PC still has WinCC flexible 2008 installed. Once the ES is removed, the reverse-compile path is closed.
3. Migrate the .fwd files into TIA Portal using the migration tool. Manually rework any VB scripts that target WinCC flexible 2008 extensions; the TIA Portal VB environment is stricter.
4. Target a modern HMI panel class (Comfort Panels for new builds, or Unified Comfort Panels for greenfield). Test the migrated project on the bench with the original PLC program before cutting over in the field.
5. Retire the Lauer industrial PC as the runtime host. If the Lauer must remain in service for non-HMI reasons, the project can be migrated to a virtual machine running TIA Portal WinCC Runtime Advanced on a current IPC, with the Lauer repurposed for the legacy PLC network.

Verification Checklist Before Returning the System to Production

• [ ] RT version installed on the IPC matches the ES version that produced the .fwx.
• [ ] Panel type string in the project matches the IPC device type (verifiable in the CE control panel).
• [ ] License is permanent, not a demo license.
• [ ] Autostart is enabled and persists across power cycles.
• [ ] All configured PLC connections come up; tag refresh works on the start screen.
• [ ] Alarms appear, acknowledge, and clear correctly.
• [ ] Recipes load, save, and export to the configured media.
• [ ] User logon and authorization work as configured.
• [ ] Touch calibration is accurate across all four corners and the centre.
• [ ] System time is set and persists across reboots (relevant for timestamped alarms).
• [ ] The .hmi and .fwd sources are archived to a versioned repository, and the compiled .fwx is stored next to them.

Frequently Asked Questions