Adding an OS Client to a Legacy SIMATIC PCS 7 V7.0 System: Prerequisites and Procedures

To add a new OS Client to an existing SIMATIC PCS 7 V7.0 plant, you must install the exact PCS 7 V7.0 client software on a supported operating system (Windows XP Professional SP2/SP3 or Windows Server 2003), configure a new OS Client station in SIMATIC Manager, assign the OS Server packages, and license the station with a valid 'SIMATIC PCS 7 OS Software Client V7.0' runtime license. Because commercial off-the-shelf modern PCs cannot run Windows XP due to hardware and chipset incompatibilities, operators must either source legacy industrial PCs (such as SIMATIC IPC547C/D) or utilize virtualization with hypervisor hardware passthrough.

Executive Summary

Operating plants running legacy SIMATIC PCS 7 V7.0 installations frequently need to expand operator interfaces by adding additional OS Clients to their terminal bus. However, attempting to integrate modern PC hardware into a V7.0 architecture presents severe operating system incompatibilities, commercial licensing boundaries, and network security hurdles. This article details the prerequisites, step-by-step engineering procedures in SIMATIC Manager, licensing requirements, and practical hardware sourcing strategies for deploying an OS Client on a legacy PCS 7 V7.0 system.

Architecture and Fundamental Mechanics

PCS 7 V7.0 Client-Server Architecture and OS Boundaries:

Operating System Support Boundaries:
PCS 7 V7.0 strictly requires Windows XP Professional SP2 / SP3 (32-bit) or Windows Server 2003 (32-bit).
Modern operating systems (Windows 7, Windows 10, Windows Server 2016/2019/2022) cannot run PCS 7 V7.0 software; installation will abort with operating system version check errors.
Modern Hardware Incompatibilities:
Contemporary computer hardware (Intel Core 8th-14th Gen, UEFI-only BIOS, NVMe storage) lacks 32-bit Windows XP drivers for network interface cards, chipsets, and integrated graphics.
Sourcing Options: Legacy refurbished industrial PCs (e.g., SIMATIC Microbox PC 427B/C, IPC547C/D) or deploying an ESXi/Hyper-V virtualized OS Client with remote thin clients.
Client-Server Communications:
OS Clients communicate with OS Servers exclusively over the Terminal Bus.
OS Clients do not connect to the Plant Bus or communicate directly with S7-400 controllers.
OS Clients display graphics and trends by loading Server Data Packages (.pck) generated by the OS Server.

Step-by-Step Implementation Procedure

Engineering Procedure to Add an OS Client to a PCS 7 V7.0 Project:

Hardware and OS Preparation:
- Prepare an industrial PC compatible with Windows XP Professional SP3 (32-bit).
- Install Windows XP SP3, configure TCP/IP on the Terminal Bus adapter, and join the plant workgroup or domain.
- Install SIMATIC PCS 7 V7.0 (select 'OS Client' installation package from DVD).
- Install the 'SIMATIC PCS 7 OS Software Client V7.0' runtime license using Automation License Manager (ALM).
Configure the OS Client in SIMATIC Manager:
- Open the PCS 7 Multiproject on the Engineering Station.
- Right-click the project -> Insert New Object -> SIMATIC PC Station.
- Name the PC Station identically to the Windows Computer Name of the new client.
Hardware Configuration:
- Open HW Config for the new PC Station.
- In Slot 1, insert WinCC Appl. Client.
- In Slot 2, insert IE General and assign its Terminal Bus IP address.
- Save and Compile HW Config.
Assign Server Data Packages:
- In SIMATIC Manager, expand the new PC Station -> WinCC Appl. Client -> open WinCC Explorer.
- In WinCC Explorer, right-click 'Server Data' -> select 'Assign...'.
- Select the server packages generated by your OS Master and Standby Servers.
- Configure the standard server for alarms and split-screen management.
Generate and Download Target Project:
- Run the OS Project Editor in WinCC Explorer to generate basic screen layouts and resolution layouts.
- Set the OS Client startup picture (e.g., @screen.pdl).
- Right-click the OS Client in SIMATIC Manager -> Target System -> Download.
Commissioning:
- On the physical client PC, open Simatic Shell; verify that the OS Servers are visible.
- Launch WinCC Runtime on the client.

Verification

To verify the OS Client operation:
1. In Simatic Shell on the client PC, verify the OS Server shows 'Deactivated/Activated' status without red cross icons.
2. Start WinCC Runtime on the client; confirm that process pictures load promptly and live values display valid quality codes.
3. Issue a setpoint change or valve toggle from the client; confirm execution on the plant floor.
4. Verify alarm logging: confirm that new alarms appear on the client alarm banner simultaneously with the server.

Limitations and Operational Precautions

Operational precautions:
- Never connect an OS Client to both the Plant Bus and Terminal Bus simultaneously; clients must be strictly isolated on the Terminal Bus.
- Windows XP is an unsupported, obsolete operating system. A comprehensive modernization path to PCS 7 V9.x should be planned.
- Do not transfer modern PCS 7 V8/V9 licenses to a V7.0 installation; V7.0 requires exact version-compatible licenses (e.g., PCS 7 OS Client V7.0).

Engineer FAQ

Can a PCS 7 V7.0 OS Client run on Windows 10?

No. PCS 7 V7.0 is strictly limited to Windows XP Professional (32-bit) and Windows Server 2003.

What software license is required for the new client?

A dedicated 'SIMATIC PCS 7 OS Software Client V7.0' runtime license key installed via ALM.

Does the OS Client need to connect to the Plant Bus?

No. OS Clients communicate solely over the Terminal Bus with OS Servers.

What hardware object represents the client in HW Config?

WinCC Appl. Client placed in the virtual PC rack.

How does the client know which server tags to display?

By importing the Server Data Package (.pck) generated on the OS Server.

Technical References

Related Tags

PCS 7 V7.0
OS Client
Windows XP
Terminal Bus
Server Data Package

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Adding an OS Client to a Legacy SIMATIC PCS 7 V7.0 System: Prerequisites and Procedures