Architectural Sizing and License Validation for PCS 7 V9.0 with CEMAT and SIMATIC PDM

In SIMATIC PCS 7 V9.0 SP1, validating an automation architecture for a heavy industrial plant (such as a cement production facility using the CEMAT library) with 250 digital sensors, 80 analog sensors, 15 actuators, and 500 to 1,000 archived variables requires strictly separating hardware capacity licensing from software runtime packages. Technological blocks (CEMAT C_DRV_1D, C_VALVE, C_MEASUR) consume standard AS RT Process Objects (sized at approximately 150 to 250 POs). The CPU 410-5H requires an identical System Expansion Card (SEC) for each controller in an H-pair. WinCC OS runtime requires a 500 OS RT PO package and an OS Archive upgrade (1,500 archive tags). SIMATIC PDM requires PDM Basic plus a 100 TAG capacity license. Validate final license quantities and order numbers with an authorized Siemens distributor or the Siemens Industry Mall.

Executive Summary

Designing a turnkey automation architecture for a continuous heavy industrial facility—such as a cement grinding or shipping terminal running PCS 7 V9.0 SP1 with the CEMAT industry library—demands rigorous commercial and technical sizing. Operating teams specifying hardware schedules (comprising 250 digital inputs, 80 analog inputs, 15 motor/actuator drives, and up to 1,000 historical trend variables) frequently miscalculate licensing requirements. Confusing physical I/O counts with Process Object (PO) counts, or omitting separately licensed packages like SIMATIC PDM and WinCC Tag Logging expansions, leads to procurement delays and runtime license enforcement alarms. This technical article provides the complete engineering sizing methodology, software entitlement rules, and license validation framework.

Architecture and Fundamental Mechanics

The licensing and sizing architecture of SIMATIC PCS 7 V9.0 separates hardware execution, software runtime, and industry options into distinct domains:
1. Controller Sizing and System Expansion Cards (SEC):
- Physical I/O count does not dictate PO consumption. Process Objects (AS RT PO) are consumed exclusively by instantiated technological control blocks (C_DRV_1D for motors, C_VALVE for dampers, C_MEASUR for analog transmitters).
- For 15 drives, 80 analog transmitters, and associated group/interlock blocks, total AS consumption is approximately 150 to 200 AS RT POs.
- On the CPU 410-5H, PO capacity is defined by the physical System Expansion Card (SEC). For a redundant AS 410H pair, two identical System Expansion Cards (e.g., SEC 500 PO) are mandatory.
2. WinCC OS Server Runtime and Process Objects (OS RT PO):
- OS Process Objects correspond to AS blocks transmitting faceplate and message data to WinCC.
- Sizing: Select SIMATIC PCS 7 OS Software Server V9.0 (500 PO). For redundant OS servers, each physical server requires an independent OS RT license and WinCC Redundancy license.
3. Historical Tag Archiving Capacity:
- Standard WinCC OS Server runtime licenses include archiving capacity for 512 archive tags.
- Logging 500 to 1,000 variables exceeds the base allocation, requiring a WinCC Archive Tag Upgrade license (e.g., +1,500 Archive Tags) installed on each server.
4. SIMATIC PDM and CEMAT Option Packages:
- CEMAT Engineering & Runtime: Requires the CEMAT Engineering V9.0 license on the ES and CEMAT Server/Client runtime options on the OS.
- SIMATIC PDM: Parameterizing smart field devices requires SIMATIC PDM Basic plus a SIMATIC PDM 100 TAG license.

Step-by-Step Implementation Procedure

Audit Technological Block Count to Calculate AS RT POs:
a. Itemize all field equipment: 15 motors/actuators (C_DRV_1D / C_VALVE = 15 POs), 80 analog measuring points (C_MEASUR = 80 POs), plus auxiliary group blocks (C_GROUP, interlocks = ~30 POs).
b. Sum total technological blocks: approximately 125 to 150 POs.
c. Add 25% spare capacity for future expansion: total AS PO demand = ~200 POs.
Size Controller Hardware and System Expansion Cards (SEC):
a. For an AS 410-5H single or redundant station, select the standard 500 PO tier.
b. Procure 2x CPU 410 System Expansion Card 500 POs (one SEC inserted into each physical CPU).
c. In SIMATIC Manager, select Options -> Process Objects -> Total Process Objects to verify allocation.
Size WinCC OS Server Runtime and Redundancy Licenses:
a. For a redundant OS server pair, procure:
- 2x SIMATIC PCS 7 OS Software Server V9.0 (500 PO).
- 2x SIMATIC PCS 7 OS Redundancy V9.0.
  b. Sizing Archive Tags: Sizing for 1,000 variables requires adding 2x SIMATIC WinCC / Archive Tag Upgrades (+1,500 Tags) to cover both physical servers.
License SIMATIC PDM for Smart Field Devices:
a. Count intelligent field instruments (HART, PROFIBUS PA, smart positioners): 80 analog sensors.
b. Procure 1x SIMATIC PDM Basic plus 1x SIMATIC PDM TAG 100 for the Engineering Station.
c. Install PDM Device Integration Manager (DIM) and device descriptions (EDD).
Verify Engineering Station Toolset and CEMAT Licenses:
a. On the Engineering Station, install:
- 1x SIMATIC PCS 7 Engineering Software V9.0 (Unlimited POs or standard tier).
- 1x CEMAT Engineering V9.0 license key.
  b. In Automation License Manager (ALM), run 'Check License Keys' to confirm all keys report green status.

Verification

In SIMATIC Manager, execute Options -> Process Objects -> Total Process Objects: confirm counted POs remain below the authorized 500 PO limit.
In HW Config online, open CPU Module Information -> 'System Expansion Card': verify authorized capacity displays 500 POs on both CPUs.
In WinCC Explorer on both OS servers, check Tag Logging: verify archive tag count accommodates 1,000 variables without license violation warnings.

Limitations and Operational Precautions

Never treat physical I/O count as the PO count; doing so inflates procurement budgets. Conversely, never omit redundant server licensing: each physical OS server requires independent WinCC Runtime, Redundancy, and Archive licenses.

Engineer FAQ

Do physical I/O channels consume Process Objects in PCS 7?

No. Standard I/O channel drivers consume zero Process Objects; POs are consumed exclusively by technological control blocks like motors, valves, and analog monitors.

How many archive tags are included with a standard WinCC OS Server license?

A standard WinCC OS Server runtime license includes 512 archive tags. Logging 1,000 tags requires an Archive Tag Upgrade license.

Must both CPUs in a redundant S7-400H pair have identical SEC cards?

Yes. A redundant CPU 410H pair strictly requires identical System Expansion Card PO capacities to synchronize into RUN-Redundant mode.

Are separate runtime licenses required for each redundant OS server?

Yes. Each physical server in a redundant OS pair requires an independent OS Runtime license, Redundancy license, and Archive upgrade.

What software manages intelligent HART transmitters in a CEMAT plant?

SIMATIC PDM (Process Device Manager), licensed by PDM Basic plus PDM TAG count packages.

Technical References

Related Tags

Architecture Sizing
Licensing
CEMAT
SIMATIC PDM
Process Objects
System Expansion Card

System Expansion Card

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Architectural Sizing and License Validation for PCS 7 V9.0 with CEMAT and SIMATIC PDM