Architecture and Licensing of OpenPCS 7 V8.1 on SIMATIC IPC Bundles

The OpenPCS 7 V8.1 software package for SIMATIC IPC Bundles provides an open, vendor-neutral connectivity gateway that exposes PCS 7 process data, historical archives, and alarms to higher-level enterprise systems (such as MES, ERP, and OSIsoft PI) via standardized OPC interfaces (OPC DA, OPC HDA, OPC A&E, and OPC UA). When ordered as an 'IPC Bundle' license, the software entitlement is pre-configured and legally coupled to a certified Siemens industrial PC workstation (such as SIMATIC IPC547, IPC647, or IPC847). The bundle includes the OpenPCS 7 Single License (Class A) supplied on a USB hardware token for installation on the designated reference PC.

Role and Functionality of OpenPCS 7 in Industrial Architectures

In modern digital manufacturing, distributed control systems must share real-time and historical operational data with external enterprise networks without exposing mission-critical automation controllers to direct network access. In SIMATIC PCS 7, OpenPCS 7 acts as the secure, standardized connectivity gateway.

Operating as an independent server or co-located on an OS Client / Single Station, OpenPCS 7 collects process variables, event logs, and historical trends from WinCC OS Servers and delivers them to Manufacturing Execution Systems (MES), Laboratory Information Management Systems (LIMS), and third-party data historians (such as OSIsoft PI).

Supported OPC Interfaces and Standards

OpenPCS 7 implements both classic COM/DCOM-based OPC protocols and modern open architecture standards:

OPC Data Access (OPC DA): Fast, cyclic exchange of real-time process values (temperatures, pressures, flow rates).
OPC Historical Data Access (OPC HDA): Querying historical time-series data logged in WinCC Tag Logging archives or the central Process Historian.
OPC Alarms & Events (OPC A&E): Event-driven distribution of operator messages, process alarms, and sequence logs from WinCC Alarm Logging.
OPC Unified Architecture (OPC UA): Cross-platform, firewall-friendly binary TCP communication with embedded encryption, user authentication, and digital certificate validation.

Hardware Coupling in SIMATIC IPC Reference Bundles

To simplify procurement and guarantee hardware-software interoperability, Siemens packages PCS 7 software into pre-configured SIMATIC IPC Bundles (detailed in the Siemens ST PCS 7 Catalog):

Reference Hardware Coupling: An OpenPCS 7 IPC Bundle license is commercially discounted and legally paired with a specific Siemens industrial PC model (such as SIMATIC IPC547, IPC647, or IPC847 Rack PC). The software entitlement is intended for deployment exclusively on that reference hardware.
License Delivery: Supplied as a Single License (Class A) with the license key stored on a physical USB hardware stick accompanying the IPC shipment. Documentation and software binaries are pre-installed or supplied via restore DVD/USB media.
Catalog Structure: In the Siemens ST PCS 7 Catalog, Section 1 covers IPC hardware platforms, Section 4 details Operator Station bundles, and Section 10 covers OpenPCS 7 interface specifications.

Equipment Schedule and Order Number Specifications

The table below details the equipment schedule, hardware platforms, and software packages for OpenPCS 7 deployments.

Component / Software DescriptionMLFB / Order NumberComponent TypeScope and FunctionalitySIMATIC PCS 7 OpenPCS 7 V8.16ES7658-7EB18-0YA0Software Runtime LicenseSingle license for OpenPCS 7 V8.1 (Class A, on USB stick)SIMATIC PCS 7 OpenPCS 7 V9.06ES7658-7EB58-0YA0Software Runtime LicenseSingle license for OpenPCS 7 V9.0 (Class A, on USB stick)SIMATIC IPC547G Rack PC6ES7660-7DF20-0BA0Industrial Hardware Platform19-inch 4U industrial workstation for OpenPCS 7 gatewaySIMATIC IPC647D Rack PC6ES7660-6DA20-0BA0Industrial Hardware PlatformCompact 2U rugged rack PC for space-constrained server roomsOpenPCS 7 Client Software Package6ES7658-7EB18-0YA1Client Communication APISoftware development kit and OLE DB provider for third-party PCs

[!IMPORTANT]
Commercial Accuracy and Procurement Disclaimer: Validate MLFB order numbers, hardware bundle options, and PCS 7 version > compatibility with authorized Siemens distributors. Bundle license terms require installation on the designated reference IPC.

Step-by-Step Installation and License Verification Procedure

Follow this procedure to install and verify OpenPCS 7 on a SIMATIC IPC bundle:

Install Hardware and Operating System:
- Unpack and rack-mount the SIMATIC IPC workstation.
- Boot the factory-installed operating system (e.g., Windows Server 2008 R2 for V8.1; Windows Server 2016 for V9.0).
- Configure network adapters: connect Port 1 to the PCS 7 Terminal Bus and Port 2 to the enterprise corporate LAN/DMZ.
Install OpenPCS 7 Software:
- Insert the PCS 7 installation media. Run Setup.exe.
- In the package selection menu, check OpenPCS 7 (or OpenPCS 7 Station).
- Complete setup and execute the Siemens Security Controller to configure DCOM and firewall policies.
Transfer License Key:
- Insert the supplied USB license stick into the IPC.
- Open Automation License Manager (ALM).
- Transfer license SIMATIC PCS 7 OpenPCS 7 from the USB drive to local drive C:.
Configure OPC DCOM / UA Endpoints:
- Open dcomcnfg and verify DCOM launch permissions for OPC DA/HDA.
- If utilizing OPC UA, configure the OPC UA server endpoint URL and export server certificates for client authentication.

Verification

Verify OpenPCS 7 gateway functionality through the following checks:
1. In Automation License Manager, verify that license key OpenPCS 7 displays valid status without license violation flags.
2. Launch Siemens OPC Scout (or third-party OPC client like UA Expert): browse the local OpenPCS 7 server node.
3. Connect to the OPC DA server: browse the technological hierarchy, add a live tag (e.g., Reactor_Temp.PV_Out.Value), and verify live value updates.
4. Query OPC HDA: execute a historical read query for the past 24 hours; verify that archived data points are retrieved successfully.

Limitations and Operational Precautions

OpenPCS 7 acts as a bridge between the DCS Terminal Bus and external networks. Never connect the OpenPCS 7 machine directly to the physical Plant Bus (Industrial Ethernet connecting S7-400 controllers). Direct plant bus connection violates industrial cybersecurity zoning (IEC 62443). Always maintain dual network segmentation, routing enterprise traffic strictly through an intermediate Demilitarized Zone (DMZ) firewall.

Engineer FAQ

Can OpenPCS 7 run on an existing OS Client?

Yes. OpenPCS 7 can be installed on a dedicated standalone PC or co-located on an existing PCS 7 OS Client, provided the hardware meets performance specifications.

Does OpenPCS 7 require an AS Process Object license?

No. OpenPCS 7 is an HMI-level communication gateway and consumes zero AS RT Process Objects. It requires only its dedicated OpenPCS 7 software license.