Coexistence and Installation Order of PCS 7 V8.0 SP1, WinCC flexible, and TIA Portal

In SIMATIC PCS 7 Engineering Stations, installing PCS 7 V8.0 SP1 alongside WinCC flexible 2008 and WinCC Advanced (TIA Portal) on the same operating system partition is officially supported only for specifically tested combinations: strictly WinCC flexible 2008 SP3 Upd3 and WinCC Runtime Advanced (TIA Portal V12/V13). To prevent registry and communication driver collisions, engineers must adhere to a strict installation sequence: install WinCC flexible first, followed by PCS 7, and finally TIA Portal. Furthermore, upgrading an existing PCS 7 project from V8.0 to V8.0 SP1 can be executed as a 'Software Update without Utilization of New Functions', which updates the engineering and runtime software without modifying CFC library blocks, faceplates, or requiring a planned controller stop.

Compatibility Guidelines for Multi-Product Engineering Stations

In industrial plants containing both centralized distributed control systems (SIMATIC PCS 7) and local machine-level operator panels (SIMATIC HMI Comfort Panels or Basic Panels), engineering teams often seek to install multiple Siemens software packages on a single Engineering Station (ES).

The primary packages involved include:
1. SIMATIC PCS 7 V8.0 SP1: The core DCS engineering platform (incorporating STEP 7 V5.5 SP3, CFC V8.0 SP1, and WinCC V7.2).
2. SIMATIC WinCC flexible 2008: Used for configuring classic operator panels (OP/TP/MP series).
3. SIMATIC WinCC Advanced (TIA Portal V12 / V13): Used for configuring modern Comfort Panels.

Because all three packages utilize shared operating system components—specifically Microsoft SQL Server instances, the Automation License Manager (ALM), the S7DOS communication layer, and SIMATIC NET drivers—installing untested versions causes severe registry corruption and communication driver collisions.

According to the official Siemens Compatibility Tool for Automation and Drive Technology, only WinCC flexible 2008 SP3 Update 3 is tested and approved for coexistence on a PCS 7 V8.0 SP1 engineering station.

Mandatory Installation Sequence for Mixed Environments

When configuring an Engineering Station with multiple Siemens software packages on a single Windows 7 SP1 (64-bit) operating system partition, adhering to the mandatory chronological installation order is essential:

flowchart TD
    A["1. Clean Windows 7 SP1 (64-Bit) OS Installation"] --> B["2. Install WinCC flexible 2008 SP3 Upd3 (Integrates with STEP 7)"]
    B --> C["3. Install SIMATIC PCS 7 V8.0 SP1 (Installs Core STEP 7, CFC, WinCC V7.2)"]
    C --> D["4. Install TIA Portal V13 / WinCC Advanced (Optional Add-on)"]
    D --> E["5. Install Automation License Manager (ALM) Latest Update"]

Installation Rules:

Install WinCC flexible First: WinCC flexible must be installed before PCS 7 so that its STEP 7 integration tools (s7tgtopx.exe) merge into the base STEP 7 directory during the subsequent PCS 7 installation.
Install PCS 7 Core: Run the PCS 7 V8.0 SP1 setup in Package Installation mode. It updates shared communication drivers to DCS-certified levels.
Virtualization Recommendation: While co-installation is possible, Siemens best practices strongly recommend hosting TIA Portal inside a dedicated virtual machine (VMware Workstation) rather than installing it on the production PCS 7 Engineering Station partition.

PCS 7 Software Update: With vs Without Utilization of New Functions

When applying service packs (such as transitioning a project from PCS 7 V8.0 to V8.0 SP1), engineers can choose between two formal upgrade paths:

Path 1: Software Update WITHOUT Utilization of New Functions

This path is designed for operational production facilities that cannot tolerate process interruptions:
- Scope: Updates the software on the Engineering Station and OS Servers/Clients.
- AS Impact: CFC and SFC charts, block types, and faceplates remain completely untouched. The Automation Station continues running its existing code.
- Compiler/Download: No block type import is performed. Delta compilation and delta download are permitted.
- Downtime: Zero controller downtime.

Path 2: Software Update WITH Utilization of New Functions

This path modernizes the plant to leverage new library features:
- Scope: Updates software and updates the Master Data Library with new APL blocks.
- AS Impact: Function blocks in all CFC charts are updated to the new library version. Module drivers are regenerated.
- Compiler/Download: Structural block changes typically alter instance data block layouts, requiring an AS program compilation and a Full Download in CPU STOP mode.
- Downtime: Requires scheduled plant turnaround.

Software Coexistence and Update Strategy Matrix

The following matrix compares the requirements and characteristics of software coexistence and upgrade paths:

Engineering DimensionWithout New Functions UpdateWith New Functions UpdateMulti-Product Coexistence (WinCC flex / TIA)CPU Operational StateRemains in RUN throughout updateRequires CPU STOP for full downloadUnaffected by external engineering toolsLibrary Block StatusExisting library blocks preservedBlocks updated to latest APL revisionN/AWinCC FaceplatesExisting faceplates retainedNew faceplates imported and compiledLocal panel runtimes updatedOS Compile ModeChanges onlyEntire OS compile recommendedIndependent compilation per toolTested VersionsV8.0 -> V8.0 SP1V8.0 -> V8.0 SP1WinCC flex 2008 SP3 Upd3 / TIA V12/V13

Verification

To confirm that software packages coexist without conflict and that project migration is valid:
1. Open the Siemens Compatibility Tool online and generate a compatibility report for your exact software versions.
2. In Windows Control Panel > Programs and Features: Verify that WinCC flexible, PCS 7, and TIA Portal display their tested service pack levels.
3. Launch SIMATIC Manager: Open an integrated project containing both PCS 7 AS/OS stations and a WinCC flexible panel project.
4. Open a CFC chart: Verify that blocks open and monitor online without DLL version mismatch warnings.
5. In WinCC flexible, open an operator panel project: Confirm that tags integrated from the STEP 7 symbol table update successfully.

Limitations and Operational Precautions

Observe the following engineering constraints:
- Never Mix Untested Versions: Installing untested versions (such as WinCC flexible 2008 SP5 on PCS 7 V8.0) can overwrite core OPC server DLLs, breaking WinCC OS runtime communication.
- Antivirus Software Exclusions: When multiple engineering packages coexist, expand antivirus exclusions to cover all Siemens directories (Siemens\Step7, Siemens\WinCC, Siemens\Automation).
- Disk Space Allocation: A combined installation of PCS 7, WinCC flexible, and TIA Portal requires at least $80\text{ GB}$ of free disk space on the system partition (C:\).

Engineer FAQ

Can I migrate an integrated WinCC flexible project without touching PCS 7 blocks?

Yes. When updating software without utilization of new functions, you can compile and download the WinCC flexible project to operator panels independently without recompiling or downloading the AS controller.

Why is installing WinCC flexible before PCS 7 mandatory?

WinCC flexible includes an integration setup component that hooks into STEP 7. Installing it after PCS 7 can overwrite newer communication components installed by the PCS 7 setup.

Where can I verify official Siemens software compatibility?

Use the official online Siemens Compatibility Tool (support.industry.siemens.com/kompatool) to verify compatibility across PCS 7, WinCC flexible, TIA Portal, and Windows operating systems.