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Configuring and Licensing OPC Server and Client Communication in SIMATIC PCS 7 V9.0

Configuring and Licensing OPC Server and Client Communication in SIMATIC PCS 7 V9.0

To exchange data between SIMATIC PCS 7 V9.0 (IPC547G with CP1623 and S7-410-5H) and an external third-party OPC server or client, licensing depends strictly on the direction of communication. If an external client reads or writes data from PCS 7, the OS station requires a SIMATIC PCS 7 OpenPCS 7 V9.0 runtime license. If PCS 7 acts as an OPC DA or OPC UA client querying an external third-party OPC server, the native WinCC OPC Channel is used without extra option licenses, consuming standard WinCC OS Process Object (PO) tags. All procurements must be verified via an authorized Siemens distributor or the Siemens Industry Mall.

Table of Contents

Executive Summary

Integrating SIMATIC PCS 7 V9.0 with external supervisory architectures, Manufacturing Execution Systems (MES), or third-party PLC islands frequently requires Open Platform Communications (OPC). Engineers commonly struggle with identifying whether standard WinCC runtime licenses suffice or whether dedicated OpenPCS 7 licenses must be procured. In a hardware topology comprising an S7-410-5H controller and an IPC547G OS single station or server equipped with a CP1623 communications processor, data exchange directionality dictates the licensing model. When the PCS 7 OS functions as an OPC Server (exposing process tags, alarms, and historical archives to external clients), Siemens mandates the SIMATIC PCS 7 OpenPCS 7 runtime package. Conversely, when PCS 7 acts as an OPC Client (collecting telemetry from external OPC servers via OPC DA or OPC UA), the standard WinCC OPC communication channel operates under existing OS Runtime Process Object (PO) licensing without separate option packages.

Architecture and Fundamental Mechanics

The architecture of OPC communication in SIMATIC PCS 7 V9.0 branches into two discrete operational models: OpenPCS 7 Server and WinCC OPC Client.

1. OpenPCS 7 Server Interface

OpenPCS 7 acts as an abstraction gateway that exposes PCS 7 automation data to external systems using OPC DA (Data Access), OPC HDA (Historical Data Access), OPC A&E (Alarms & Events), and OPC UA (Unified Architecture). Rather than having external clients connect directly to internal WinCC runtime databases—which risks performance degradation and security vulnerabilities—OpenPCS 7 queries the WinCC ODK (Open Development Kit) and OS server data packages. In redundant OS configurations, OpenPCS 7 abstracts server redundancy; external clients connect to OpenPCS 7, which automatically queries the active OS Master and fails over seamlessly to the Standby partner. Installing OpenPCS 7 on an OS Single Station or OS Server activates the OPC interfaces but requires a dedicated local license.

2. WinCC OPC Communication Channel (OPC Client)

When PCS 7 needs to ingest data from a third-party DCS, package unit, or power monitoring system that already hosts an OPC DA or OPC UA server, the PCS 7 OS station acts as an OPC Client. WinCC includes the native 'OPC' communication channel within its standard channel unit library (OPC.chn). This channel establishes client connections to local or remote OPC DA 2.05a/3.0 servers or OPC UA servers. Data imported through the OPC channel is mapped directly to WinCC internal or process tags. These tags do not require an OpenPCS 7 license; however, they count toward the total licensed WinCC OS Runtime Process Objects (PO) or tag limit of the OS station.

Step-by-Step Implementation Procedure

The following procedural workflow outlines configuring and licensing both communication directions in SIMATIC PCS 7 V9.0:

Scenario A: Configuring PCS 7 as an OPC Server via OpenPCS 7

  1. Procure and Transfer OpenPCS 7 License:
    - Procure the license package: SIMATIC PCS 7 OpenPCS 7 V9.0 (MLFB: 6ES7658-0EX58-0YB5 for Single License).
    - Open Automation License Manager (ALM) on the target OS Server or Single Station (IPC547G).
    - Transfer the OpenPCS 7 license key from the installation USB stick to drive C:.
  2. Install OpenPCS 7 Software:
    - Launch the SIMATIC PCS 7 V9.0 installation media and select 'Package Installation' -> 'OpenPCS 7'.
    - Complete the installation and reboot the IPC547G.
  3. Configure OpenPCS 7 Station in SIMATIC Manager:
    - In the Component View of SIMATIC Manager, insert an 'OpenPCS 7 Station' or enable OpenPCS 7 properties on the OS Station.
    - Open NetPro, configure the network interfaces, and compile the station.
    - Open WinCC Explorer, verify that the OPC UA / DA servers are enabled in the Computer Properties, and start WinCC Runtime.

Scenario B: Configuring PCS 7 as an OPC Client via WinCC OPC Channel

  1. Add OPC Communication Channel in WinCC Explorer:
    - Open the WinCC project on the Engineering Station (ES).
    - In the navigation tree, right-click 'Tag Management' and select 'Add new driver'.
    - Select 'OPC.chn' (or 'OPC Unified Architecture.chn') from the list.
  2. Configure Connection to Remote OPC Server:
    - Under the newly added 'OPC' driver branch, right-click the channel unit (e.g., 'OPC Groups' or 'UA Client') and create a 'New Connection'.
    - Specify the connection parameters: Host IP address/computer name of the external server and Server ProgID (e.g., Matrikon.OPC.Simulation or opc.tcp://192.168.1.100:4840).
    - Configure security parameters (None, Basic256Sha256) and import the external server certificate into the WinCC UA certificate store if using OPC UA.
  3. Tag Browsing and Mapping:
    - Right-click the configured connection and select 'Open Tag Browser'.
    - Browse the address space of the external OPC server, select the required telemetry tags, and map them to WinCC tag variables.
  4. Compile and Download OS:
    - Generate server data and download the OS project from the ES to the target OS station (IPC547G).
    - Verify in Automation License Manager that total configured tags remain within the licensed WinCC OS RT PO count.

Verification

To verify proper operation and licensing compliance:

  1. OpenPCS 7 Verification:
    - Launch an external OPC test client (such as OPC Scout V10 or Matrikon OPC Explorer) on an engineering laptop on the terminal bus.
    - Connect to OPC.SimaticNET or PCS7.OPCDAServer. Browse tags and confirm successful read/write operations without license dialog popups.
    - Open C:\Program Files (x86)\Siemens\WinCC\Diagnose\License_Info.log on the IPC547G and confirm that the OpenPCS 7 license is successfully acquired.

  2. WinCC OPC Client Verification:
    - Start WinCC Runtime on the OS station.
    - Open the WinCC Channel Diagnosis utility (WinCC Explorer -> Tools -> Channel Diagnosis or run WinCCChannelDiagnosis.exe).
    - Select the 'OPC' or 'OPC UA Client' channel tab and verify that the connection status displays a green checkmark with status 'Ready / OK'.
    - Verify that process values update smoothly on WinCC process screens.

Limitations and Operational Precautions

Operational limitations and commercial precautions:

  1. License Isolation: OpenPCS 7 licenses are Single Node licenses locked to the physical machine or dongle; they cannot be floated across network license pools.
  2. Bandwidth and Performance: OpenPCS 7 queries impose additional CPU and memory loads on the WinCC OS Server. For high-volume external historian data collection (> 10,000 tags updating at 1-second intervals), Siemens strongly recommends deploying a dedicated standalone OpenPCS 7 station rather than hosting OpenPCS 7 on an active OS Server.
  3. Firewalls and DCOM: OPC Classic (DA, HDA, A&E) relies on Microsoft DCOM, which is prone to security restrictions in modern Windows environments (Windows 10, Server 2016/2019). OPC UA is strongly recommended to avoid DCOM configuration failures.
  4. Commercial Disclaimer: License quantities, options, and MLFBs must be validated against the official Siemens Industry Mall or an authorized Siemens distributor before procurement.

Engineer FAQ

Do I need an OpenPCS 7 license if WinCC only reads data from an external OPC server?

No. When WinCC acts as an OPC Client reading from an external third-party OPC server, it uses the standard WinCC OPC communication channel included with WinCC Runtime. Only standard WinCC OS Process Object (PO) tags are consumed.

Can OpenPCS 7 be installed directly on an OS Single Station?

Yes. OpenPCS 7 can be installed directly on an OS Single Station or OS Server. However, if data throughput is high, deploying a separate OpenPCS 7 station avoids loading the operator station runtime.

Does OpenPCS 7 support OPC UA natively in PCS 7 V9.0?

Yes. SIMATIC PCS 7 V9.0 OpenPCS 7 includes both OPC Classic (DA, HDA, A&E) and OPC UA Server interfaces, allowing encrypted, firewall-friendly communication over standard TCP ports.

How does OpenPCS 7 handle redundant OS Servers?

OpenPCS 7 connects to both redundant OS servers simultaneously. It transparently directs external client requests to the active master and automatically switches to the standby server if the master fails, without requiring external script logic.

What happens if an external client connects to OpenPCS 7 without a valid license?

If the OpenPCS 7 license is missing or expired in Automation License Manager, the software enters Demo Mode. A recurrent license popup appears on the OS station every 10 minutes, and communication terminates after a grace period.

Technical References

Related Articles

Related Tags

  • OpenPCS 7
  • WinCC OPC
  • PCS 7 V9.0
  • OPC UA
  • Automation License Manager
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