Expanding SIMATIC PCS 7 BOX Systems with Additional OS Clients and Redundancy Licensing

To expand a SIMATIC PCS 7 BOX system (e.g., IPC627D / 6ES7650-4BB82-3TB0) to support additional WinCC operator stations with redundancy, you must convert the Box OS Single Station into an OS Server using a 'Conversion Pack Single Station to OS Server', add a second redundant OS Server node with an 'OS Server Redundancy' license package, and purchase dedicated OS Client licenses for the additional runtime stations. A standard PCS 7 BOX runtime license is strictly an OS Single Station license; it cannot serve multi-client architectures or participate in server redundancy without conversion packages. Final license quantities and MLFBs must be validated against the Siemens ST PCS 7 catalog and an authorized distributor quotation.

Executive Summary

The SIMATIC PCS 7 BOX PC is a compact, cost-effective solution combining the controller (AS RTX software controller or embedded hardware) and operator interface on a single industrial PC. However, as production lines grow, plants often need to expand the system to include dedicated operator terminals (OS Clients) and server-level redundancy. Because the factory Box PC is licensed exclusively as an OS Single Station, engineers cannot simply connect additional clients or add a second Box PC as a redundant twin without restructuring the licensing architecture. This article explains the architectural differences between Single Station and Client/Server topologies, details the required Siemens conversion packs, and outlines the step-by-step expansion workflow.

Architectural and System Mechanics

Siemens PCS 7 licensing strictly distinguishes Single Station, Server, and Client operational tiers:

PCS 7 BOX Architecture: Typically bundled with an OS Single Station runtime license (e.g., 250 or 500 Process Objects). An OS Single Station communicates directly with the AS, but cannot generate server packages for OS Clients.
Multi-Client / Server Architecture: In this topology, one or two OS Servers process automation data, manage archives, and generate a downloadable server data package (*.pck). OS Clients connect to the server package and do not consume AS Process Objects.
Single Station Redundancy vs OS Server Redundancy:
Single Station Redundancy: Connects two independent single stations to the AS. It does NOT support OS Clients.
OS Server Redundancy: Consists of an OS Server plus an OS Server Redundancy license package on the partner server. This architecture supports multiple distributed OS Clients.
Required Conversion Packages:
Conversion Pack OS Single Station to OS Server.
WinCC OS Server Redundancy Package.
Dedicated WinCC OS Client licenses (one per physical client station).

Step-by-Step Engineering and Implementation Procedure

Step 1: Audit Existing BOX Licenses in Automation License Manager

Open Automation License Manager (ALM) on the PCS 7 BOX. Identify the exact installed license keys:
- Look for SIMATIC PCS 7 OS Software Single Station and verify the Process Object count (e.g., 250, 500, or 1000 PO).
- Verify whether the system uses an embedded software controller (WinAC RTX) or an external AS hardware controller.

Step 2: Procure the Proper Conversion and Expansion Packages

To transition to a redundant server pair supporting two new OS Clients, procure:
1. One 'SIMATIC PCS 7 OS Conversion Pack Single Station to OS Server' for the existing Box PC.
2. One 'SIMATIC PCS 7 OS Software Server' license for the new secondary server hardware (e.g., SIMATIC IPC547/IPC647).
3. One 'SIMATIC PCS 7 OS Server Redundancy' license package.
4. Additional AS RT PO / OS RT PO volume expansion packs if the plant tag count expands.
5. Two 'SIMATIC PCS 7 OS Client' runtime licenses for the two new operator terminals.

[!NOTE]
Validate all final license quantities, MLFBs, and software versions with your Siemens authorized distributor quotation prior to procurement.

Step 3: Install Licenses via Automation License Manager

Transfer the conversion license keys to the respective target PCs:
- Box PC (Server 1): Install OS Server Conversion key and matching OS RT POs.
- New Server (Server 2): Install OS Server, OS Server Redundancy, and identical OS RT PO counts.
- Operator Terminals (Client 1 & 2): Install OS Client licenses.

Step 4: Reconfigure Engineering Station and Multiproject

In SIMATIC Manager, open the Multiproject.
In the component view, convert the OS Single Station object into a 'SIMATIC PC Station' configured with a WinCC Appl. (Server).
Insert a redundant partner PC station with WinCC Appl. (stby).
Insert two PC stations configured with 'WinCC Appl. Client'.
Assign terminal bus IP addresses and configure Simatic Shell on all four stations.
Compile the OS and generate the server data package for the clients.

Verification

To verify the expanded system:
1. In ALM on all four nodes, run 'Check License Keys' to confirm zero license deficit or missing key warnings.
2. Start WinCC Runtime on Server 1 and Server 2. Verify that @RM_SERVER_STATE reaches 2 (Master) and 3 (Standby).
3. Start WinCC Runtime on both OS Clients; confirm that clients download the server package and display active process graphics.
4. Disconnect the network cable on Server 1; verify that both OS Clients switch seamlessly to Server 2 without loss of visualization.

Limitations and Operational Precautions

Operational precautions:
- A PCS 7 BOX PC acting as an AS/OS combined station has limited hardware resources (CPU, RAM). When converted to an OS Server serving multiple clients, monitor CPU utilization closely.
- Remote Desktop Protocol (RDP) must never be used to access the OS Server in production; physical OS Clients or industrial KVM extenders are required for additional operator stations.
- Redundant OS Servers must have identical process object and archive tag license capacities.

Engineer FAQ

Q: Can I connect OS Clients directly to a PCS 7 BOX without converting to a server?

A: No. WinCC OS Single Station runtime does not generate server data packages and strictly rejects OS Client connections.

Q: Can a single station redundancy pack support clients?

A: No. Single Station Redundancy is intended for two stand-alone single stations; it cannot host WinCC OS Clients.

Q: Do OS Clients consume Process Objects (POs)?

A: No. OS Clients require an OS Client runtime license, but do not consume AS or OS Process Object counts.

Q: Can I use an ordinary commercial PC for the redundant secondary server?

A: While technically possible if hardware meets PCS 7 specifications, Siemens strongly recommends certified SIMATIC IPCs for OS Server redundancy.

Q: What happens if the OS Server runs out of PO licenses after expansion?

A: WinCC displays a license deficit warning modal dialog at runtime, but does not stop active process control.

Technical References

Related Tags

PCS 7 BOX, Licensing Expansion, OS Server Redundancy, WinCC Client, Process Objects

PCS 7 BOX

`Licensing Expansion`

`OS Server Redundancy`

WinCC Client

Process Objects

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Expanding SIMATIC PCS 7 BOX Systems with Additional OS Clients and Redundancy Licensing