Hardware Replacement and Software Order When Upgrading PCS 7 V7.1 to V9.1 SP2

Hardware Replacement and Software Order When Upgrading PCS 7 V7.1 to V9.1 SP2

Upgrading an enterprise SIMATIC PCS 7 installation from legacy V7.1 to modern V9.1 SP2 requires synchronizing physical hardware replacements with a disciplined chronological software migration order. Performing the software upgrade requires replacing obsolete plant computers (IPCs), retiring legacy PCI communication processors (CP 1613) in favor of modern PCIe cards (CP 1623/1628), and verifying that controller CPUs possess compatible firmware. Software execution follows a strict sequence: project archiving and database reorganization in V7.1, intermediate SQL and chart conversion in a PCS 7 V8.2 SP1 staging virtual machine, and final software deployment onto new Windows 10 Enterprise LTSC hardware running PCS 7 V9.1 SP2.

Table of Contents

• Hardware Obsolescence and Required Station Replacements
• Chronological Software Execution and Installation Order
• Communication Processor and Network Upgrades (CP 1613 to CP 1623)
• Method: Step-by-Step Staged Cutover Procedure
• Verification
• Limitations and Operational Precautions
• Engineer FAQ
• Technical References
• Related Articles
• Related Tags

Hardware Obsolescence and Required Station Replacements

A software update from PCS 7 V7.1 to V9.1 SP2 cannot run on legacy computing hardware. The complete physical station footprint must be upgraded:

Legacy IPC motherboards lack 64-bit drivers, UEFI firmware, and hardware TPM modules required by modern operating systems and WinCC V7.5 SP2.

Chronological Software Execution and Installation Order

The software migration must follow an exact chronological pipeline:

1. V7.1 Baseline Consolidation:
   - On the running V7.1 system: execute Save As... (With Reorganization).
   - Purge unused symbols and verify zero CFC compile errors.
   - Archive the multiproject to an external drive.
2. Intermediate V8.2 Staging (Virtual Machine):
   - In an offline VM running Windows 7 SP1 (64-bit) and PCS 7 V8.2 SP1:
   - Restore archive and execute the WinCC Project Migrator (SQL 2005 -> SQL 2014).
   - Update CFC internal data structures and execute full chart compile.
   - Run OS Project Editor and compile OS.
   - Archive the sanitized V8.2 project.
3. Target V9.1 SP2 Modernization:
   - On the new physical IPC running Windows 10 LTSC and PCS 7 V9.1 SP2:
   - Restore the V8.2 archive and run the V9.1 WinCC Migrator (SQL 2014 -> SQL 2017).
   - Update block types in the Master Data Library to APL V9.1 SP2.
   - Run OS Project Editor and full OS Compilation.

Communication Processor and Network Upgrades (CP 1613 to CP 1623)

Industrial Ethernet communication processors must be physically replaced:
- Retirement of CP 1613: The classic CP 1613 / CP 1613 A2 card utilizes the legacy 32-bit PCI bus. Modern industrial PCs no longer feature legacy PCI slots. Furthermore, 64-bit Windows 10 lacks driver support for the CP 1613.
- Adoption of CP 1623 / CP 1628: Replace with the CP 1623 (PCIe x1) or CP 1628 (with integrated hardware security/firewall).
- SIMATIC NET Hardware Configuration: In the newly deployed V9.1 station hardware configuration, open the Station Configuration Editor and insert the CP 1623 into the designated virtual slot (matching the PCS 7 HW Config project index).

Method: Step-by-Step Staged Cutover Procedure

Execute the physical and software cutover during a scheduled maintenance turnaround:

Step 1: Pre-Commission New Hardware Offline

1. Install Windows 10 Enterprise LTSC, SIMATIC PCS 7 V9.1 SP2, and Automation License Manager on the new IPCs.
2. Transfer all upgraded licenses (V9.1 upgrade keys) to the local hard drives.
3. Perform the complete two-stage software migration in the office/staging lab: confirm that the V9.1 project compiles with 0 errors.

Step 2: Establish Parallel Plant Bus and Terminal Bus

1. Install new SCALANCE switches or connect new IPC network cables to existing plant bus infrastructure.
2. Configure IP addresses and subnet masks matching the migrated project documentation.
3. Verify Simatic Shell network bindings on all new stations.

Step 3: Controller Cutover and Program Download

1. Place the plant in a safe shutdown condition.
2. Switch the AS controllers to STOP mode.
3. If upgrading CPUs to CPU 410-5H, physically swap the controller modules and connect PROFINET/PROFIBUS cables.
4. Download the newly compiled Hardware Configuration from the V9.1 ES.
5. Download the entire S7 program (Entire Scope) including safety programs.
6. Switch controllers to RUN mode: verify that controllers reach RUN-Redundant status without error LEDs.

Step 4: Activate OS Runtime and Verify

1. Activate WinCC Runtime on the primary OS Server, followed by the standby OS Server.
2. Launch WinCC Runtime on all OS Clients.
3. Confirm that client faceplates connect, alarms populate, and historical trends initiate logging.

Verification

To verify that the newly deployed V9.1 SP2 system is fully operational:
- Inspect controller diagnostic buffer: confirm zero I/O access faults or continuous time error interrupts (OB80).
- Open WinCC Runtime on all clients: verify that faceplate response time is sub-second and alarm logging records incoming process events.
- Test server redundancy: simulate a network disconnection on OS Server 1: confirm that OS Server 2 executes a bumpless takeover and clients switch without loss of visualization.
- Verify historical data logging: confirm that Process Historian or local Tag Logging archives record process variables into SQL database segments.

Limitations and Operational Precautions

• Do Not Re-Use Obsolete Communication Cables: When replacing legacy transceivers or AUI drop cables, replace old cabling with shielded Industrial Ethernet Cat6A cables to prevent packet dropouts.
• Firmware Verification Prior to Cutover: If retaining classic S7-400 CPUs, check CPU firmware revisions weeks before the turnaround. Upgrading CPU firmware requires memory cards and must not be delayed to cutover day.
• Redundant Server Activation Order: Always activate OS Server 1 first, wait for the project to reach full runtime status, and only then activate OS Server 2 to establish correct master-standby synchronization.

Engineer FAQ

Can I install PCS 7 V9.1 on Windows 7?

No. PCS 7 V9.1 and V9.1 SP2 strictly require 64-bit Windows 10 Enterprise LTSC (2019 or 2021) or Windows Server 2019. Windows 7 is completely unsupported.

Is it possible to keep the old V7.1 OS running while testing V9.1?

Yes. By pre-commissioning the new V9.1 engineering environment in a staging lab using virtual controllers (S7-PLCSIM), you can validate all graphics and logic without disturbing the operating V7.1 plant.

What should I do if a CP 1623 is not recognized by Windows 10?

Install the SIMATIC NET PC Software package supplied with the PCS 7 installation media. Ensure that the card is firmly seated in a compatible PCIe slot and that motherboard UEFI power management is configured correctly.

Can an S7-400 CPU running V7.1 code communicate with a V9.1 WinCC OS Server?

Yes. During staged migrations, an upgraded V9.1 WinCC OS Server can communicate with a CPU running older blocks over S7 communication, provided the S7 connection is compiled and downloaded.

Technical References

• Siemens Industry Online Support: SIMATIC PCS 7 Software Update with Migration Guides (V7.1 -> V8.2 and V8.2 -> V9.1).
• SIOS Entry 109742323: PCS 7 Compendium Part A - Configuration Guidelines (Section: Hardware and Software Upgrades).
• SIOS Entry 109809264: SIMATIC Process Control System PCS 7 Released Modules and Operating Systems.
• Siemens Manual: SIMATIC NET Industrial Communication with CP 1623 / CP 1628.

Related Articles

• Step-by-Step Software Migration Sequence for Upgrading PCS 7 V7.1 to V9.1 SP2
• How to Locate and Plan Official Migration Paths from PCS 7 V7.1 to V9.1 SP2
• How to Upgrade SIMATIC PCS 7 Software on Existing IPC Stations Without Buying New Hardware

Related Tags

• Hardware Migration
• SIMATIC IPC
• CP 1623
• PCS 7 V7.1
• PCS 7 V9.1
• Windows 10 LTSC
• Industrial Automation