C135 PCS 7 (PCS7)
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How to Locate and Apply the Official Migration Procedure for PCS 7 V9.1 SP2

How to Locate and Apply the Official Migration Procedure for PCS 7 V9.1 SP2

To execute a software update or migration to SIMATIC PCS 7 V9.1 SP2, engineers must follow one of two dedicated Siemens migration manuals published on Siemens Industry Online Support (SIOS): 'Software Update with Utilization of Existing Hardware' (Entry ID 109814424) or 'Software Update with New Hardware' (Entry ID 109814425). PCS 7 V9.1 SP2 supports direct project migration without intermediate versions only from PCS 7 V8.2, V9.0, or V9.1; older systems running PCS 7 V7.1 or V8.0 must first be upgraded to V8.2. The migration workflow requires updating operating systems to Windows 10 LTSC 2019 or Server 2019, migrating the multiproject structure, updating CFC block types, converting OS project graphics, and performing a sequential OS server download.

Table of Contents

Official Siemens Migration Documentation Structure

Siemens structures PCS 7 software update documentation into two distinct guides depending on physical plant infrastructure:

  1. Software Update with Utilization of Existing Hardware (SIOS Entry ID 109814424):
    - Applies when retaining installed Industrial PCs, controllers, and fieldbuses.
    - Focuses on clean operating system installations, driver updates, and in-place database conversions.
  2. Software Update with New Hardware (SIOS Entry ID 109814425):
    - Applies when staging a parallel plant upgrade using new IPCs (such as IPC547J / IPC847E) or upgrading controllers to the CPU 410-5H.
    - Details network side-by-side commissioning, export/import of historical archives, and minimized operational changeover windows.

Attempting to migrate without these manuals risks database corruption, orphaned block instances, and runtime compiler deadlocks.

Supported Direct Migration Paths and Intermediate Milestones

A common engineering misconception is that any legacy PCS 7 project can be opened and converted directly into PCS 7 V9.1 SP2:

Source VersionDirect Upgrade to V9.1 SP2?Required Intermediate StepsPCS 7 V9.1 / V9.1 SP1Yes (Direct)Install Service Pack 2; no database schema conversion required.PCS 7 V9.0 / V9.0 SP1/SP2/SP3Yes (Direct)Direct migration supported; run OS Project Migrator.PCS 7 V8.2 / V8.2 SP1Yes (Direct)Direct migration supported; requires APL library update.PCS 7 V8.0 / V8.1NoMust first migrate to PCS 7 V8.2 SP1 before migrating to V9.1 SP2.PCS 7 V7.0 / V7.1NoTwo-step migration: Upgrade to V8.0/V8.2, then upgrade to V9.1 SP2.

Migrating directly from V7.x or V8.0 to V9.1 SP2 causes project conversion utilities to fail because internal database tables and CFC chart formats evolved significantly between versions.

Hardware Preservation vs. Hardware Replacement Workflows

Choosing whether to preserve or replace hardware determines the upgrade path:
* Preserving Hardware: Requires wiping the primary drive of each station, installing Windows 10 Enterprise LTSC 2019 (Clients/ES) or Windows Server 2019 (Servers), and installing PCS 7 V9.1 SP2 from scratch. Existing licenses are converted using Software Upgrade Packages.
* Replacing Hardware: Allows pre-staging the entire V9.1 SP2 system in an engineering workshop. The legacy system continues operating the plant while the new system is fully compiled, verified against SIMIT simulation, and tested before physical cutover.

Method: Step-by-Step Multiproject Migration Sequence

Follow this sequence from Siemens Entry ID 109814424 to migrate a multiproject to PCS 7 V9.1 SP2:

  1. Pre-Migration Preparations (Source System):
    - In SIMATIC Manager, perform a full archive of the multiproject (File > Archive).
    - Run Options > Shared Declarations > Check Consistency.
    - Read and record active controller license allocations via Options > Process Objects.
  2. Project Retrieval on V9.1 SP2 Engineering Station:
    - On the newly prepared PCS 7 V9.1 SP2 Engineering Station, select File > Retrieve and open the archived multiproject.
    - When prompted to convert the project database to the new format, click Yes.
  3. Updating Block Libraries and CFCs:
    - Copy updated block types from the PCS 7 V9.1 SP2 Advanced Process Library (APL) into the master data library.
    - Select Options > Charts > Update Block Types to propagate updated algorithms, status words, and feature bits across all CFC charts.
    - Compile all CFC charts selecting Scope: Entire Program with Generate SCL source.
  4. Migrating the OS Projects:
    - In SIMATIC Manager, open each WinCC OS project. The OS Project Migrator launches automatically.
    - Confirm migration of the database schema (SQL Server 2016).
    - In WinCC Explorer, open the OS Project Editor and click OK to apply updated V9.1 SP2 system picture templates (@Screen.pdl, @Buttons.pdl).
  5. Compiling and Downloading OS:
    - Right-click the OS project in SIMATIC Manager and select Compile OS (Scope: Entire OS).
    - Open Simatic Shell and download server data to the redundant OS Server pair.

Verification

To verify that the migration to PCS 7 V9.1 SP2 is complete and validated:

  1. In SIMATIC Manager, select Options > Version Cross Manager (VXM). Compare the migrated project against the pre-migration archive to verify that no functional logic was unintentionally altered.
  2. In the CFC editor, verify that compilation reports 0 Errors, 0 Warnings.
  3. Open WinCC Runtime on an OS Server. Verify that the title bar displays SIMATIC WinCC V7.5 SP2 Upd... (PCS 7 V9.1 SP2).
  4. Verify that process faceplates open, horn alarm bells sound upon new trip events, and historical trends retrieve data from the new SQL Server database.

Limitations and Operational Precautions

  • CPU Firmware Compatibility: PCS 7 V9.1 SP2 requires minimum firmware baselines for S7-400 and AS 410 controllers (AS 410 requires Firmware V8.2.2 or higher). Check controller firmware before attempting to download migrated programs.
  • Discontinued Hardware: Legacy I/O modules (such as older ET 200M modules or third-party PROFIBUS DP slaves) may lack updated device drivers in V9.1 SP2. Review the PCS 7 V9.1 SP2 Released Modules catalog before upgrading.
  • AS Stop Requirement for Major Library Jumps: If migrating from the Standard Library to APL, or jumping multiple major APL releases, an Automation System restart (CPU STOP) is mandatory to initialize new block instance data.

Engineer FAQ

Where can I download the official PCS 7 V9.1 SP2 migration manuals?
Navigate to Siemens Industry Online Support (support.industry.siemens.com) and search directly for Entry IDs 109814424 (Existing Hardware) and 109814425 (New Hardware).

Can I migrate from PCS 7 V9.1 SP1 to V9.1 SP2 without stopping the plant?
Yes. Minor service pack updates within V9.1 support redundant OS server runtime updates and AS Configuration in Run (CiR) downloads without interrupting plant production.

Does PCS 7 V9.1 SP2 support Windows 11?
No. PCS 7 V9.1 SP2 is validated and supported strictly on Windows 10 Enterprise LTSC 2019 and Windows Server 2019. Windows 11 support was introduced in PCS 7 V10.0.

Technical References

  • Siemens Industry Online Support Entry ID 109814424: SIMATIC Process Control System PCS 7 Software Update with Utilization of Existing Hardware (V9.1 SP2)
  • Siemens Industry Online Support Entry ID 109814425: SIMATIC Process Control System PCS 7 Software Update with New Hardware (V9.1 SP2)
  • Siemens Industry Online Support Entry ID 109809264: Software update without utilization of the new functions in SIMATIC PCS 7

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Related Tags

  • https://industrialautomation.net/search?query=simatic+pcs7
  • https://industrialautomation.net/search?query=migration
  • https://industrialautomation.net/search?query=software-update
  • https://industrialautomation.net/search?query=apl
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