How to Track and Manage Phased-Out SIMATIC PCS 7 Hardware Modules Lacking Direct Successors

To track and manage SIMATIC PCS 7 hardware modules undergoing phase-out without a direct 1:1 successor product, utilize the Siemens Industry Online Support (SIOS) product lifecycle portal and mySupport notification filters. In the SIOS portal, query specific module MLFBs to inspect their Milestone status: PM400 (Phase-out Announcement, 10-year spare parts warranty begins), PM410 (Product Cancellation, available primarily as spare parts), PM490 (Discontinuation), and PM500 (End of Service). When no successor MLFB is designated in the product milestone notification, engineers must consult the PCS 7 Compendium Part D (Operation and Maintenance) to select an engineered migration architecture—such as migrating ET 200M distributed racks to ET 200SP HA or ET 200MP, replacing point-to-point communication processors with Industrial Ethernet gateways, or implementing modern fieldbus proxies. Always validate procurement and replacement availability with an authorized Siemens distributor.

Siemens Product Lifecycle Milestones and Phase-Out Framework

Siemens manages all industrial automation hardware and communication processors through a standardized product lifecycle framework consisting of five primary milestones:

PM300 (Active Delivery Release): The product is in full mass production and actively supported across current SIMATIC PCS 7 software versions.
PM400 (Product Phase-Out Announcement): Siemens announces that normal commercial promotion has ceased. The product remains orderable as a standard new component for approximately one year, and Siemens initiates a 10-year spare parts availability commitment.
PM410 (Product Cancellation): The module is no longer supplied as a standard production item. Deliveries occur primarily on an exchange/spare parts basis, often subject to a spare parts pricing surcharge.
PM490 (Product Discontinuation): Complete cessation of manufacturing. Spare parts are available only while remaining factory warehouse stocks last.
PM500 (End of Product Lifecycle): Complete legal, technical, and commercial discontinuation. No technical support or replacement hardware is guaranteed.

When a module reaches PM400 without a direct plug-and-play successor MLFB, it indicates that architectural modernization or subsystem redesign is required to preserve plant availability.

Configuring SIOS mySupport Tracking and Phase-Out Notifications

To track impending module obsolescence automatically across an installed base:

Navigate to the Siemens Industry Online Support portal (https://support.industry.siemens.com).
Log into your mySupport user account.
Access mySupport Cockpit and navigate to Notifications / Filter Settings.
Create a dedicated notification profile:
* Under Product Selection, enter the exact MLFBs of all installed legacy controllers, communication modules (e.g., 6GK7443-1EX30-0XE0), and I/O families (e.g., 6ES7321-1BL00-0AA0).
* Select Notification Types: Check Product News, Phase-Out Notifications (PM400/PM410), and Product Discontinuation (PM490).
* Configure delivery frequency to weekly or monthly digest emails.
Utilize the SIOS search bar to query any specific MLFB and inspect the Product Details pane. The product status tab displays current milestone dates and explicitly lists the recommended functional successor MLFB if one exists.

Engineering Migration Strategies for Modules Lacking Direct Successors

When a legacy module has no 1:1 successor, process engineers must implement one of three migration strategies:

1. Distributed I/O Subsystem Migration

Legacy ET 200M (6ES7153-2BA10-0XB0) interface modules and S7-300 signal modules reaching end-of-life are transitioned to modern ET 200SP HA or ET 200MP stations. ET 200SP HA provides native PROFINET redundancy, push-in terminal blocks, compact footprints, and full SIMATIC PCS 7 Advanced Process Library (APL) driver generator support.

2. Communication Interface Modernization

Legacy point-to-point interface processors (e.g., CP 441-2, CP 341) communicating via Modbus RTU or ASCII are replaced by Industrial Ethernet communication processors (e.g., CP 443-1 6GK7443-1EX30-0XE0) coupled with external Modbus TCP/RTU field gateways, or modern remote I/O serial communication modules.

3. Maintaining Strategic Spare Parts Inventories

For critical continuous process lines where control cabinet rewiring is impossible without a major shutdown, establish a strategic buffer stock during the PM400 phase-out window before PM410 cancellation surcharges take effect.

Hardware Lifecycle Milestone Reference and Migration Matrix

The following table summarizes the Siemens hardware lifecycle milestones, commercial implications, and architectural resolution paths:

Milestone CodeMilestone DesignationSpare Parts AvailabilityCommercial & Operational ImpactRecommended Engineering ActionPM300Active DeliveryUnlimited new supplyStandard catalog pricingStandard engineering and maintenancePM400Phase-Out Announced10-year spare part commitment beginsNormal lead times; 1-year window for final purchasesConduct plant audit; procure spare parts bufferPM410Product CancellationExchange/repair basis onlySpare part surcharges; potential supply lead timesPlan subsystem upgrade to ET 200SP HA / PROFINETPM490DiscontinuationWarehouse stock only; no remanufacturingRisk of stockouts; secondary market relianceExecute migration; replace legacy racks and bus linksPM500End of ServiceNonePlant unavailability risk during hardware faultsDecommission module; complete system modernization

Always validate final spare parts availability and upgrade hardware schedules against current manufacturer catalogs with an authorized Siemens distributor.

Verification

To verify that obsolete hardware tracking and replacement plans are properly established:
1. Open the SIOS mySupport dashboard and verify that all registered legacy MLFBs have active notification subscriptions.
2. Confirm that a simulated or recent SIOS search for an installed module displays its accurate current lifecycle status (e.g., PM400 or PM410).
3. Review plant maintenance records to confirm that critical modules without successors have verified spare units stored in climate-controlled spare parts facilities.
4. In SIMATIC PCS 7 HW Config, verify that proposed replacement modules (e.g., ET 200SP HA interface modules) are fully supported in the installed PCS 7 version and library catalog.

Limitations and Operational Precautions

Never procure unverified surplus modules from unauthorized third-party brokers without confirming firmware compatibility and hardware release revisions.
Hardware Upgrade Packages (HUPs) must be officially released for your specific PCS 7 version before attempting to configure newly released hardware in HW Config.
Transitioning from ET 200M to ET 200SP HA requires architectural planning for PROFINET network infrastructure, switch configurations, and field wiring adaptations.
Always validate final license quantities, module availability, and MLFBs against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

How long does Siemens guarantee spare parts availability after PM400 announcement?

Siemens commits to spare parts availability for 10 years following the PM400 phase-out announcement, although pricing typically increases once PM410 cancellation takes effect.

Can I use standard STEP 7 Hardware Support Packages (HSPs) in SIMATIC PCS 7?

No. In SIMATIC PCS 7, only officially validated Hardware Upgrade Packages (HUPs) may be installed. Standard STEP 7 HSPs can break driver wizard generation and cause compilation faults.

Where can I find published phase-out letters for SIMATIC PCS 7 components?

Siemens publishes phase-out notices under the 'Product News' category on the Siemens Industry Online Support (SIOS) website, filterable by product family and milestone code.