Migrating SIMATIC Route Control from PCS 7 V7.1 SP1 to V8.2: Intermediate Steps and Database Upgrade Strategies

A direct, one-step migration from SIMATIC Route Control (RC) V7.1 SP1 to V8.2 is not supported by standard Siemens setup wizards because the underlying software architectures span major generational leaps in Windows OS (32-bit to 64-bit), Microsoft SQL Server (2005 to 2014), and database schemas. To successfully migrate Route Control across this gap, engineers must utilize an intermediate migration step—typically PCS 7 V8.0 SP2 or V8.1. The workflow requires converting the STEP 7 multiproject and Route Control Wizard configuration in the intermediate environment, upgrading the Route Control Center (RCC) database schema, updating the AS library blocks to RC V8.2, and applying RC upgrade licensing.

Generational Architecture Gap: Route Control V7.1 SP1 vs V8.2

SIMATIC Route Control (RC) is the PCS 7 optional software package responsible for dynamic routing, pathfinding, and element control (valves, pumps, pipes, tanks) in liquid and solids transport systems. Migrating an existing plant from PCS 7 V7.1 SP1 to V8.2 represents a generational technological leap:

Operating System Transition: PCS 7 V7.1 SP1 ran exclusively on 32-bit platforms (Windows XP Professional SP3 / Windows Server 2003 R2). PCS 7 V8.2 runs exclusively on 64-bit platforms (Windows 7 Enterprise SP1 64-bit / Windows Server 2012 R2 Standard 64-bit).
Database Engine Transition: Route Control V7.1 relied on Microsoft SQL Server 2005. Route Control V8.2 relies on Microsoft SQL Server 2014 SP1. Direct in-place database schema attachment across three SQL generations is rejected by the Microsoft SQL engine.
Route Control Server Architecture: The internal IPC and COM/DCOM interfaces between the Route Control Server (rcs_server.exe) and WinCC were completely rewritten between V7.1 and V8.2 to support modern 64-bit security contexts.

Why Direct Migration Is Not Documented in Single Manuals

Engineers attempting this migration frequently search for a dedicated guide titled 'How to Migrate Route Control V7.1 SP1 to V8.2' and find none. Siemens product documentation for optional packages (Route Control, SIMATIC BATCH, CEMAT) intentionally documents only n-1 to n upgrades (e.g., V8.1 to V8.2). Multi-version jumps across major OS and software paradigms are covered by the comprehensive system upgrade manuals:

PCS 7 Software Update with Utilization of New Functions (Entry ID: 109736706)
PCS 7 Software Update without Utilization of New Functions (Entry ID: 109736696)

These system guides establish the mandatory prerequisite of bridging generational database gaps through an intermediate software version.

The Recommended Multi-Step Migration Route (V7.1 -> V8.0/8.1 -> V8.2)

To safely bridge the database and OS gap, the industry-standard migration pathway employs an intermediate engineering VM:

Phase 1: Project Archive in V7.1 SP1: Perform a complete archive of the STEP 7 multiproject including Route Control data. Export the Route Control database (*.rcd or SQL backup) from Route Control Engineering.
Phase 2: Intermediate Upgrade in PCS 7 V8.0 SP2 or V8.1:
- Restore the project onto an intermediate 64-bit engineering station running PCS 7 V8.0 SP2 (SQL Server 2008 R2) or V8.1 (SQL Server 2014).
- Open SIMATIC Manager and allow STEP 7 to execute the internal project format conversion.
- Open Route Control Engineering and execute the Route Control Wizard. The wizard converts legacy V7.1 route configurations and updates the internal database schema to V8.x format.
- Compile and save the multiproject.
Phase 3: Final Upgrade in PCS 7 V8.2:
- Transfer the upgraded project to the final PCS 7 V8.2 Engineering Station.
- Run the Route Control Wizard in V8.2 to finalize the project structure.

Route Control Engineering and Database Schema Conversion

During the Route Control upgrade process, the internal engineering database undergoes critical transformations:

Route Control Wizard Execution: In SIMATIC Manager, right-click the project and select SIMATIC Route Control -> Configure. The wizard validates that all Route Control elements (locations, partial routes, elements, modes) conform to the new relational database constraints.
Route Control Center (RCC) Views: The graphical client layouts in Route Control Center are converted to modern OCX controls compatible with WinCC V7.4.
Consistency Check: Run Options -> Consistency Check inside Route Control Engineering. Resolve any orphaned locations or deprecated signal linkages before proceeding to AS compilation.

AS Block Library Updating and OS Client-Server Synchronization

Once the engineering database is converted, the controller and operator station tiers must be aligned:

Master Data Library AS Blocks: Replace the legacy Route Control V7.1 blocks in your Master Data Library with the updated blocks from the PCS 7 Route Control Library V8.2 (RC_IF_CFG, RC_ROUTE, RC_PE, RC_SE).
Update Block Types: In SIMATIC Manager, execute Options -> Charts -> Update Block Types across all target AS programs. This updates block interfaces while preserving existing parameter interconnections.
OS Server Data and WinCC Controls: In the OS Server WinCC projects, re-run the OS Project Editor to update Route Control system pictures and scripts (@RC_*.pdl). Re-generate and load server packages onto all OS Clients.

Comparative Upgrade Matrix: Route Control Across PCS 7 Generations

The following table compares Route Control system requirements across versions:

System PropertyRoute Control V7.1 SP1Route Control V8.0 SP2 (Intermediate)Route Control V8.2 (Target)Host Operating SystemWindows XP / Server 2003 (32-bit)Windows 7 / Server 2008 R2 (64-bit)Windows 7 / Server 2012 R2 (64-bit)Microsoft SQL ServerSQL Server 2005 Standard (32-bit)SQL Server 2008 R2 Standard (64-bit)SQL Server 2014 SP1 Standard (64-bit)Direct Upgrade PathDirect to V8.0 / V8.1Direct to V8.2End StateAS Library CompatibilityRC Library V7.1 (S7-300 / S7-400)RC Library V8.0 (S7-400 only)RC Library V8.2 (S7-400 / CPU 410-5H)WinCC IntegrationWinCC V7.0 SP1 OCX controlsWinCC V7.2 ControlsWinCC V7.4 Modern ControlsLicense RequirementRC V7.1 Base + RoutesRC V8.0 Upgrade LicenseRC Upgrade Package V7.1 -> V8.x

Verification

Validate successful Route Control migration through the following steps:

In SIMATIC Manager on PCS 7 V8.2, open Route Control Engineering and verify that all routes, partial routes, and elements load without database error prompts.
Execute Route Control -> Compile and Download to AS and verify 0 errors in the compilation log.
Perform an OS Compilation and download to the Route Control Server.
Launch Route Control Center (RCC) in WinCC Runtime and verify that the server connects, displaying all locations with live dynamic states.
Execute a test route request from source to destination; verify pathfinding, valve alignment, and route start sequencing.

Limitations and Operational Precautions

Adhere to the following migration precautions:

Never Attempt Direct SQL Attachment: Never copy the raw SQL database files from V7.1 directly into SQL Server 2014; the schema version mismatch will corrupt the Route Control catalog.
Commercial Upgrade Licensing: Upgrading to RC V8.2 requires Siemens upgrade licenses (e.g. SIMATIC Route Control Upgrade Package V7.1 -> V8.x). Confirm routes capacity licenses in Automation License Manager prior to site commissioning.
S7-300 Controller Support: Note that Route Control V8.2 phased out legacy S7-300 block execution; route control blocks must reside in S7-400 or CPU 410-5H controllers.

[!NOTE]
Commercial Accuracy Disclaimer: Software order numbers (MLFBs), package structures, and hardware capacity prerequisites vary across PCS 7 versions > and hardware platforms. System integrators must confirm exact software entitlements and licensing requirements against the official Siemens > Catalog CA 01 and obtain an authorized Siemens distributor quotation prior to purchasing.

Engineer FAQ

Are my existing Route Control route counts and license tags preserved during the upgrade?

Yes, but you must procure the official Siemens Route Control Upgrade License package to authorize the existing route capacity on PCS 7 V8.2.

Can I run Route Control V8.2 on an S7-300 controller?

No. Route Control V8.2 requires execution in S7-400 or CPU 410-5H controllers; legacy S7-300 controllers running RC V7.1 must be upgraded or interfaced as external I/O.

Do I need to re-enter all partial routes and plant elements in Route Control Engineering?

No. Running the Route Control Wizard in the intermediate and target versions converts all existing elements, partial routes, and control strategies automatically.