Migration Roadmap and Licensing Requirements from PCS 7 V6.0 SP2 to V9.0 SP1

Upgrading a SIMATIC PCS 7 system directly from V6.0 SP2 HF1 to V9.0 SP1 is technically impossible in a single engineering step; it requires a multi-stage migration path through intermediate versions (V6.0 SP2 -> V7.1 SP4 -> V8.2 SP1 -> V9.0 SP1). Furthermore, Siemens does not offer direct upgrade license packages spanning three generational leaps, requiring the procurement of new full engineering, runtime, and AS/OS Process Object licenses. Existing CP 1613 PCI network cards must be replaced with CP 1623 (PCIe) or standard Intel Gigabit adapters running SOFTNET-IE, and legacy standard library blocks must be migrated to the Advanced Process Library (APL) or supplemented with the PCS 7 Basis Library migration package.

Generational Architecture Gap: V6.0 to V9.0 SP1

Migrating a PCS 7 installation from V6.0 SP2 HF1 (circa 2004, running Microsoft Windows 2000 / XP) to PCS 7 V9.0 SP1 (running Microsoft Windows 10 Enterprise LTSB / Windows Server 2016) represents a 14-year technology transition. Key architectural gaps include:

Operating System & SQL Architecture: Transition from Windows 2000 / XP 32-bit with Microsoft SQL Server 2000 to Windows 10 / Server 2016 64-bit with Microsoft SQL Server 2014 SP2.
Engineering Database Structures: Legacy CFC/SFC databases and WinCC Sybase/SQL database structures cannot be parsed directly by the V9.0 SP1 project migrator.
Controller Libraries: PCS 7 V6.0 utilized the legacy SIMATIC PCS 7 Standard Library. PCS 7 V9.0 relies on the Advanced Process Library (APL). While legacy blocks can run in V9.0 using the PCS 7 Basis Library migration package, full modernization requires an AS library exchange.
Hardware Communication Interfaces: Legacy CP 1613 communications processors use the 5V PCI bus architecture, which is physically incompatible with modern IPC PCIe bus architectures.

Multi-Step Intermediate Migration Strategy

A successful migration requires intermediate staging engineering environments:

Stage 1: PCS 7 V6.0 SP2 -> PCS 7 V7.1 SP4 (Windows XP):
- Perform database reorganization and project integrity checks in V6.0.
- Open the project in PCS 7 V7.1 SP4. The WinCC Project Migrator converts WinCC V6.0 graphics and alarms to WinCC V7.0.
- CFC/SFC data structures are converted to V7.1 database formats.
Stage 2: PCS 7 V7.1 SP4 -> PCS 7 V8.2 SP1 (Windows 7 / Server 2008 R2):
- Migrate project from V7.1 to V8.2. WinCC databases are converted from SQL Server 2005 to SQL Server 2008 R2.
- Decide whether to execute library migration (Standard Library to APL) or retain legacy blocks using the PCS 7 Basis Library V8.2.
- Convert OS faceplates and compile the OS.
Stage 3: PCS 7 V8.2 SP1 -> PCS 7 V9.0 SP1 (Windows 10 / Server 2016):
- Open and convert the project in PCS 7 V9.0 SP1.
- Update hardware configurations: replace CP 1613 with CP 1623 or SOFTNET-IE; verify S7-400 CPU firmware compatibility (V5.3 minimum required; older CPUs require hardware replacement or CPU 410-5H upgrade).
- Execute full CFC compilation and OS compilation with memory reset.

Hardware Replacement and Network Card Transition Matrix

The following table summarizes the mandatory hardware transitions required when moving from V6.0 to V9.0 SP1:

Hardware ComponentLegacy V6.0 SP2 InstallationTarget V9.0 SP1 ModernizationReplacement Order Number (MLFB)ES / OS PC HardwareLegacy Industrial PC (PCI slots, 32-bit)SIMATIC IPC547G / IPC647D (64-bit)6ES7660-... / 6ES7661-...Communications ProcessorCP 1613 (Legacy 5V / 3.3V PCI)CP 1623 (PCI Express x1) or SOFTNET-IE6GK1162-3AA00 (CP 1623)AS Controller (CPU)S7-414-3 / S7-417-4 (Firmware < V4.0)Firmware Upgrade to V5.3+ or CPU 410-5H6ES7410-5HX08-0AB0 (CPU 410-5H)Distributed Field I/OET 200M IM 153-1 / IM 153-2ET 200M (V5.0+) or ET 200SP HA6ES7153-2BA10-0XB0 / 6DL1155-6AU00-0PM0Network SwitchesOSM / ESM Optical SwitchesSCALANCE X-200 / X-300 / XC-2006GK5208-0BA00-2AC2 (XC208)

Software Licensing and Process Object Transition Rules

Because direct upgrade licenses from V6.x to V9.x do not exist in the Siemens catalog, licensing must be handled as follows:

Engineering System (ES): Procure a new full license for SIMATIC PCS 7 Engineering Station V9.0 SP1 (6ES7658-5AX58-0YA5).
Operator Stations (OS): Procure new full licenses for OS Single Station Runtime V9.0 SP1 (6ES7658-2AA58-0YA0) or Server/Client packages.
Process Object (PO) Counting Rules: PCS 7 V6.0 utilized legacy tag/variable licensing or early PO packages. PCS 7 V9.0 enforces strict runtime PO accounting:
AS RT PO: Consumed by technological blocks in the CPU (e.g., motors, valves, controllers).
OS RT PO: Consumed by wincc operator objects.
The user must calculate total AS RT and OS RT POs and purchase matching PO expansion packs (6ES7653-2BA00-0XB5).

[!NOTE]
Commercial Accuracy Guardrail: Siemens software order numbers (MLFBs) and Process Object calculations must be verified against Siemens Catalog ST PCS 7 and quoted through an authorized distributor. Staged intermediate software used solely for migration conversions may be requested via Siemens Technical Support migration loan services.

Verification

Verify the multi-stage migration result:
1. Open the migrated project in PCS 7 V9.0 SP1 SIMATIC Manager. Perform Options -> Reorganize and verify 0 database errors.
2. Open HW Config for AS1 and AS2. Verify that network interfaces and CPU models pass consistency check (Station -> Check Consistency).
3. Perform a full CFC compilation with Generate Module Drivers checked. Confirm compilation completes without syntax errors.
4. Open WinCC Explorer, verify that the WinCC Project Migrator log indicates successful migration of all PDL graphic screens and alarm configurations.
5. Start WinCC Runtime in a test environment or S7-PLCSIM to verify tag communication and faceplate functionality.

Limitations and Operational Precautions

No Direct Jump: Skipping intermediate migration stages corrupts the CFC chart database, leading to missing block instances and unrecoverable chart links.
Driver Replacement: Legacy PCS 7 V6.0 channel driver blocks (CH_AI, CH_DI) are obsolete. They must be replaced with PCS 7 Basis Library or APL channel drivers (Pcs7AnIn, Pcs7DiIn).
Plant Shutdown Requirement: A migration of this magnitude requires complete controller and server replacement during a planned plant turnaround; online migration in RUN is impossible.

Engineer FAQ

Can I buy an upgrade license from PCS 7 V6.0 directly to V9.0 SP1?

No. Siemens upgrade packages only cover upgrades from the immediately preceding generation (e.g., V8.x to V9.0). Upgrades from V6.0 require purchasing new full V9.0 licenses.

Can existing CP 1613 cards be reused in new Windows 10 computers?

No. CP 1613 uses a legacy PCI interface that is physically and electrically incompatible with modern PCIe slots and lacks 64-bit Windows 10 drivers. Replace with CP 1623 or SOFTNET-IE.

Do I have to convert all logic blocks to APL when migrating to V9.0?

Not immediately. By installing the legacy PCS 7 Basis Library V8.2 / V9.0 migration package, legacy standard library blocks can continue to run in the controller, though modernizing to APL is recommended.

Where can I obtain intermediate versions like PCS 7 V7.1 and V8.2 for migration?

Intermediate installation media and temporary migration authorization licenses can be requested through your local Siemens Technical Sales Representative or Siemens Technical Support.