C135 PCS 7 (PCS7)
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Migration Roadmap: Upgrading Legacy SIMATIC PCS 7 Projects from V6.0/V6.1 to V8.1

Migration Roadmap: Upgrading Legacy SIMATIC PCS 7 Projects from V6.0/V6.1 to V8.1

To upgrade a legacy SIMATIC PCS 7 project from V6.0 or V6.1 to V8.1, engineers must follow a mandatory multi-step intermediate migration path, because a direct 1-step project conversion is not supported. The universal intermediate bridge release is SIMATIC PCS 7 V7.1 SP4. The verified migration workflow requires first upgrading the project from V6.0/V6.1 to V7.1 SP4 (converting database structures, hardware profiles, and graphics), followed by upgrading from V7.1 SP4 to V8.1 SP1. For industry-specific projects utilizing CEMAT (e.g., Holcim or standard minerals libraries), the project can be upgraded initially 'without utilization of new functions', allowing existing logic and blocks to run until the final PCS 7 V8.1 environment is established, at which point the CEMAT V8 upgrade package is applied.

Table of Contents

Why Direct Single-Step Upgrades from V6.x to V8.x Are Prohibited

Upgrading across two decades of process automation involves fundamental structural paradigm shifts:
* Operating System Evolution: PCS 7 V6.x operated on 32-bit Windows 2000 / Windows XP, whereas PCS 7 V8.1 operates on 64-bit Windows 7 SP1 / Windows Server 2008 R2 / 2012.
* Database Format Transformations: Internal project database schemas, Microsoft SQL Server versions (SQL 2000 -> SQL 2005 -> SQL 2008 R2), and Sybase/Microsoft access engines underwent complete redesigns.
* Library Generations: Transition from the legacy PCS 7 Standard Library to the modern Advanced Process Library (APL).

Attempting to open a V6.x project directly in PCS 7 V8.1 fails because the V8.1 database migrator lacks conversion filters for legacy V6.0/V6.1 Sybase metadata structures.

The Universal Intermediate Bridge Release: PCS 7 V7.1 SP4

Siemens established SIMATIC PCS 7 V7.1 SP4 as the official, certified intermediate migration bridge:

Step 1: Migration from V6.0 / V6.1 to V7.1 SP4

  1. Install PCS 7 V7.1 SP4 on an intermediate migration PC or virtual machine running Windows XP SP3 or Windows Server 2003.
  2. Retrieve the V6.x multiproject in SIMATIC Manager.
  3. Open the project: SIMATIC Manager automatically triggers database migration routines.
  4. Open HW Config and save/compile all AS racks and PC stations.
  5. In CFC, execute Options -> Block Types and re-read block types.
  6. Open each WinCC OS project to convert the WinCC database from SQL Server 2000 to SQL Server 2005 format.
  7. Archive the successfully converted V7.1 SP4 project.

Step 2: Migration from V7.1 SP4 to V8.1 SP1

  1. Transfer the archive to the final PCS 7 V8.1 SP1 Engineering Station (running Windows 7 64-bit).
  2. Retrieve the project in SIMATIC Manager V8.1.
  3. Run the OS Migrator to upgrade the WinCC project to SQL Server 2008 R2.
  4. Execute OS Project Editor on all OS projects to update standard screens and scripts.

Upgrade Strategies: With vs Without Utilization of New Functions

Engineers must choose between two contractual upgrade philosophies:

1. Upgrade 'Without Utilization of New Functions' (Fastest & Lowest Risk)

  • Retains existing controller code, interlocks, and Classic Library blocks in the AS controllers.
  • Upgrades the engineering tools, OS servers, and operator stations to modern hardware and Windows versions.
  • AS code can be downloaded without altering block interfaces or rewriting logic.
  • Highly recommended for operating plants with limited shutdown windows.

2. Upgrade 'With Utilization of New Functions' (Modernization)

  • Converts all legacy blocks to the Advanced Process Library (APL).
  • Requires replacing block icons on all .pdl graphics, rewiring faceplate connections, and extensive loop re-testing.
  • Typically executed during major plant turnarounds or revamps.

Special Considerations for Industry Add-ons: CEMAT Migration

For cement, mining, and minerals plants running the CEMAT library (e.g., CEMAT V6.1 for Holcim):

  • Software Upgrade Package (Order No. 6DL5430-8AX18-0XE0): Allows upgrading CEMAT licenses from V6.1 directly to V8.x.
  • Block Migration Sequence:
  • During the intermediate migration to V7.1, do not update CEMAT block types; allow the existing V6.x blocks to be migrated as legacy objects.
  • Once the project is opened in PCS 7 V8.1, install the CEMAT V8.1 library package.
  • In SIMATIC Manager, update CEMAT block types in the master data library and execute the CEMAT OS Project Update to deploy new faceplates and scripts.
  • This ensures that plant logic remains consistent throughout the intermediate conversion steps.

PCS 7 Version Upgrade Path and Operating System Matrix

The following table outlines the sequential migration roadmap and required engineering operating systems:

Migration StageSource VersionTarget VersionEngineering OSDatabase TransitionStep 1 (Bridge)PCS 7 V6.0 / V6.1PCS 7 V7.1 SP4Windows XP SP3 / Server 2003SQL 2000 -> SQL 2005Step 2 (Target)PCS 7 V7.1 SP4PCS 7 V8.1 SP1Windows 7 SP1 64-bit / Server 2008 R2SQL 2005 -> SQL 2008 R2Subsequent StepPCS 7 V8.1 SP1PCS 7 V9.0 / V9.1Windows 10 Enterprise / Server 2016SQL 2008 R2 -> SQL 2014 / 2016

Adhering to this phased sequence prevents database corruption and preserves project history.

Verification

To verify successful multi-version project migration:
1. Open the migrated project in SIMATIC Manager V8.1; verify that all AS stations, OS projects, and libraries open cleanly without conversion error prompts.
2. In CFC, execute Options -> Check Consistency; confirm zero structural errors.
3. In HW Config, compile all hardware configurations; confirm that all legacy and upgraded modules are recognized.
4. Open WinCC Explorer for the OS project; confirm that the project database attaches cleanly in SQL Server 2008 R2.
5. In Graphics Designer, open several process pictures; verify that block icons and faceplates render without missing script warnings.

Limitations and Operational Precautions

  • Never attempt to skip the intermediate V7.1 SP4 bridge; direct conversion from V6.x to V8.x results in unrecoverable database errors.
  • Legacy hardware modules (e.g., older CP cards or obsolete ET 200M modules) reaching PM490 discontinuation must be audited for V8.1 compatibility in HW Config.
  • Back up the original V6.x multiproject to write-protected external storage before initiating migration.
  • Always validate final license quantities, upgrade packages, and MLFBs against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Can I upgrade directly from PCS 7 V6.1 to V8.0 instead of V8.1?

No. Whether targeting V8.0, V8.1, or V8.2, the intermediate upgrade to V7.1 SP4 is mandatory for all projects originating on V6.x.

What happens to existing WinCC historical archive data during the upgrade?

Historical archives from WinCC V6.x cannot be directly attached to WinCC V8.x. Historical data must be exported or archived to an external repository prior to migration.

Do I need to buy full new licenses or upgrade licenses?

Siemens provides cost-effective Upgrade Packages (e.g., Upgrade from V6.x to V8.x) that update existing license keys in Automation License Manager at a fraction of full package cost.

Technical References

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Related Tags

  • PCS 7 Upgrade
  • V6.1 to V8.1 Migration
  • Intermediate Bridge V7.1
  • CEMAT Upgrade
  • Database Migration
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