Navigating SIMATIC PCS 7 Software Upgrade Documentation - With New Functions vs Without New Functions

When upgrading a SIMATIC PCS 7 system between major versions (such as from V8.0 to V8.1), Siemens provides two distinct, mutually exclusive migration manuals: 'Software Update without Utilization of New Functions' and 'Software Update with Utilization of New Functions'. The manual chosen dictates the engineering scope. The 'without new functions' path minimizes downtime by preserving existing block libraries and AS programs without requiring full block type updates or controller re-testing. Conversely, the 'with new functions' path upgrades the Advanced Process Library (APL), updates all block types, refreshes OS faceplates, and compiles the entire automation architecture to unlock new platform features.

The Two Fundamental PCS 7 Upgrade Methodologies

Engineers seeking upgrade instructions on the Siemens Industry Online Support (SIOS) technical portal often encounter confusion when searching for PCS 7 migration documentation. Rather than offering a single unified upgrade guide, Siemens intentionally splits software updates into two specialized manuals:

SIMATIC PCS 7 Software Update without Utilization of New Functions: Focuses on modernizing operating systems, engineering tools, and runtime software while keeping existing AS control programs untouched.
SIMATIC PCS 7 Software Update with Utilization of New Functions: Details the comprehensive migration of AS blocks, APL faceplates, CFC/SFC features, and system typicals to fully leverage the latest technological enhancements.

Understanding which path aligns with plant operational constraints is the critical first step in project planning.

Software Update Without Utilization of New Functions

This upgrade philosophy is specifically tailored for validated or operational production facilities (such as pharmaceutical, chemical, or continuous refining plants) where plant shutdown windows are minimal and extensive re-validation of control logic is cost-prohibitive:

Characteristics of the 'Without New Functions' Path

Preservation of AS Blocks: The existing Master Data Library blocks (such as APL V8.0 blocks) remain in the S7 program. Engineers do not run Update Block Types.
Minimizing AS Stop Requirements: Because block interfaces and internal structures remain identical, the AS program can be downloaded under Change in RUN (CiR) or does not require a full controller reload.
OS Compatibility Runtime: WinCC OS Servers and Clients are upgraded to the new version (e.g., WinCC V7.3 in PCS 7 V8.1), and project graphics are migrated using the WinCC Project Migrator. However, existing @PG_... faceplates and block icons from the previous library version continue to function via backward-compatible script runtimes.
Goal: Achieve software supportability, modern Windows OS compatibility, and hardware lifecycle renewal with the least operational disruption.

Software Update With Utilization of New Functions

This path is recommended during major turnaround turnarounds or plant expansions where the engineering team intends to utilize newly introduced PCS 7 features, updated APL algorithms, improved alarm management functions, and modern vector graphics:

Characteristics of the 'With New Functions' Path

Master Data Library Replacement: The project's Master Data Library is refreshed with the latest library blocks (e.g., upgrading from APL V8.0 SP2 to APL V8.1 SP1).
Central Block Type Update: The engineer executes Options -> Update Block Types across all S7 programs, which updates block algorithms and extends DB interfaces.
Regenerating Faceplates and Icons: Old @Template_APL.pdl and @PCS7Typicals_APL.pdl pictures are replaced with current versions. An OS Compile with Create/update block icons updates every process graphic.
Full Re-Testing: Because block interfaces change, an AS full compile and target reload are typically required, followed by comprehensive loop testing and safety re-certification.

Comparison Table - PCS 7 Upgrade Paths

The following table compares the two official Siemens software update paths across key engineering parameters.

Upgrade ParameterWithout Utilization of New FunctionsWith Utilization of New FunctionsPrimary Engineering ObjectiveFast upgrade, minimal risk, zero re-testingMaximum functionality, latest APL featuresAS Master Data LibraryRetains existing library versionsUpgraded to latest version-specific libraryExecution of 'Update Block Types'Prohibited (Blocks remain untouched)Mandatory across all multiproject AS programsWinCC Block Icons & FaceplatesRetains existing graphic typicalsReplaced and regenerated from new templatesPlant Downtime RequirementMinimal (Supports redundant OS rolling upgrade)Significant (May require AS STOP and loop validation)Qualification / Validation ImpactLow (Control logic algorithms unchanged)High (Requires full re-qualification of logic)Applicable Siemens ManualSoftware update without utilization...Software update with utilization...

Step-by-Step Navigation and Execution Guide

Follow this guide to locate official Siemens documentation and execute the selected upgrade path:

Locate Manuals on SIOS:
* Navigate to the Siemens Industry Online Support (SIOS) portal.
* Search for the exact publication title:
- SIMATIC Process Control System PCS 7 Software update without utilization of new functions (V8.1)
- SIMATIC Process Control System PCS 7 Software update with utilization of new functions (V8.1)
- Alternatively, in the PCS 7 electronic documentation installed with the engineering system, open SIMATIC Manager -> Help -> Documentation -> English and select the respective PDF.
Verify License Entitlements:
* Procure the official PCS 7 Upgrade Package (e.g., 6ES7658-2DF00-0YB0 or version-appropriate upgrade licenses).
* Upgrade existing licenses on the Engineering Station and OS Servers using Automation License Manager (ALM -> License Key -> Upgrade).
Archive Multiproject and Create Checkpoint:
* In SIMATIC Manager, perform a complete archive: File -> Archive -> Multiproject. Store on external media.
* Back up all WinCC OS project directories, SQL database archives, and user credentials.
Execute Upgrade Sequence:
* If upgrading Without New Functions:
1. Upgrade Windows OS and install PCS 7 V8.1.
2. Open Multiproject in SIMATIC Manager and run Project Migrator.
3. Run WinCC Project Migrator on OS Server and Client projects.
4. Compile OS without updating block icons.
  * If upgrading With New Functions:
5. Complete base software and OS installation.
6. Copy new APL blocks from the new PCS 7 library into the Master Data Library.
7. Execute Options -> Update Block Types.
8. Copy updated @PCS7Typicals_APL.pdl into OS project GraCS folders.
9. Perform full CFC compile and OS compile with block icon regeneration.

Verification

Confirm successful execution of the software update using the following checks:

Verify Software Versions:
* In SIMATIC Manager, open Help -> About -> Installed Software.
* Confirm that all components (STEP 7, CFC, SFC, WinCC, APL) reflect the target version (e.g., V8.1 SP1).
Verify License Status:
* Open Automation License Manager.
* Check all installed keys to confirm zero 'Missing License' alerts or temporary trial mode banners.
Verify OS Runtime Health:
* Launch WinCC Runtime on OS Servers and Clients.
* Open process pictures and confirm that block icons show live values without @ substitution errors.
* Click multiple technological blocks to verify that faceplates open promptly and operator commands execute normally.

Limitations and Operational Precautions

Never Mix Upgrade Paths Within a Project: Attempting to partially update some AS stations with new blocks while leaving others on old libraries within the same multiproject causes graphic typical conflicts in WinCC. Choose one methodology for the entire system.
License Upgrade Prerequisite: Upgrade licenses cannot be transferred onto target machines until base licenses are detected. Keep legacy license keys in ALM before applying the upgrade keys.
Firmware Validation: Verify that installed S7-400 CPU firmware is compatible with the new PCS 7 version before updating the software environment.

Engineer FAQ

Where can I find the direct link to the PCS 7 upgrade manuals?

On SIOS, enter search query 'Software update PCS 7 V8.1' and filter by 'Manual'. The technical overview pages for each PCS 7 release group all system documentation under the 'System Documentation' heading.

Can an AS stay in RUN mode during an upgrade with new functions?

Generally no. Updating block types modifies data block interfaces, which often exceeds the capacity of Change in RUN (CiR), requiring a CPU STOP to download the new block architectures.

Can I upgrade directly from PCS 7 V6.1 to V8.1 using these manuals?

No. Upgrading from legacy V6.1 requires a staged, multi-step migration path (V6.1 -> V7.1 SP4 -> V8.1). Direct jump migration across multiple major generations without intermediate database conversion is not supported.

What happens to custom faceplates during an upgrade with new functions?

If custom faceplates overwrite standard @PG_ files in the project GraCS directory, regenerating block icons or updating APL may overwrite them. Custom faceplates should always use unique variant names (e.g., @PG_MotSpdCL_Custom.pdl).