C135 PCS 7 (PCS7)
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Operating System Migration Pathways and Clean Install Rules for SIMATIC PCS 7 V9.1 Upgrades

Operating System Migration Pathways and Clean Install Rules for SIMATIC PCS 7 V9.1 Upgrades

When upgrading a SIMATIC PCS 7 installation from V9.0 to V9.1, Siemens strictly mandates performing a clean installation of the operating system (Windows 10 Enterprise LTSC 2019 for OS Clients/ES and Windows Server 2019 Standard/Datacenter for OS Servers). Performing an in-place Windows operating system upgrade on an existing PCS 7 computer irreparably corrupts Microsoft SQL Server instances (WINCC and WinCCPLUS), invalidates SIMATIC security group allocations, breaks DCOM permissions, and leaves residual registry entries that cause runtime crashes. The mandatory upgrade procedure requires archiving all project databases and transferring license keys via Automation License Manager to external media, formatting the disk, performing a fresh clean installation of the certified Windows OS, installing verified prerequisite updates, installing PCS 7 V9.1, and restoring the project.

Table of Contents

Executive Summary

Upgrading a distributed process control system from SIMATIC PCS 7 V9.0 to V9.1 involves transitioning not only the control system software but also the underlying Microsoft Windows operating system ecosystem. PCS 7 V9.1 officially discontinues support for Windows 7, Windows 10 LTSC 2015/2016, and Windows Server 2012 R2/2016, requiring Windows 10 Enterprise LTSC 2019 (64-bit) for engineering and client stations and Windows Server 2019 Standard or Datacenter Edition (64-bit) for OS/Batch/Route Control servers.

Faced with this requirement, system administrators frequently inquire whether an in-place Windows upgrade (e.g., upgrading Windows 7 or Server 2016 directly using Microsoft upgrade media) is permissible to preserve installed software and custom server configurations. Siemens guidelines explicitly prohibit in-place operating system upgrades across all PCS 7 installations. An in-place OS migration inevitably corrupts Microsoft SQL Server database engines, shatters user rights definitions, and causes fatal runtime failures during WinCC startup and redundancy synchronization. This guide provides the architectural reasons behind this strict mandate, outlines the end-to-end clean install workflow, and establishes the required license migration steps.

Architecture and Fundamental Mechanics

The PCS 7 software architecture is deeply intertwined with Microsoft Windows system components, active directory structures, and Microsoft SQL Server:
1. SQL Server Instance Coupling: PCS 7 installs customized, hardened instances of Microsoft SQL Server (specifically MSSQL$WINCC and MSSQL$WinCCPLUS). These instances rely on exact file paths, registry keys, and local service security identifiers (SIDs). An in-place Windows OS upgrade replaces core operating system binaries and alters internal SID management, breaking the SQL Server service startup mechanism and causing fatal error codes (e.g., Error 912 or Error 2775).
2. SIMATIC Security Framework: During PCS 7 installation, the SIMATIC Security Control utility creates local security groups (SIMATIC HMI, SIMATIC NET, SQLServer2016WinCCOptionUser, etc.) and assigns precise DCOM, COM+, and registry access rights. In-place Windows upgrades reset default Windows security baselines and DCOM security templates, revoking the execution rights required by WinCC and SIMATIC Communication processes.
3. Network Stack and Driver Incompatibilities: Network adapter drivers and virtual communication protocols (such as SIMATIC NET Softnet and Hardnet protocols) bound to the Windows NDIS stack are broken during in-place upgrades, preventing communication between WinCC and AS controllers.

Consequently, attempting an in-place upgrade results in an unsupportable, unstable hybrid environment where OS compiles fail, runtime fails to activate, and server redundancy cannot synchronize. A fresh, clean installation onto a formatted partition is the only method that guarantees complete system integrity and manufacturer support.

Step-by-Step Implementation Procedure

Step 1: Backup Automation Licenses and Project Archives

  1. Connect a USB storage drive or map a secure external network share.
  2. Open Automation License Manager (ALM) on each ES, OS Server, and OS Client.
  3. Transfer all installed Siemens license keys (ALM licenses) from local drive partitions to the external storage media.
  4. In SIMATIC Manager on the ES, perform a complete project archive: File > Archive, selecting all multiproject components, master data libraries, and user archives.
  5. Export historical process archives and configuration data from WinCC and Information Server if required.

Step 2: Validate Computer Hardware Compatibility

  1. Ensure the host hardware (IPC or industrial server) meets the hardware requirements for PCS 7 V9.1:
    * Multi-core 64-bit processor (Intel Xeon or Core i5/i7/i9).
    * Minimum 16 GB RAM (32 GB recommended for OS Servers and ES).
    * High-performance SSD or hardware RAID-1/RAID-5 enterprise storage.
  2. Verify that original equipment manufacturer (OEM) hardware drivers (chipset, network, RAID controller) are certified for Windows Server 2019 or Windows 10 Enterprise LTSC 2019.

Step 3: Perform a Clean Installation of the Operating System

  1. Boot the target machine using verified Microsoft installation media (Windows 10 Enterprise LTSC 2019 64-bit or Windows Server 2019 Standard 64-bit).
  2. At the partition selection prompt, delete existing operating system partitions to ensure a completely clean disk.
  3. Format the installation partition as NTFS and proceed with the Windows installation.
  4. Configure local administrator credentials, computer hostname, and static IP addresses on plant and terminal bus network adapters according to your engineering documentation.

Step 4: Configure Mandatory Windows Prerequisites and Security Settings

  1. Apply all cumulative security updates for Windows approved by Siemens in the official PCS 7 compatibility tool.
  2. Enable required Windows features: open Turn Windows features on or off and enable .NET Framework 3.5 (includes .NET 2.0 and 3.0) and .NET Framework 4.8 Advanced Services.
  3. On OS Servers requiring WebNavigator or Information Server, install Internet Information Services (IIS) with the features specified in the PCS 7 V9.1 Readme.
  4. Disable Windows fast startup, configure power settings to 'High Performance', and disable automatic Windows updates during production hours.

Step 5: Install SIMATIC PCS 7 V9.1 and Restore Assets

  1. Insert or mount the SIMATIC PCS 7 V9.1 installation media.
  2. Run Setup.exe with administrative rights and select the appropriate package (Engineering Station, OS Server, or OS Client).
  3. Allow the installer to deploy Microsoft SQL Server, WinCC, SIMATIC NET, and PCS 7 system components.
  4. Run the SIMATIC Security Control wizard when prompted to configure local security groups and firewall rules.
  5. Restart the computer.
  6. Launch Automation License Manager and transfer the upgraded PCS 7 V9.1 license keys from external media to local drive C:.
  7. Retrieve the project archive in SIMATIC Manager and perform project migration.

Verification

  1. Launch Automation License Manager: verify that all PCS 7 V9.1 licenses (Engineering, AS RT, OS RT PO, Server redundancy) show status 'OK' with zero errors.
  2. In Windows Computer Management (compmgmt.msc), check Services: verify that MSSQL$WINCC and MSSQL$WinCCPLUS are running with 'Automatic' startup type.
  3. Open SIMATIC Shell: verify that all networked PCS 7 stations (ES, Servers, Clients) are discoverable and that encrypted terminal bus communication is operational.
  4. Open the migrated project in SIMATIC Manager, execute a complete OS Compile ('Entire project'), and verify zero compilation errors.
  5. Download to the OS Server, activate WinCC Runtime, and confirm that process pictures, alarms, and trend archives operate normally without event log errors.

Limitations and Operational Precautions

  1. In-place operating system upgrades are completely unsupported by Siemens Customer Support; if encountered, Siemens support will require a clean reinstallation prior to troubleshooting.
  2. License keys from PCS 7 V9.0 are not valid for PCS 7 V9.1 runtime execution and must be upgraded using official Siemens upgrade license packages.
  3. Hardware capacity planning, equipment lists, and software entitlements must be verified prior to migration. Final license quantities and order numbers must be confirmed with an authorized Siemens distributor or the Siemens Industry Mall.
  4. Third-party software (such as antivirus suites, backup agents, and domain controller group policies) must be certified compatible with both Windows Server 2019 and PCS 7 V9.1.

Engineer FAQ

Can I upgrade from Windows 7 to Windows 10 LTSC 2019 without formatting my drive?

While Microsoft installer media technically offers an upgrade path, executing it on a PCS 7 computer destroys the SQL Server WinCC instance and DCOM security configuration. You must back up your data and perform a clean format and install.

Why is Windows 10 Enterprise LTSC 2019 required instead of standard Windows 10 Pro?

PCS 7 requires the Long-Term Servicing Channel (LTSC) because standard Windows 10 editions receive forced feature updates (semi-annual channel) that frequently break process control software. LTSC provides a stable 10-year support lifecycle without disruptive feature changes.

Do OEM restore discs provided by Dell or HP wipe existing data during OS installation?

Yes. Most OEM server recovery discs repartition and format the primary hard drive array. Always ensure project archives and license keys are transferred to external media prior to running OEM recovery media.

Can I migrate a PCS 7 project directly from V9.0 to V9.1?

Yes. A project developed in PCS 7 V9.0 can be directly retrieved and migrated in PCS 7 V9.1 by opening the project in SIMATIC Manager and running the automated project migration wizard.

Where can I verify software and hardware compatibility for PCS 7 V9.1?

Always consult the online Siemens Kompatibilitäts-Tool (Compatibility Tool for Automation and Drive Technology) to verify operating system build numbers, updates, and software version combinations.

Technical References

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Related Tags

  • PCS 7 V9.1
  • Windows 10 LTSC
  • Windows Server 2019
  • Clean Install
  • OS Migration
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