OS Server Redundancy Sizing, PO Expansion, and Windows Server Compatibility in PCS 7 V9.0

For a redundant SIMATIC PCS 7 OS Server pair, the base software package 'SIMATIC PCS 7 OS Software Server Redundancy V9.0 (PO 100)' provides the core redundancy synchronization entitlement and an initial 100 Process Objects. To expand beyond 100 POs, you do not purchase the base package multiple times; instead, purchase additive count-relevant 'OS RT PO' expansion packages (available in 100, 1000, and 5000 PO increments) in Automation License Manager (ALM). Regarding operating system compatibility, PCS 7 V9.0 base and SP1 support Windows Server 2012 R2, and V9.0 SP3 supports Windows Server 2016; Windows Server 2019 is not supported in PCS 7 V9.0 and requires upgrading to PCS 7 V9.1.

Executive Summary

When sizing and licensing high-availability PCS 7 Operator Stations (OS), system architects frequently face confusion regarding redundant server licensing bundles, Process Object expansion packages, and operating system compatibility matrices. Purchasing redundant base packages multiple times instead of count-relevant expansion keys creates costly procurement errors. Furthermore, attempting to deploy PCS 7 V9.0 on Windows Server 2019 leads to unresolvable setup aborts. This guide clarifies the commercial licensing architecture of OS Server Redundancy, PO expansion rules, and exact version-specific OS support boundaries.

Architecture and Fundamental Mechanics

OS Server Redundancy Licensing and Operating System Compatibility Architecture:

Commercial Licensing Architecture for Redundant OS Servers:
Base Redundancy Package: OS Software Server Redundancy V9.0 (PO 100) includes the base server runtime licenses, server redundancy synchronization license, and an initial capacity of 100 Process Objects.
Additive PO Expansion: To scale PO capacity (e.g., to 2500 POs), purchase count-relevant OS RT PO packages (PO 100, PO 1000, PO 5000). ALM sums these additive keys to establish the total licensed capacity.
Redundancy Sizing Rule: Determine the required runtime PO and archive capacities for both server nodes according to the applicable Siemens licensing manual and ordering package. Do not assume that a standard OS Server license must be purchased in addition to an OS Server Redundancy license.
Operating System Compatibility Matrix for PCS 7 OS Servers:
PCS 7 V9.0 (Base / SP1): Released for Windows Server 2012 R2 Standard (64-bit).
PCS 7 V9.0 SP3: Released for Windows Server 2016 Standard (64-bit).
Windows Server 2019: Strictly unsupported in PCS 7 V9.0 releases; formal support for Windows Server 2019 was introduced with SIMATIC PCS 7 V9.1.
Software License vs Hardware Capacity:
Software license keys in ALM are independent of the physical Windows Server edition, but the PCS 7 software installation binaries enforce strict operating system version checks during setup.

Step-by-Step Implementation Procedure

Procedure to Correctly Size, License, and Deploy a Redundant OS Server Pair:

Determine Total Project Process Object (PO) Requirements:
- In SIMATIC Manager, open the project -> Options -> PCS 7 License Information.
- Review the total OS Process Object count (e.g., 2,350 POs).
Formulate Commercial Procurement Package:
- Core Package: 1x SIMATIC PCS 7 OS Software Server Redundancy V9.0 (PO 100).
- Additive PO Expansion Keys:
- 2x SIMATIC PCS 7 OS Runtime Licenses PO 1000 (provides +2000 POs).
- 3x SIMATIC PCS 7 OS Runtime Licenses PO 100 (provides +300 POs).
- Total licensed PO capacity: $100 + 2000 + 300 = 2400\text{ POs}$.
- Validate the final license quantities and MLFBs against the applicable Siemens catalog and authorized distributor quotation.
Select Supported Operating System Hardware:
- If deploying PCS 7 V9.0 SP3: Install Windows Server 2016 Standard (64-bit) on both server nodes.
- If plant standards mandate Windows Server 2019: Plan project deployment on SIMATIC PCS 7 V9.1 rather than V9.0.
Install and Transfer Licenses via ALM:
- On both OS Server nodes, open Automation License Manager (ALM).
- Transfer the base redundancy license and required OS RT PO capacity licenses to the servers.
Configure Redundancy in WinCC Explorer:
- Open WinCC Explorer on the master OS Server -> open the Redundancy editor.
- Check 'Activate Redundancy'; assign the Redundant Partner Server computer name and serial/network connection.

Verification

To verify redundant OS licensing and operation:
1. In ALM on both servers, inspect the License Key table; confirm OS Software Server Redundancy and OS RT PO show total valid count with zero license deficit warnings.
2. In WinCC Explorer, start Runtime on both servers; open WinCC Redundancy Control; verify states report 'Master' on Server 1 and 'Standby' on Server 2.
3. Simulate an unexpected network disconnection on Server 1; verify Server 2 smoothly takes over master alarm logging and client connections without license interruption.

Limitations and Operational Precautions

Operational precautions:
- Never attempt to bypass the operating system version check by running the PCS 7 setup in Windows compatibility mode; doing so results in SQL Server database engine instability and runtime crashes.
- Do not infer licensing quantities solely from CPU count, I/O count, or number of tags; always use verified counting rules in the PCS 7 Licenses and Configuration Limits manual.
- Separate OS archive licenses from OS RT PO licenses; historical tag archiving beyond the initial 512 tags requires additive WinCC / OS Archive licenses.

Engineer FAQ

Do I need to buy the OS Server Redundancy package multiple times to get more POs?

No. The base redundancy package is purchased only once. Additional PO capacity is added via count-relevant 'OS RT PO' expansion licenses (PO 100, 1000, 5000).

Can PCS 7 V9.0 run on Windows Server 2019?

No. PCS 7 V9.0 base and SP1 support Windows Server 2012 R2, and V9.0 SP3 supports Windows Server 2016. Support for Windows Server 2019 requires PCS 7 V9.1.

What happens if my running OS project exceeds the licensed PO count?

WinCC operates with periodic license deficit pop-up warnings in the event log, but process operation is not immediately shut down. Product-specific documentation should always be referenced.

Where can I use an online configurator to size Siemens IPCs?

In the Siemens Industry Mall under the IPC Configurator tab, or using the Concept & Design Tool (CDT) as a planning aid.

Are OS RT PO licenses required for both servers in a redundant pair?

Redundant OS configurations must be licensed correctly according to the applicable Siemens licensing manual and ordering package, ensuring both nodes satisfy runtime licensing requirements.