C135 PCS 7 (PCS7)
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Process Object Counting Rules and Historical Licensing in SIMATIC PCS 7 v6.1 vs Modern Versions

Process Object Counting Rules and Historical Licensing in SIMATIC PCS 7 v6.1 vs Modern Versions

In SIMATIC PCS 7 v6.1, Process Objects (POs) were tracked and licensed independently for the Engineering Station (ES) and Operator Station (OS). The ES PO count was calculated per individual S7-Program container via CFC Chart Reference Data > Statistics, counting all blocks marked with the 'S7_m_c' (operator control and monitoring) attribute. ES PO licenses were tiered in fixed blocks (250, 1000, 2000, 3000, 5000, and Unlimited POs). Modern PCS 7 versions (v7.0 and later) replaced this legacy system with unified AS RT PO and OS RT PO electronic counting under the Automation License Manager, verified through Options > PCS 7 License Information.

Table of Contents

Historical Context: Process Object Licensing in PCS 7 v6.1

In the early architecture of SIMATIC PCS 7 (specifically version 6.0 and version 6.1 released between 2003 and 2006), the concept of the Process Object (PO) governed system licensing, but with fundamental structural differences compared to modern releases:

  • Dual Independent Licensing: Licensing was bifurcated into distinct ES Process Objects (Engineering Station) and OS Process Objects (Operator Station).
  • ES PO Licensing: The Engineering Station required an authorization diskette (using the legacy AuthorsW authorization system or early Automation License Manager). The ES PO tier granted permission to configure and compile a specific maximum number of process objects in CFC. The fixed tiers were 250, 1000, 2000, 3000, 5000, and Unlimited POs.
  • OS PO Licensing: The WinCC-based Operator Station was licensed based on OS PO runtime tiers (250, 2000, 3000, 5000, 8500 POs). Under PCS 7 v6.1 rules, one OS Process Object was formally defined as roughly equivalent to 30 to 50 process tags / archive tags and associated alarm messages generated by a technological block (e.g., motor, valve, analog monitoring).
  • AS Hardware Runtime: In PCS 7 v6.1, the S7-400 CPU hardware had no concept of AS Runtime PO capacity cards (such as the modern System Expansion Card). Hardware capacity was constrained purely by the physical RAM/work memory of the CPU (e.g., CPU 414-3 or CPU 417-4).

How the CFC Reference Data Statistics Tool Counted POs in v6.1

Engineers working in PCS 7 v6.1 audited their project's PO consumption using the Chart Reference Data tool within the CFC editor:

  1. In the CFC editor, selecting Options > Reference Data > Display opened the reference data matrix.
  2. Filtering by Statistics generated a summary table displaying memory utilization, runtime group distribution, and the line item:
    Configured Process Objects: <Count>
  3. Internal Counting Logic: The CFC compiler inspected all blocks instantiated across the charts. A function block was categorized as a Process Object if it fulfilled the following technological criteria:
    * It contained the block attribute S7_m_c := 'true' (indicating operator control and monitoring capability in WinCC).
    * It generated WinCC messages (contained message IDs via Alarm_8P or NOTIFY_8P).
    * Typical PO blocks included MOTOR, VALVE, MEAS_MON, PID_CONTR, and DOSE. Pure mathematical blocks (such as ADD_R, MUL_R, AND, OR) were strictly categorized as elementary calculation blocks and did not count as Process Objects.

Why PO Counts Differed Between S7-Programs and Multi-Projects

A frequent point of confusion among engineers in PCS 7 v6.1 was observing an identical PO count (e.g., 4,591 POs) regardless of which CFC chart or AS station was selected when running Reference Data Statistics:

  • S7-Program Container Scope: The CFC Chart Reference Data tool evaluates statistics exclusively for the local S7-Program container belonging to the specific AS station where the chart resides. It does not calculate a cumulative total across the entire multi-project.
  • Master Library Mirroring: If an engineer tested two different AS programs that were cloned from a common master plant template or shared identical technological block allocations, the PO counts appeared identical.
  • License Aggregation: When purchasing an ES license in v6.1 (e.g., a 5,000 PO ES license), the license covered the maximum PO count compiled simultaneously on that engineering station. If a single AS program contained 4,591 POs, an ES license of at least 5,000 POs was legally mandated.

Evolution to Modern AS RT PO and OS RT PO Architecture (v7.x - v10.x)

With the release of PCS 7 v7.0 and reinforced throughout v8.x, v9.x, and v10.x, Siemens fundamentally revamped PO management into an automated, electronic counting architecture:

  1. Automation License Manager (ALM) Integration: Authorization diskettes were completely replaced by modern ALM license keys (.sik format).
  2. AS RT PO (Automation Station Runtime Process Objects):
    * Introduced license enforcement directly at the controller level. Each S7-400 or CPU 410-5H controller requires sufficient AS RT PO license volumes (e.g., 6ES7653-2BA00-0XB5 for CPU 410 expansion or cumulative AS RT PO runtime packages 6ES7658-2CX58-0YB5).
    * Modern counting rules count any block that possesses S7_m_c := 'true' and creates an OS message or faceplate connection.
  3. OS RT PO (Operator Station Runtime Process Objects):
    * OS runtime licenses (6ES7658-2CX58-0YB5) enforce strict limits on the number of process objects downloaded and activated in WinCC Explorer.
  4. Unified License Information Dialog:
    * In modern versions, engineers no longer rely on CFC Reference Data for licensing verification. Navigating to SIMATIC Manager > Options > PCS 7 License Information opens a consolidated diagnostic window displaying exact configured POs vs licensed POs across all AS stations and OS servers in the multi-project.

Comparison Table: PCS 7 v6.1 vs Modern PCS 7 PO Licensing

The following table contrasts Process Object counting rules, licensing mechanics, and verification tools between legacy PCS 7 v6.1 and modern PCS 7 architectures:

Feature / AttributePCS 7 v6.1 ArchitectureModern PCS 7 (v8.x / v9.x / v10.x)Licensing MechanismYellow Authorization Floppy (AuthorsW / early ALM)Automation License Manager (ALM) License KeysPrimary Licensing TiersES PO: 250, 1k, 2k, 3k, 5k, Unlimited
OS PO: 250, 2k, 3k, 5k, 8.5kAS RT PO: 100, 500, 1000 PO increments
OS RT PO: 100 to 12,000+ PO packagesController Capacity ControlPhysical CPU Work Memory limits onlyCPU 410 System Expansion Card (SEC) + AS RT POPO Verification ToolCFC > Options > Reference Data > StatisticsSIMATIC Manager > Options > PCS 7 License InformationMulti-Project ScopeScanned individually per S7-ProgramCentrally audited across all AS & OS stations simultaneouslyOS PO Definition~30 to 50 variables / archive tags per POStrict 1:1 technological block mapping with WinCC representationHardware MLFB ReferenceLegacy software authorizations (Discontinued)AS RT PO (6ES7658-2CX58-0YB5), SEC (6ES7653-2BA00-0XB5)Runtime Overrun ReactionWarning message during compilation/transferDemo mode banner, event log warning, or download block

Step-by-Step Procedure to Audit PO Consumption Across Generations

To audit PO consumption in existing projects:

For Legacy PCS 7 v6.1 Projects:
1. Open the target project in SIMATIC Manager v6.1.
2. In the Plant View or Component View, open any CFC chart within the specific AS S7-Program.
3. In the CFC menu, click Options > Reference Data > Display.
4. In the Reference Data window, select the Statistics radio button.
5. Record the number listed under Configured Process Objects. Repeat this procedure for each individual AS program in the multi-project.
6. Verify against installed floppy disk authorizations in the authorization manager.

For Modern PCS 7 Projects (v8.x / v9.x / v10.x):
1. Open SIMATIC Manager and select the top-level Multi-project folder.
2. Click Options > PCS 7 License Information.
3. Inspect the AS Process Objects tab to view total booked POs per controller versus available AS RT PO license keys.
4. Inspect the OS Process Objects tab to verify total WinCC process objects versus installed OS RT PO licenses in Automation License Manager.
5. Export the report to CSV for compliance audits.

Verification

Confirm accurate PO accounting and licensing compliance using the following steps:
1. In modern PCS 7, open Automation License Manager (ALM) on the Engineering Station and confirm that installed license keys match or exceed the counts reported in the PCS 7 License Information window.
2. Execute a test compilation of the OS (Compile OS) and confirm that the transfer log reports zero license warnings or licensing overrun errors.
3. On the target Operator Station, open WinCC Explorer and activate Runtime. Confirm in the WinCC diagnostic log (license.log in <WinCC_Project>\Diagnostics\) that runtime licensing executes in normal mode without entering demo mode.
4. For legacy v6.1 installations, ensure the compiled PO count in CFC Statistics does not exceed the maximum tier of the active engineering authorization.

Limitations and Operational Precautions

  • Never Infer Licensing from Tag Count Alone: In modern PCS 7, process objects cannot be estimated strictly from raw I/O or tag counts. A single technological block (such as MotL) utilizes dozens of internal tags but consumes exactly one Process Object.
  • Redundant OS Server Licensing: Redundant OS server architectures require independent, fully licensed OS RT PO packages on both the Master and Standby server machines. Licenses do not float across redundant servers.
  • CPU 410-5H System Expansion Cards: The SIMATIC S7-400 CPU 410-5H requires a hardware System Expansion Card (SEC, e.g., 6ES7653-2BA00-0XB5) matching the controller's required PO capacity (from 100 POs up to 2600+ POs). Upgrading CPU capacity requires an online PO expansion order.
  • Commercial Accuracy: Process object licensing, expansion card limits, and software entitlements must be confirmed against official Siemens product documentation. Always validate final ordering numbers and quantities with an authorized Siemens distributor quotation.

Engineer FAQ

Do basic CFC logic blocks like AND gates or timers consume Process Objects in PCS 7?

No. Elementary logical, arithmetic, and conversion blocks (e.g., AND, OR, XOR, TIMER_P, ADD_R) do not possess the S7_m_c attribute, do not generate WinCC alarm messages, and do not consume Process Objects in either legacy v6.1 or modern PCS 7.

What happens in modern PCS 7 if the configured AS RT PO count exceeds the installed licenses?

In modern PCS 7, exceeding the AS RT PO license count generates a licensing warning in ALM and during CFC compilation. While the compiler may allow a download to occur, a persistent license violation warning is logged in the system diagnostics, and plant compliance is breached.

Can a legacy PCS 7 v6.1 authorization floppy disk be transferred into modern Automation License Manager?

Early yellow authorization floppies (evacc.aut) can be recognized by older versions of ALM (v3.x / v4.x), but modern PCS 7 software releases (v8.x through v10.x) require modern upgrade license keys (.sik) and do not accept legacy v6.1 authorization keys.

How are Process Objects counted when using the Advanced Process Library (APL)?

Under APL rules, each instantiated control block (such as MotL, VlvL, PIDConL, or MonAnL) that generates an associated OS faceplate and message instance consumes exactly one Process Object upon compilation to the OS.

Technical References

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Related Tags

  • PCS 7 Licensing
  • Process Objects
  • CFC Reference Data
  • Automation License Manager
  • PCS 7 V6.1
  • AS RT PO
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