C135 PCS 7 (PCS7)
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Resolving License Overrun and PowerPack Upgrade Sequencing from SIMATIC PCS 7 V7.0 to V7.1

Resolving License Overrun and PowerPack Upgrade Sequencing from SIMATIC PCS 7 V7.0 to V7.1

When upgrading SIMATIC PCS 7 from V7.0 to V7.1, an OS Software Single Station PowerPack license (PO 250 -> PO 1,000) cannot be applied directly to an existing WinCC RC PO 250 Version 7.0 base license because PowerPacks only expand capacity within the same major software version. To resolve the 'PO is more than 250' license overrun popup, first purchase and install the version upgrade license (SIMATIC PCS 7 OS Software Single Station Upgrade V7.0 to V7.1) in Automation License Manager (ALM). This elevates the base license to V7.1. Then apply the V7.1 PowerPack license to expand capacity from 250 to 1,000 Process Objects.

Table of Contents

Executive Summary

Upgrading industrial control systems across major releases requires meticulous alignment of software entitlements. In SIMATIC PCS 7, the Operator Station (OS) licensing framework governs both the permitted software release version and the quantity of Process Objects (POs) that can be monitored in WinCC Runtime. When migrating a Single Station OS from PCS 7 V7.0 to V7.1, engineers expanding plant capacity often purchase an OS Software Single Station PowerPack (PO 250 -> PO 1,000). However, attempting to activate WinCC Runtime under V7.1 triggers license warning popups stating that the PO count exceeds 250. In Automation License Manager (ALM), the PowerPack license appears invalid, unassigned, or incompatible. This failure stems from a fundamental licensing rule: PowerPacks increase capacity, but do not perform version upgrades. This technical guide clarifies the mandatory licensing chain and ALM execution procedure.

PCS 7 Licensing Architecture: Version Upgrades vs Capacity PowerPacks

Siemens enforces strict demarcation between two licensing mechanisms:

  • Version Upgrade License: Upgrades the authorized software version without changing capacity (e.g. PCS 7 OS Single Station Upgrade V7.0 to V7.1 upgrades a V7.0 PO 250 license into a V7.1 PO 250 license).
  • Capacity PowerPack License: Expands the licensed quantity of Process Objects within a specific, already-licensed version (e.g. PCS 7 OS Single Station PowerPack V7.1 PO 250 -> PO 1,000 expands an existing V7.1 PO 250 license into V7.1 PO 1,000).

Because a V7.1 PowerPack requires an authentic V7.1 base license as a prerequisite, attempting to apply it to a V7.0 base license fails in ALM.

WinCC Process Object (PO) Counting Rules in PCS 7 OS

In SIMATIC PCS 7, an OS Process Object (PO) represents an interconnected technological block with operator control and monitoring capabilities (S7_m_c = true), such as MotL, VlvL, PIDConL, or SFC charts. Raw I/O points, intermediate logic gates, and internal flags do not consume OS POs. If the actual count of configured technological blocks in the OS database exceeds the total licensed PO capacity, WinCC Runtime enters demo mode or generates periodic licensing popups.

License Elevation Sequencing Matrix

The following table details the mandatory license elevation progression from PCS 7 V7.0 to V7.1:

Migration PhaseExisting License in ALMApplied License PackageResulting License State in ALMValid for V7.1 Runtime?Initial Legacy StateWinCC RC PO (250) V7.0NoneBase V7.0 / 250 POsNo (Version mismatch on V7.1 OS)Incorrect Direct AttemptWinCC RC PO (250) V7.0OS PowerPack V7.1 (250->1000)License rejected / IncompatibleNo (PowerPack cannot upgrade version)Step 1: Version UpgradeWinCC RC PO (250) V7.0OS Single Station Upgrade V7.0->V7.1WinCC RC PO (250) V7.1Yes (Limited to 250 POs)Step 2: Capacity PowerPackWinCC RC PO (250) V7.1OS PowerPack V7.1 (250->1000)WinCC RC PO (1000) V7.1Yes (Fully licensed for 1,000 POs)

Step-by-Step Procedure to Upgrade and PowerPack Licenses in ALM

Method: Executing Sequential Upgrade in Automation License Manager

  1. Procure the mandatory upgrade entitlement: SIMATIC PCS 7 OS Software Single Station Upgrade V7.0 to V7.1.
  2. Open Automation License Manager (ALM) on the Engineering / Single Station PC.
  3. Insert the Siemens License USB drive or log into the Online Software Delivery (OSD) portal to transfer the upgrade license key.
  4. In ALM, select the local hard drive (e.g. C:) containing the legacy WinCC RC PO (250) V7.0 license.
  5. From the menu bar, select License Key > Upgrade....
  6. ALM detects the upgrade license key, consumes the V7.0 key, and generates the new WinCC RC PO (250) V7.1 license.
  7. Now select the freshly upgraded WinCC RC PO (250) V7.1 license in ALM.
  8. Select License Key > Upgrade... again to apply the OS PowerPack (PO 250 -> PO 1,000) license key.
  9. ALM consolidates the keys into a single active entitlement: WinCC RC PO (1000) V7.1.
  10. Restart WinCC Runtime; verify that the licensing popup no longer appears.

Verification

To verify that licensing and PO capacity are fully compliant:

  1. ALM Key Audit: In ALM, verify that the license status displays 'OK' with Version '7.1' and Count '1000'.
  2. WinCC Runtime Activation: Start WinCC Runtime. Confirm that the application initializes cleanly without demo popups.
  3. PO Calculation Check: In SIMATIC Manager, select the OS project and execute Options > OS > Compile. Review the compilation summary to confirm that total used POs are within the 1,000 PO limit.
  4. Commercial Validation Disclaimer: Always validate final license quantities and specific order numbers (MLFBs) against the applicable Siemens ST PCS 7 catalog and an authorized Siemens distributor quotation.

Limitations and Operational Precautions

  • Separate AS and OS PO Licensing: Expanding OS Runtime POs does not increase AS Process Object capacity; if the CPU program exceeds AS PO limits, separate AS RT PO licenses must be booked.
  • Single Station vs Server PowerPacks: Ensure the PowerPack MLFB matches the station architecture; an OS Server PowerPack cannot be applied to an OS Single Station base license.
  • Emergency Operation: If WinCC Runtime exceeds its PO capacity, runtime continues but issues non-acknowledged license violation warnings that obscure operator views.

Engineer FAQ

Can I install multiple PO 250 licenses to get 500 POs?

No. PCS 7 OS licenses are non-additive; capacity must be expanded using dedicated PowerPacks that replace the base quantity.

What is the difference between WinCC RC and WinCC RT licenses?

RC (Runtime + Configuration) permits both engineering in Graphic Designer and runtime execution; RT permits runtime execution only.

Can an upgraded V7.1 license run older V7.0 projects?

Siemens licenses are generally backward-compatible within the same product family, but runtime should match the installed software release.

Technical References

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