C135 PCS 7 (PCS7)
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SIMATIC PCS 7 License Allocation and Station Assignment Audit: Redundant OS Servers, Web Server, Dual ES, and Clients

SIMATIC PCS 7 License Allocation and Station Assignment Audit: Redundant OS Servers, Web Server, Dual ES, and Clients

In SIMATIC PCS 7 multi-station architectures, software licenses must be precisely assigned according to physical station roles. A WinCC OS Client configured as a Web Server cannot simultaneously serve as an operated operator station on the control floor, meaning operator visualization packages (such as SFC Visualization or Logic Matrix Viewer) are required only on dedicated clients. The PCS 7 OS Software Server Redundancy package covers a redundant server pair, while HARDNET-IE S7-REDCONNECT licenses must be installed on each redundant OS Server. AS Process Object (AS RT PO) licenses reside exclusively on the Engineering Stations in Automation License Manager (ALM) and are dynamically booked during AS downloads.

Table of Contents

PCS 7 Multi-Station Licensing Topology and Core Principles

Designing a distributed SIMATIC PCS 7 system requires a rigorous audit of software entitlements, engineering options, and runtime capacity across all network tiers. A typical medium-to-large PCS 7 topology comprises redundant Automation Stations (AS 410-5H or AS 417-4H), redundant OS Servers, multiple Engineering Stations (ES), dedicated Operator Stations (OS Clients), and an OS Web Server for remote management access.

A frequent source of system misconfiguration and procurement error stems from conflating station roles, misallocating redundancy packages, and misunderstanding how Siemens Automation License Manager (ALM) tracks Process Objects. Each computer node requires explicit license keys installed on its local hard disk via ALM, matching its designated network service role.

Station Role Assignment: Dedicated OS Clients vs OS Web Servers

Siemens PCS 7 system documentation establishes strict operational segregation between standard Operator Stations and OS Web Servers:

  • Dedicated OS Clients: These stations provide interactive, low-latency control screens for plant operators. They require the PCS 7 OS Software Client runtime license. Optional operator add-ons—such as SIMATIC PCS 7 SFC-Visualization (for interactive SFC control from faceplates) and SIMATIC PCS 7 Logic Matrix Viewer—must be licensed and installed on each operator client where those functions are manipulated.
  • OS Web Server (Web Navigator / WebUX): An OS Client machine designated as a Web Server acts as an application gateway converting WinCC graphics into web streams for thin clients. Siemens rules dictate that an OS Client operating as a Web Server must NOT be utilized as an active local operator station on the plant floor. Operating heavy graphics and operator actions locally while simultaneously processing HTTP/HTTPS requests from dozens of remote web sessions introduces CPU starvation, rendering jitter, and potential supervisory control stalls. Consequently, operator visualization add-ons (such as local SFC-Visu or Logic Matrix Viewer) are unnecessary and should not be allocated to the Web Server machine.

Redundant OS Server and Communication Licensing (REDCONNECT)

Licensing redundant OS Servers involves two distinct layers: OS Runtime Redundancy and S7 Fault-Tolerant Communication:

  1. OS Server Redundancy: The orderable package SIMATIC PCS 7 OS Software Server Redundancy (e.g., MLFB 6ES7658-2CX00-0YB0) contains the redundancy license pair designed for one server pair. Through ALM, this package provides the entitlement to operate Server 1 and Server 2 with continuous database synchronization (CCRedundantServer.exe). In addition, each OS server requires its base OS Server runtime license (e.g., PCS 7 OS Software Server) scaled to the project's OS Process Object count.
  2. HARDNET-IE S7-REDCONNECT: When the OS Servers communicate with fault-tolerant S7-400H / CPU 410-5H controllers over redundant Industrial Ethernet plant buses using CP 1623 or CP 1613 A2 communications processors, redundant S7 connection routing is required. Each OS Server requires one SIMATIC NET HARDNET-IE S7-REDCONNECT license (or HARDNET-IE S7-REDCONNECT Powerpack upgrade from base HARDNET-IE S7). Therefore, a redundant server pair requires two individual REDCONNECT licenses—one installed on Server 1 and one on Server 2.

Engineering Station Architecture and AS RT Process Object Dynamic Accounting

In multi-ES environments (e.g., Primary Master ES and Secondary/Commissioning ES), engineering licenses and runtime Process Objects are managed dynamically:

  • AS RT Process Object (AS RT PO) Accounting: AS RT PO licenses (e.g., packages of 100, 500, or 1000 POs) reside in ALM on the Engineering Station. They are NOT permanently transferred to the CPU. When an engineer downloads CFC charts from the ES to an AS, the PCS 7 compiler calculates the PO consumption and books the required count against the local ALM license counter. When technological blocks are deleted and changes downloaded, the PO credit is booked back to the ES.
  • Deficit and Credit Handling: If an ES executes a download with insufficient PO licenses, ALM records an internal 'debt' (negative PO balance) and displays a license warning in the compilation log. This debt must be equalized by installing additional PO licenses or downloading from an ES with an adequate PO balance.
  • Dual ES Partitioning: You can either centralize all AS RT POs on Master ES 1 and perform all production downloads from ES 1, or partition POs geographically (e.g., 500 POs on ES 1 for AS 1, 500 POs on ES 2 for AS 2). Note that any ES where engineers configure specialized packages (such as S7 F-Systems, Logic Matrix Tool, or Safety Matrix Tool) must have those respective engineering licenses installed locally.

Operating OS Simulation vs Direct WinCC Runtime on the Engineering Station

Engineers frequently wonder why activating direct WinCC Runtime (Activate Runtime) on an Engineering Station connected to the plant network is strictly prohibited, and why Start OS Simulation must be used instead:

  • Network Identity Spoofing: If the ES has the full OS project open and the engineer activates WinCC Runtime directly while connected to the plant bus, the ES begins announcing itself as an active server on the network. Operating OS Clients configured to resolve the server name may establish rogue dCOM/RPC connections to the ES rather than the true production OS Server.
  • Database Pollution: Activating direct Runtime on the ES generates local Tag Logging archives, alarm history records, and lock files (*.ldf, *.mdf). When the engineer subsequently performs an OS Target Download from the ES to the OS Servers, these dirty runtime database files can be copied over, corrupting the SQL Server instance or causing download failure (Database Context Does Not Exist).
  • OS Simulation Safeguard: Selecting Options -> OS -> Start OS Simulation in SIMATIC Manager launches WinCC in an isolated sandbox mode that does not advertise network server broadcast services and prevents runtime database pollution.

Comprehensive PCS 7 Multi-Station License Assignment Schedule

The following schedule details the required license placement across a typical distributed PCS 7 multi-station system:

Station RoleTarget HardwareMandatory Siemens License PackagesOptional / Role-Specific PackagesMaster ES (ES 1)Industrial WorkstationPCS 7 Engineering Toolset, AS RT PO (Pooled balance), ALMS7 F-Systems, Logic Matrix Tool, CFC/SFC V9.0Secondary ES (ES 2)Workstation / Field PGPCS 7 Engineering Toolset, AS RT PO (if downloading AS2)Identical engineering add-ons as ES 1 for edited toolsPrimary OS Server (SERV 1)Industrial Server RackPCS 7 OS SW Server, OS Server Redundancy (1 of pair), OS RT POHARDNET-IE S7-REDCONNECT, SIMATIC LogonSecondary OS Server (SERV 2)Industrial Server RackPCS 7 OS SW Server, OS Server Redundancy (2 of pair), OS RT POHARDNET-IE S7-REDCONNECT, SIMATIC LogonOperator Client (OP 1)Desktop Box PCPCS 7 OS Software ClientSFC-Visualization, Logic Matrix ViewerOS Web ServerIndustrial Rack/Box PCPCS 7 OS Software Client, WinCC Web Navigator ServerWinCC DataMonitor, Web Client concurrent licenses

[!NOTE]
Commercial Accuracy Disclaimer: Software order numbers (MLFBs), package structures, and hardware capacity prerequisites vary across PCS 7 versions > and hardware platforms. System integrators must confirm exact software entitlements and licensing requirements against the official Siemens > Catalog CA 01 and obtain an authorized Siemens distributor quotation prior to purchasing.

Verification

Verify correct multi-station licensing and station deployment through the following audit steps:

  1. Open Automation License Manager (ALM) on each station and execute Check Licenses to confirm that all license keys show status 'Valid' without expiring demo countdowns.
  2. In Master ES SIMATIC Manager, select the multiproject root and open Options -> Process Objects -> Available Licenses to verify total AS RT PO capacity, assigned POs, and remaining balance.
  3. In WinCC Explorer on SERV 1 and SERV 2, open Redundancy properties and confirm that the partner server node is reachable and redundancy handshake is healthy.
  4. On the OS Web Server, confirm that WinCC Web Configurator runs cleanly and that operator visualization faceplate add-ons are omitted to conserve system threads.

Limitations and Operational Precautions

Adhere to the following architectural precautions:

  • Never Share Web Server with Physical Plant Control: Do not assign operators to physically drive equipment from the OS Web Server console; remote client request spikes can cause local interface lag during critical process upsets.
  • ALM Transfer Media: Always transfer licenses between engineering stations and servers using the official ALM network transfer or Siemens USB license sticks; never copy license files via raw Windows file explorer.
  • Redundant Server License Symmetry: Ensure both OS Servers possess identical base OS PO counts and archive sizes; asymmetric licensing causes failover server errors when tag quantities exceed secondary capacity.

Engineer FAQ

If I have two Engineering Stations, do I need to purchase double the AS RT PO licenses?

No. AS RT PO licenses represent runtime capacity in the physical automation controllers, not engineering seats. If your plant requires 1,000 Process Objects total across two CPUs, you only purchase 1,000 AS RT POs. You can place all 1,000 POs on Master ES 1 or split them across engineering stations in ALM.

Can an OS Client connect to redundant OS Servers without HARDNET-IE S7-REDCONNECT?

Yes. OS Clients communicate exclusively with OS Servers via the WinCC Terminal Bus, not directly with the PLCs. Therefore, OS Clients only require standard Windows network cards and base PCS 7 OS Software Client licenses. Only OS Servers communicating with redundant S7-400H CPUs require HARDNET-IE S7-REDCONNECT.

What happens if an ES runs out of AS RT PO licenses during an emergency plant download?

PCS 7 allows the download to proceed, but records the missing Process Objects as a licensing debt in ALM and logs a non-fatal warning. The controller continues operating normally, but the deficit must be cleared promptly by installing required PO packages.

Technical References

Related Articles

Related Tags

  • PCS 7 Licensing
  • Automation License Manager (ALM)
  • OS Server Redundancy
  • HARDNET-IE S7-REDCONNECT
  • AS RT Process Objects
  • OS Web Server
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