C135 PCS 7 (PCS7)
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Sizing and Licensing Rules for Redundant OS Servers and Fault-Tolerant AS in PCS 7 V8.1

Sizing and Licensing Rules for Redundant OS Servers and Fault-Tolerant AS in PCS 7 V8.1

When sizing software licenses for a SIMATIC PCS 7 V8.1 plant with redundant WinCC OS Servers and a redundant S7-400H controller for 1,000 Process Objects, strict counting rules apply: AS Runtime Process Objects (6ES7653-2BB00-0XB5) require only 1 license for the redundant AS pair, whereas OS Runtime Process Objects (6ES7658-2XB00-0XB0) and OS Archive licenses (6ES7658-2EA00-2YB0) must be purchased twice (1 per redundant server PC). One OS Server Redundancy package (6ES7652-3BA18-2YA0) covers both physical servers. Redundant communication requires HARDNET-IE S7-REDCONNECT licenses on both server stations.

Table of Contents

PCS 7 Licensing Guardrails: Redundant AS vs Redundant OS Rules

Siemens enforces fundamentally different licensing paradigms between automation controllers and operator stations:

  1. Automation System (AS) Rule: In an S7-400H or CPU 410-5H fault-tolerant controller pair, AS Runtime Process Objects (AS RT PO) license the technological automation program, not the physical silicon. Therefore, only 1 AS RT PO license is consumed for the redundant pair. You do NOT double AS RT PO licenses for redundant CPUs.
  2. Operator Station (OS) Rule: In a redundant WinCC OS Server pair (Server 1 and Server 2), each physical computer executes an independent WinCC runtime engine and alarm/archive manager. Therefore, every software license running on the server must be duplicated, including OS Runtime POs, OS Archive tags, and communication driver licenses.
  3. OS Redundancy Package Exception: The specialized license package OS Software Server Redundancy provides license keys designed specifically to authorize two physical PCs under a single order item.

Hardware and Software Sizing Schedule (1000 PO Architecture)

For a standard high-availability facility running PCS 7 V8.1 with 1 Engineering Station, 1 Redundant OS Server Pair (2 PCs), 1 OS Client, and an S7-400H controller:

  • Engineering Station (ES): Requires 1x AS/OS Engineering Floating License (6ES7658-5AX18-0YA5) and 1x SIMATIC PDM Floating License (6ES7658-3LD18-0YA5).
  • Fieldbus / Communication: 1x SIMATIC Modbus/TCP PN Red license (6AV6676-6MB10-0AX0) licenses redundant Modbus on S7-400H.
  • OS Server Pair: Requires 1x OS Server Redundancy package (6ES7652-3BA18-2YA0), 2x OS RT 1000 PO (6ES7658-2XB00-0XB0), and 2x OS Archive 1500 Var (6ES7658-2EA00-2YB0).
  • OS Client: Requires 1x OS Software Client (6ES7658-2CX18-0YB5) and 1x SFC Visualization (6ES7652-0XD18-2YB5).

Detailed Analysis of Redundant Software Packages

Understanding exact package contents prevents procurement overspending or licensing shortages:

  • OS Software Server Redundancy V8.1 (6ES7652-3BA18-2YA0): Quantity required is 1. The package contains 2 server runtime authorizations (1 for Server A, 1 for Server B) and includes an initial base allocation of 100 OS POs for each node.
  • OS RT PO 1000 Expansion (6ES7658-2XB00-0XB0): Quantity required is 2. Server A and Server B each consume 1 expansion package to expand capacity from 100 to 1100 POs.
  • AS RT PO 1000 Expansion (6ES7653-2BB00-0XB5): Quantity required is 1. Covers the combined S7-400H controller pair.

Industrial Ethernet Communication Licensing: HARDNET vs REDCONNECT

When servers communicate with redundant S7-400H controllers over dual rings via CP 1623 cards (6GK1162-3AA00):

  • If IPCs are ordered from Siemens with pre-installed CP 1623 cards, the basic HARDNET-IE S7 license is included with the hardware.
  • To activate fault-tolerant communication, you must order 2x Power Pack HARDNET-IE S7-REDCONNECT (6GK1716-0HB13-0AC0).
  • If using custom-built server hardware or standard commercial PCs, you must purchase the full standalone package 2x HARDNET-IE S7 REDCONNECT V13 (6GK1716-0HB13-0AA0), one for each physical server.

Procurement Schedule for Redundant PCS 7 V8.1 System

The table below details the verified equipment and software schedule for procurement validation:

Component DescriptionSiemens Order Number (MLFB)License TypeQty RequiredOperational TargetAS/OS Engineering V8.16ES7658-5AX18-0YA5Floating (1 User)1Engineering Station (ES)SIMATIC PDM V8.1 (100 Tag)6ES7658-3LD18-0YA5Floating (1 User)1Engineering Station (ES)Modbus/TCP PN Red for S7-400H6AV6676-6MB10-0AX0Single License1S7-400H Controller PairAS RT License (1000 PO)6ES7653-2BB00-0XB5Single License1S7-400H Controller Pair (Not doubled)OS Software Server Redundancy V8.16ES7652-3BA18-2YA0Single (Covers 2 PCs)1OS Server 1 and OS Server 2OS RT License (1000 PO)6ES7658-2XB00-0XB0Single License21 for Server 1; 1 for Server 2OS Archive (1500 Variables)6ES7658-2EA00-2YB0Single License21 for Server 1; 1 for Server 2HARDNET-IE S7 REDCONNECT6GK1716-0HB13-0AA0Single License21 for Server 1; 1 for Server 2OS Software Client V8.16ES7658-2CX18-0YB5Floating (1 User)1OS Client StationSFC Visualization V8.16ES7652-0XD18-2YB5Floating (1 User)1OS Client Station

Verification

Verify license allocation in Automation License Manager (ALM):

  1. Open ALM on the Engineering Station; verify floating licenses for AS/OS Engineering and SIMATIC PDM show status Valid.
  2. Open ALM on OS Server 1; verify keys for WinCC Server, WinCC Redundancy, 1000 OS PO, OS Archive 1500, and S7-REDCONNECT are installed locally.
  3. Open ALM on OS Server 2; verify an identical set of keys is installed locally.
  4. In SIMATIC Manager, select Charts > Book Process Objects; confirm consumed AS POs do not exceed 1000 PO on the AS.
  5. Activate WinCC Runtime on both servers; confirm that no demo mode dialogs appear and redundancy synchronization completes.

Limitations and Operational Precautions

Review the following commercial and operational licensing precautions:

  • Commercial Procurement Guardrail: Sizing software licenses must adhere strictly to Siemens licensing documentation. Never order hardware or software solely based on estimates; always validate final license quantities and MLFBs against the applicable Siemens catalog and an authorized Siemens distributor quotation.
  • No Floating Server Licenses: OS Runtime and Redundancy licenses are tied to physical server installations and cannot float dynamically across corporate networks.
  • Version Successor MLFBs: When ordering older releases (e.g. V8.1 in 2018 or later), verify whether specific MLFBs (such as V12 communication packages) have been superseded by newer revisions (e.g. V13 or V14).

Engineer FAQ

Why don't I need two AS RT PO licenses for a redundant S7-400H controller pair?

Siemens licenses the automation program execution, not the hardware redundancy. Because both CPUs in an S7-400H pair execute the identical technological program in event-synchronized lockstep, only one AS RT PO license is consumed.

Why do I need two OS RT PO licenses for a redundant OS Server pair?

Unlike controllers, each OS Server runs its own independent WinCC runtime database, tag manager, and alarm logging engine. Therefore, Siemens counting rules require full runtime PO licensing on both Server 1 and Server 2.

How many OS Server Redundancy packages are needed for one redundant server pair?

Only 1 package (6ES7652-3BA18-2YA0) is needed. The redundancy package is specifically structured by Siemens to authorize two physical server PCs.

Technical References

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Related Tags

  • PCS 7 Licensing
  • 6ES7652-3BA18-2YA0
  • 6ES7653-2BB00-0XB5
  • 6ES7658-2XB00-0XB0
  • S7-REDCONNECT
  • Redundant OS Server
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