C135 PCS 7 (PCS7)
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Sizing and Licensing SIMATIC PCS 7 V9.0 Packages for Redundant S7-400H and Distributed Pump Stations

Sizing and Licensing SIMATIC PCS 7 V9.0 Packages for Redundant S7-400H and Distributed Pump Stations

To size and license a SIMATIC PCS 7 V9.0 system comprising redundant S7-400H controllers (CPU 414-4H, 6ES7414-4HJ04-0AB0) and distributed pump stations controlled by S7-300 CPUs (CPU 315-2 DP), you must independently evaluate and purchase distinct license categories: an Engineering Station (ES) license, AS Runtime Process Object (AS RT PO) licenses, OS Runtime Process Object (OS RT PO) licenses for each OS server, WinCC Redundancy licenses, and SIMATIC NET communication licenses (such as S7-REDCONNECT). Never infer licensing quantities solely from CPU count, I/O count, or pump numbers. Actual license consumption is calculated in the PCS 7 engineering software based on instantiated technological blocks in CFC and tags mapped for operator control. Utilize the Siemens Concept & Design Tool (CDT) as an interactive planning aid, and validate all final license quantities, software packages, and hardware order numbers with an authorized Siemens distributor or the Siemens Industry Mall.

Table of Contents

Executive Summary

Designing and procuring a SIMATIC PCS 7 V9.0 control architecture requires a clear distinction between physical hardware capacity, communication topologies, software engineering entitlements, and runtime Process Object (PO) licensing. A common engineering scenario involves a central redundant automation station—such as a dual CPU 414-4H (6ES7414-4HJ04-0AB0) configuration—overseeing distributed remote package units, such as pump stations driven by S7-300 controllers (CPU 315-2 DP) linked via PROFIBUS DP or Industrial Ethernet.

Procurement teams frequently attempt to estimate license costs using rough heuristics, such as raw I/O counts or motor tallies. In PCS 7, however, licensing is governed by strict, version-specific manufacturer counting rules. Runtime licensing is segregated into AS RT POs (which track instantiated technological blocks in controller charts) and OS RT POs (which govern process visualization tags on WinCC servers). Furthermore, redundant OS servers require separate, identical runtime license allocations alongside dedicated redundancy packages. This guide provides the complete architectural breakdown for sizing PCS 7 V9.0 systems, explains how to calculate actual license requirements using engineering tools, outlines the role of the Siemens Concept & Design Tool (CDT), and establishes essential commercial verification guardrails.

Architecture and Fundamental Mechanics

The PCS 7 licensing framework segregates software entitlements into distinct operational layers:
1. Engineering Station (ES) Licensing:
* Licensed per engineering workstation via a floating license key (e.g., SIMATIC PCS 7 Engineering V9.0).
* Authorizes the use of SIMATIC Manager, CFC, SFC, NetPro, and WinCC configuration tools.
2. Automation System Runtime (AS RT) Process Objects:
* In PCS 7 V9.0, an AS Process Object (PO) represents a technological block that processes process variables and provides operator control and monitoring (e.g., MotL, VlvL, PIDConL, MonAnL).
* Basic elementary logic blocks (e.g., AND, OR, ADD) and pure driver blocks (Pcs7AnIn) consume zero AS POs.
* AS PO licenses are loaded into Automation License Manager (ALM) on the ES and assigned to the S7 Program. During CFC compilation, the compiler tallies consumed POs against available license volume.
3. Operator Station Runtime (OS RT) Process Objects:
* OS POs license the process objects visualized on WinCC OS Servers or Single Stations.
* Each block icon and faceplate linked to an AS technological block consumes 1 OS PO on the server.
* In a redundant OS server pair, each individual server must be licensed for the full OS RT PO volume, supplemented by the WinCC Redundancy option package.
4. Communication and Networking Licenses:
* Redundant communication from WinCC PC stations to the S7-400H controller requires SIMATIC NET S7-REDCONNECT (for Hardnet CP 1623/CP 1613 or Softnet-IE).
* Integrating S7-300 sub-controllers (such as CPU 315-2 DP) into PCS 7 can be accomplished via PROFIBUS DP coupling, Open PCS 7, or standard S7 communication blocks, which may require additional communication licenses depending on the integration path.
5. Hardware Constraints on CPU 414-4H:
* The 6ES7414-4HJ04-0AB0 is a legacy S7-400H controller (V4.x architecture) with finite work memory (approx. 1.4 MB code / 1.4 MB data). Engineers must confirm memory capacity in STEP 7 to ensure the planned CFC chart volume and communication instances do not exceed physical CPU work memory.

Step-by-Step Implementation Procedure

Step 1: Model the Plant Architecture in the Siemens Concept & Design Tool (CDT)

  1. Access the Siemens Concept & Design Tool (CDT) on the Siemens Industry Online Support portal.
  2. Select SIMATIC PCS 7 V9.0 as the target system version.
  3. Configure the hardware topology: add the central redundant S7-400H station and the distributed S7-300 pump stations.
  4. Input the estimated process equipment count (e.g., 14 electrical pumps, associated valves, analog pressure/flow transmitters, and digital interlocks).
  5. Use CDT to generate an initial planning report and equipment list. Note that CDT serves as a planning aid and does not replace final engineering verification.

Step 2: Calculate Actual AS RT Process Object Consumption in CFC

  1. In the PCS 7 Engineering Station, open the project multiproject in SIMATIC Manager.
  2. In the component view, right-click the Charts folder of the S7-400H program and select Process Objects > Display.
  3. Review the PO calculation table:
    * Inspect the count of instantiated technological blocks (motors, valves, analog monitors).
    * Note the total calculated AS RT PO consumption.
  4. Determine the required AS RT PO license volume (e.g., 100 PO, 600 PO, or 1000 PO packages) required to cover the application plus planned expansion reserves.

Step 3: Determine OS Server Runtime and Redundancy Licensing

  1. Count the number of OS Servers, OS Clients, and Single Stations in the architecture.
  2. For a redundant OS Server pair:
    * Calculate the OS RT PO count (typically matching or slightly exceeding the AS PO count).
    * Select the OS Server Software package for Server 1 with the required PO capacity.
    * Select an identical OS Server Software package for Server 2.
    * Include the WinCC Redundancy license option for the server pair.
  3. For OS Clients, allocate one SIMATIC PCS 7 OS Client runtime license per physical operator station.

Step 4: Verify Industrial Communication Licenses

  1. On the PC stations connecting to the S7-400H fault-tolerant CPUs, determine the network interface hardware (CP 1623 Hardnet vs. standard network adapter Softnet).
  2. Allocate SIMATIC NET S7-REDCONNECT licenses for the ES and each OS server.
  3. For communication with the S7-300 pump stations (CPU 315-2 DP), verify whether data exchange occurs via PROFIBUS DP master/slave mapping or S7 communication via CP 343-1, and allocate corresponding communication blocks.

Step 5: Validate Final License Schedule with Authorized Distributor

  1. Compile the complete software and hardware license schedule.
  2. Cross-reference all part numbers and software package titles against current Siemens catalog publications.
  3. Submit the schedule to an authorized Siemens distributor or request a quotation through the Siemens Industry Mall to verify order code validity, software delivery formats (OSD - Online Software Delivery vs. DVD), and maintenance agreement eligibility.

Verification

  1. Launch Automation License Manager (ALM) on the Engineering Station: verify that the SIMATIC PCS 7 Engineering V9.0 license and AS RT PO license packages show status 'OK'.
  2. In SIMATIC Manager, perform a test compile of the CFC chart folder: confirm that the compiler reports: 'Process Objects: [Consumed] of [Licensed] available' with zero license deficit errors.
  3. On OS Server 1 and OS Server 2, open ALM: verify that identical OS RT PO licenses and WinCC Redundancy licenses are present and valid.
  4. Activate WinCC Runtime on both servers: verify that no demo-mode banners or missing license warning dialogs appear during runtime startup.
  5. In WinCC Explorer, verify that the Redundancy status dialog indicates normal redundant partner synchronization without licensing faults.

Limitations and Operational Precautions

  1. Never infer licensing quantities solely from CPU count, I/O count, or pump numbers; license counting is based strictly on software block instantiations.
  2. S7-400H CPU 414-4H (6ES7414-4HJ04-0AB0) has strict memory limits; verify that the user program fits within physical work memory without causing CPU stop.
  3. Redundant OS servers must be licensed symmetrically; installing an OS PO license on only one server will cause the partner server to enter demo mode or abort redundancy.
  4. Siemens Concept & Design Tool (CDT) outputs are planning aids only; final license quantities and MLFB order numbers must be confirmed with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

How many AS Process Objects does a standard MotL motor block consume?

In PCS 7 APL, a standard technological block such as MotL, VlvL, or PIDConL consumes exactly 1 AS Process Object and 1 OS Process Object.

Do elementary logic gates like AND, OR, and XOR consume Process Objects?

No. Elementary logic blocks, math blocks, and signal conversion blocks from the standard library consume zero AS RT Process Objects.

Can I share an OS RT PO license between redundant servers?

No. In a redundant WinCC server configuration, each individual server must have its own full OS RT PO runtime license matching the required tag capacity.

What is the difference between AS RT PO and OS RT PO?

AS RT PO licenses technological execution in the controller (CFC blocks). OS RT PO licenses visualization and operator control on the WinCC operator station.

Where can I find the official license order numbers for PCS 7 V9.0?

Official order numbers (MLFBs) are published in the Siemens ST PCS 7 Catalog and can be verified through an authorized Siemens distributor or the Siemens Industry Mall.

Technical References

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Related Tags

  • PCS 7 Licensing
  • Process Objects
  • S7-400H
  • Concept Design Tool
  • Commercial Accuracy
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