C135 PCS 7 (PCS7)
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Step-by-Step Software Migration Sequence for Upgrading PCS 7 V7.1 to V9.1 SP2

Step-by-Step Software Migration Sequence for Upgrading PCS 7 V7.1 to V9.1 SP2

To execute a software migration from legacy SIMATIC PCS 7 V7.1 to PCS 7 V9.1 SP2, you must follow an exact chronological installation and conversion sequence spanning intermediate software stages. A direct database jump is architecturally impossible because database table engines, Microsoft SQL Server platforms, and CFC compiler formats evolved fundamentally across intermediate releases. The certified engineering sequence requires preparing the V7.1 project, migrating through a staging environment running PCS 7 V8.2 SP1 to convert SQL databases and chart structures, and performing final modernization in PCS 7 V9.1 SP2. Each stage mandates complete project compilation, library updates, and consistency verification before progressing.

Table of Contents

Overview of the Two-Stage Migration Sequence

Upgrading an enterprise DCS across multiple decades requires separating database schema updates from operational commissioning:

[Phase 1: V7.1 System] ──► Archive & Clean Up 
                                │
[Phase 2: V8.2 Staging] ──► WinCC Migrator ──► CFC DB Update ──► Compile & Archive
                                                                       │
[Phase 3: V9.1 Target] ──► SQL 2017 Upgrade ──► OS Project Editor ──► Full Commissioning

By utilizing a dedicated intermediate virtual machine (VM) running Windows 7 SP1 and PCS 7 V8.2 SP1, the engineering team converts legacy project data without taking the operating plant offline until final cutover.

Phase 1: Project Preparation and Housekeeping in PCS 7 V7.1

Before moving files to modern engineering systems, clean and consolidate the source project on the original V7.1 ES:

Step 1: Clean Up Project Databases

  1. Open the multiproject in SIMATIC Manager on the V7.1 engineering station.
  2. For each project in the multiproject, select File -> Save As..., check With Reorganization (Slow), and save to a local staging directory.
    - Reorganization purges deleted block fragments, compresses internal database indices, and repairs orphaned pointers.
  3. Open each CFC chart folder and execute Options -> Check Block Types / Clean Up....
  4. Open the Symbol Table and remove any unassigned or duplicate symbols.

Step 2: Document Safety CRCs and Hardware Settings

  1. If the project utilizes S7 F Systems, open Options -> Safety Program and print the complete safety configuration log, including collective F-signatures and CRC hashes.
  2. In NetPro, document all configured S7 named connections, subnet IDs, and IP addresses.
  3. Create a verified archive of the multiproject using File -> Archive....

Phase 2: Intermediate Conversion in PCS 7 V8.2 SP1

Deploy a staging virtual machine configured with 64-bit Windows 7 SP1 and SIMATIC PCS 7 V8.2 SP1:

Step 1: Restore and Migrate Project in V8.2

  1. Restore the project archive in SIMATIC Manager on the V8.2 staging machine.
  2. A prompt appears indicating that the project was created with an older version. Click Yes to allow STEP 7 to convert the project database.
  3. Open each OS project: SIMATIC Manager automatically launches the WinCC Project Migrator.
    - The Migrator converts Microsoft SQL Server 2005 tables into Microsoft SQL Server 2014 format.
    - Wait for the migration log to report: Project migrated successfully with 0 errors.

Step 2: Update Chart Data and Compile in V8.2

  1. Open the CFC editor in any chart: CFC updates the internal chart data structures to V8.2 format.
  2. In SIMATIC Manager, select the Chart folder and execute Chart -> Compile -> Charts as Program:
    - Select Entire Scope.
    - Ensure Generate module drivers is checked.
  3. Open WinCC Explorer for the OS project: run the OS Project Editor with default V8.2 layout templates to modernize system graphics.
  4. Execute an OS Compile (Entire Scope) to confirm database alignment.
  5. Once verified with 0 errors, execute File -> Save As... (With Reorganization) and archive the V8.2 project.

Phase 3: Final Modernization and OS Compilation in PCS 7 V9.1 SP2

Transfer the V8.2 project archive to the permanent target engineering station running Windows 10 Enterprise LTSC and PCS 7 V9.1 SP2:

Step 1: Final Step 7 and WinCC Migration

  1. Open SIMATIC Manager in PCS 7 V9.1 SP2 and restore the V8.2 project archive.
  2. Allow STEP 7 to upgrade project containers to V9.1.
  3. Open each WinCC OS project: the WinCC Migrator runs a second time to upgrade SQL Server 2014 tables to Microsoft SQL Server 2017.
  4. Confirm successful database migration in the migration log.

Step 2: Master Data Library Alignment and Block Type Updates

  1. Open the Master Data Library (MDL).
  2. Update block types: copy the latest APL V9.1 SP2 blocks from the system catalog into the MDL block folder.
  3. In SIMATIC Manager, select Options -> 'Charts' -> Update Block Types....
    - Select all participating AS projects to propagate updated block interfaces across all CFC charts.
  4. Execute Chart -> Compile -> Charts as Program (Entire Scope with Generate Module Drivers).

Step 3: Run OS Project Editor and Update Typicals

  1. Open WinCC Explorer on the OS server projects.
  2. Open OS Project Editor: on the Basic Data tab, ensure that standard @ picture files are updated to V9.1 SP2 versions.
  3. In SIMATIC Manager, right-click the OS project and select Plant Hierarchy -> Create/Update Block Icons.
  4. Perform a full OS Compilation (Entire Scope).

Verification

To confirm that the multi-step migration is 100% complete and plant-ready:
- Verify compiler logs: confirm that all AS charts compile with 0 Errors and all WinCC OS compiles finish with 0 Errors.
- Check block versions: in SIMATIC Manager, open Options -> Reference Data -> Block Types and verify that no obsolete V7.1 library blocks linger in active charts.
- Start WinCC Runtime on an engineering test station: verify that process graphics load, block icons link to faceplates, and alarm banners display active system messages without script fault popups.
- Validate controller communication: test S7 named connections to the AS CPU via NetPro diagnostics.

Limitations and Operational Precautions

  • Do Not Skip the V8.2 Step: Attempting to migrate directly from V7.1 to V9.1 corrupts Alarm Logging archive segments and results in unresolvable C-script compilation errors in Graphics Designer.
  • Preserve Original V7.1 Backups: Keep multiple immutable copies of the original V7.1 project archive on external offline media. If an unforeseen defect occurs during staging, you must be able to restart the migration sequence from clean raw data.
  • Plant Downtime Planning: Loading the newly migrated program into the AS controllers requires a full download (Entire Scope), which requires placing the CPU in STOP mode. Schedule a plant maintenance shutdown for hardware cutover.

Engineer FAQ

How long does the intermediate migration in V8.2 take?

For an average project (2 to 4 AS controllers, 2 OS servers, ~2,000 Process Objects), executing the V8.2 intermediate migration and reorganization typically requires 4 to 8 engineering hours.

Can I migrate the project if some obsolete AS hardware is still in the project?

HW Config will flag unsupported legacy modules (e.g., obsolete CP 443-1 cards or discontinued ET 200M modules). You must replace obsolete hardware catalog objects with supported equivalents in HW Config before the final compile in V9.1.

Why does the WinCC Project Migrator need to run twice?

The WinCC database schema cannot jump directly from SQL Server 2005 (V7.1) to SQL Server 2017 (V9.1). The intermediate Migrator converts the Sybase/SQL 2005 format to SQL 2014, allowing the V9.1 Migrator to successfully upgrade to SQL 2017.

What should I do if a custom block type shows interface conflicts during block update?

If a custom user block has modified inputs or outputs, do not execute a blind block update. Review the block interface changes in SCL/STL, adjust call instances in CFC, and ensure instance data blocks are updated accordingly.

Technical References

  • Siemens Industry Online Support: SIMATIC PCS 7 Software Update with Migration from V7.1 to V8.2.
  • Siemens Industry Online Support: SIMATIC PCS 7 Software Update with Migration from V8.2 to V9.1 SP2.
  • SIOS Entry 109742323: PCS 7 Compendium Part A - Configuration Guidelines (Section: Migration Workflows).
  • SIOS Entry 109809264: SIMATIC Process Control System PCS 7 Released Modules and Operating Systems.

Related Articles

Related Tags

  • Migration
  • PCS 7 V7.1
  • PCS 7 V8.2
  • PCS 7 V9.1
  • WinCC Migrator
  • SQL Server
  • Industrial Automation
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