PCS7 MIGRATION V6.1 TO V8.

0 WITH BATCH Fox Control

PCS7 Migration from V6.1 to V8.0 with Batch

Purpose of this Documentation

This documentation provides a overview of the basic steps to adapt to existing PCS 7 process control
system to the new SIMATIC PCS 7 version 7.1 and further to V8.0. It will assist in updating PCS 7 project
for installation and commissioning of the up-to-date software.
For PCS7 versions below V6.1 should be initially upgraded to V6.1.

Scope
This document explains a typical scenario for migration of project from PCS7 V6.1 to PCS7 V7.0 and then
to PCS7 V8.0, without implementing the new PCS7 functionalities available with different libraries of
PCS7. The implementation procedure herein includes the basic software upgrade procedure and also
the procedure to migrate the project from lower to higher version.

Changes compared with previous versions

In the following you will find an overview of the most important changes compared with previous
versions:
 Single clients are no longer supported by PCS 7 V7.0 and higher.
 PCS 7 setup automatically installs the necessary hot fixes and SQL server.
 Use of OS clients as maintenance clients (default configuration for an OS client in terms of the
maintenance server).
 The architecture for SIMATIC PDM has been modified. You can find additional information about
this in the section titled "How to configure the SIMATIC PDM Server.
 The PCS 7 licensing scheme has been changed for some PCS 7 components.
 You can find information on updating the SIMATIC BATCH configuration in the following
documentation; - SIMATIC BATCH Readme - Part C1, Installation and Manual Process Control
System PCS 7; SIMATIC BATCH.
 Improved PC station diagnostics
 Use of the Advanced Process Library (APL) V8.0 as standard library for configuration

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Reference Documents
Following are the reference documents for project migration/software update:
 Manual Software update without utilization of new functions (PCS 7 V6.x or higher to V7.1) and
(PCS 7 V7.1 SP3 or higher to V8.0).
This both documents describe the procedure for the software update of PCS 7 Version 6.x or higher
to 7.1 SP3 and then to V8.0 without utilization of new functions.
 Manual Software update with utilization of new functions (PCS 7 V6.x or higher to V7.1) and (PCS 7
V7.1 SP3 or higher to V8.0).
This both document describe the procedure for the software update of PCS 7 Version 6.x or higher to
7.1 SP3 and then to V8.0 with utilization of new functions.

OTHER USEFULL DOCUMENTS

Documentation Content
Manual Process Control System PCS 7; Ensuring the Availability of a PCS 7 System; contains
Service Support and Diagnostics information on creating backups and how to perform
firmware updates.
Manual Process Control System PCS 7; PCS 7 PC - Hardware and Installation; Windows
PC Configuration and Authorization settings and tools; Software packages and
authorizations required.
Configuring Manual Process Control Guide to configuration steps in SIMATIC Manager,
System PCS 7; Engineering System CFC,SFC, NetPro
Configuring Manual Process Control Guide to configuration steps in WinCC
System PCS 7; Operator Station
Manual Process Control System Guide to configuration steps for fault-tolerant process
PCS 7; Fault-tolerant Process Control Systems control systems
Documentation Process Control System PCS 7; All of the modules released for use in SIMATIC PCS7
Released Modules are listed with the following specifications:
 Product designation
 Order number
 Firmware version
 Brief Description
Online Help for WinCC Information System Describes the updating of WinCC projects.
Manual Process Control System PCS 7; Describes the installation process for and application
OS Web Option of the OS Web Option in PCS 7.
Manual Process Control System PCS 7; Describes how an OPC A&E server with hierarchical
OPC A&E for PCS 7 access is used in PCS 7 systems
Manual Process Control System PCS 7; Describes the principles of use of fault-tolerant
Fault-tolerant Process Control Systems (redundant) components in SIMATIC PCS 7
SIMATIC manual S7 F/FH Automation Systems Describes the configuration & programming of failsafe
Readme for SIMATIC S7 F Systems S7 F/FH systems with the help of S7 F Systems.
(V5.2 SP4 or V6.0) Contains important information which must be strictly
observed when installing and using the S7 F Systems
options package.
The section "Options package S7 F Systems projects
only with F-modules or migration from PCS 7 to PCS 7
V6.0" describes how to migrate a project from the PCS
7 driver block library V5.2 to library V7.0, or how to
create a project which only contains F-modules.
What's new? Information on the differences between this version
and the previous version of PCS 7

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Overview of the Update Procedure

Step Action
1 Backing up the PCS 7 project to be updated
a Back up project data (AS Project, OS Project, Batch)
b Back up the libraries you created
c Export operator and display texts
2 Installation and settings on the ES and OS
a Install the Microsoft SQL Server
b Update PCS 7
c Install additional libraries
3 General adaptations in the project
a Update the OS with the Project Migrator
b Check the PH consistency
4 Adaptations in Net Pro and conversion of the CFC/SFC charts
a Check and adapt the connection data
b Convert CFC/SFC charts
Adaptation of OS-relevant settings
a Convert single clients
5 Adaptations in Batch
6 Testing of Migrated Project in PCS7 V7.1 SP3
7 Repeating steps 1 through 4 for PCS7 V8.0
8 Testing of Migrated Project in PCS7 V8.0

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Selecting the Update type :

The selection and use of the correct update type depends on the comprehensiveness of your software
update. The current status of the software and any boundary conditions that may exist. The update
types are - With Utilization of functions and without utilization of functions. Currently the update type
selected is "Without utilization of functions" for APL project.

Flowchart for Update type selection :

In case if all the installations will be done on new PC's / IPC'S, SO no software updates required in
installation side.

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General Requirements
The following requirements must be met regardless of whether to execute the software update with or
without the utilization of new functions. These are the minimum requirements.

Processor INTEL Core 2 Duo E6600/E8400, INTEL Core 2 Quad Q9400 or higher
Hard disk 250 GB SATA RAID 1 array in servers and ES/OS single stations
250 GB SATA in client systems
Partition size C:\ 50 GB
Work memory (RAM) 2.0 GB for PCS7 V7.1 SP3 AND 4.0 GB for PCS7 V8.0
Communications interfaces
For terminal bus communication RJ45 on-board gigabit Ethernet
For plant bus communication CP1613 A2 for PCS7 V7.1 SP3 and CP 1623 for PCS7 V8.0 or BCE
network adapter for engineering station and OS server

Operating System OS REQUIREMENT

PC PCS7 V7.1 PCS7 V8.0
ES WINDOWS XP SP3 WINDOWS 7 ULTIMATE
OS SERVER WINDOWS 2003 WINDOWS 2008 R2 SP2
BATCH SERVER WINDOWS 2003 WINDOWS 2008 R2 SP2
OS / BATCH CLIENT WINDOWS XP SP3 WINDOWS 7 ULTIMATE

The PC where the PCS 7 software is installed must meet one of the following requirements:
– It can access a DVD drive via a network.
– It has its "own" DVD drive (example: USB DVD drive).

Note: Before beginning with any additional changes to the configuration, software update must be
completed.

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Requirements for Performing a Software Update

 Information on the operating systems and the service packs required can be found in the PCS 7
Readme file.
 Since using the Windows 7/Windows Server 2008 R2 operating system, will have to update the
version of the communication components in the Station Configuration Editor and HW Config. The
version depends on the version of SIMATIC NET installed on the target station.
 As of Windows 7 or Windows Server 2008 R2, SIMATIC NET V8.2.x is installed. Depending on the
network adapter used, select the following version of the communication component in HW Config:
- When using 'IE General' standard network adapters: V8.2
- When using communication processors (e.g. CP 16xx): V8.1.1
The CP 1613 A1 communication processor is no longer supported by PCS 7 on operating systems as of
Windows 7/Windows Server 2008.
 PA devices with a profile earlier than 3.0 and slave family 12 : As of PCS 7 V5.2 + SP3, PA devices are
supported by the new signal and diagnostic blocks. This includes the "Generate module driver"
function. The GSD file (Rev. 3) of the corresponding device must contain the entry "Slave Family =
12" for proper execution of this PCS 7 function. If it does not contain this entry, contact the device
manufacturer to obtain an appropriately corrected GSD file.

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Libraries installed in PCS 7 V7.1 or higher

The following default libraries are installed in PCS 7 V7.1:
 PCS 7 Basis Library and PCS 7 Library
Contain the updated blocks of the PCS 7 Library up to PCS 7 V7.0 SP1
 PCS 7 Advanced Process Library
Contains the blocks of the PCS 7 Advanced Process Library
 PCS 7 V8.0
Installation of PCS7 libraries prior to PCS7 V8.0 to be installed from the folder "Additional Products"
is required for the software update without utilization of the new functions.
Libraries that were supplied prior to PCS 7 V8.0 cannot be installed directly from their original
setup.

Note : Installation of the original PCS 7 library (original project PCS7 Version) is required for the
software update without utilization of new functions.

Changes in the License Concept

The licensing scheme has changed in PCS 7 V7.0:
 The method for counting process objects between the OS and engineering system has been
simplified.
 The Certificate of License for the AS process mode is supplemented by a license key. When the AS is
loaded, the number of process objects already loaded will be determined.
Further information about the selection of the correct license key/authorization is available in the
manual Process Control System PCS 7; PC Configuration and Authorization.

Rules to be Followed :
 Follow information for every step as to be carried out for configuration work.
 Functional expansion of the PCS 7 project at a later point in time can be done.

Note : The exact sequence of configuration steps specified in this documentation must be followed in
order to carry out the software update.

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Overview of preparations

Perform the steps listed below prior to starting the software update (i.e. under PCS 7 V6.1), in order to
prevent data being lost.

Carry out the following instructions in succession before taking Backup.

1. Comparing Time Stamps :

Open your PCS 7 project in SIMATIC Manager.

1. In the
component
view, select
the chart
folder of an
AS.
2. Double-click
on any
chart. The
CFC editor
opens.
3. Select the menu command CPU > Compare.
4. Compare the time stamps "Last compilation" and
"Compilation of the loaded program".

If the time stamps are... ... Then

Identical 1. Click "Close".
The dialog box is closed.
Different 1. Select the menu command CPU > Download.
2. Select the "Changes" check box and apply all other standard settings.
3. Click "OK".
Changes start to be downloaded.
4. If changes have been downloaded without errors, select the
menu command CPU > Compare.
The "Last offline program change" and "Last online program
change" time stamps must match up.

5. Perform steps 2 to 5 for each automation system (AS1, AS2, . . . etc).

6. This ensures the backup taken is the latest as of Program in PLC.

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2. Reading Back the AS Parameter Settings :

If parameters which are not in the

configuration have been set in the AS, that can
be able to read these settings back into the
project.

1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
Open the PCS 7 project in SIMATIC Manager.
2. In the component view, select the chart
folder of an AS.
3. Double-click on any chart. The CFC editor
opens.
4. Select the menu command Chart > Read
Back.
5. Select the entries "Program on the CPU"
and "Only data relevant for operator
control and monitoring" in the "Read Back"
dialog box.
6. Click "OK". The read-back process begins.
7. Perform steps 2 to 6 for the other automation systems (AS1, AS2, AS3) also.

3. Archiving the project :

1. In SIMATIC
Manager,
select the
menu
command
File >
Archive.
The
"Archive"
dialog box
opens.

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2. Select the "Multiprojects" tab.

3. Click "Browse" and select the project you want to
archive from the list.
4. Click "OK" to save your settings. The "Archive - Select
Archive" dialog box opens.
5. Make the following settings for archiving:
 Select the drive and the folder for the archive file
from the "Save" drop down list box.
 Enter the name under which the archive file should
be saved in the "File name" text box.

Recommendation:
Choose a name for the project's archive file which indicates the date on which
archiving took place. Example: "year_month_day_projectname"; e.g. 2013_09_23_name
6. Click "Save" to apply your entries. The "Archive – Options" dialog box opens.
7. Click "OK". The archiving process begins. When the "Archive" dialog box closes, archiving is finished.

Note : The archived project will reflect the state of the project before the software update.

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4. Backing Up OS Data :

1. To operate the OS server on a newly installed PC following the software update, back up the OS
project of the OS server.
2. Deactivate the OS server from runtime, and then copy the project folder from the root path. If
required restart the PC once.
3. This will ensure the backup of the manually created tags, custom faceplates and other bmp/Emf files
as well as pop-ups configured in project. By default, the configuration data and the archive data of
the OS are stored in the OS project of the OS server.

5. Simatic PDM :
SIMATIC PDM configuration data is included automatically in the backup of a SIMATIC project.

6. Backing Up User Created Libraries :

Generate a backup copy of project library that contains a collection of user-specific blocks for the
project to be updated so that you can retrieve this data after having updated the software. Carry out
these steps for each library for back up.

1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
Start SIMATIC Manager. No PCS 7 project must be open.
2. In SIMATIC Manager, select the menu
command File > Archive.
The "Archiving" dialog box opens.
3. Open the "Libraries" tab.
4. Select the library to be backed up and click
"OK".
The "Archiving - Select an Archive" dialog
box opens.
5. Specify the file name and the storage
path.
6. Click on the "Save" button.

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Note : Exporting Operator and Display Texts, not required if Multilanguage has been not setup in
project.
If you want to display text in more than one language in PCS 7 (for example, message texts or OS
area IDs), always use the export/import function to change the multilingual texts (menu command
Options > Manage Multilingual Texts > Export and then Import after the changes have been made).
User Achieves : You must always import runtime data from the user archives in the language in which
the runtime data was exported.

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7. BATCH Backup :

1. Select the main project folder in left top corner of Simatic manager screen. (As in Fig. ‘ WPB ‘)
2. Right click and select Simatic Batch. Simatic batch control center will open.
3. Select the process cell (WPB) and then in menu command Options > Backup as shown in fig below.

Note : To avoid errors do not rename the Backup file.

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Preparations in ES station of versions PCS7 V7.1 SP3 and PCS7 V8.0

Preparations :
1. Create a folder on any of the drives (D: or E:). Rename the folder as “Project_Name”
2. Create Subfolders as : 1.Project, 2.Backup, 3.Batch, 5.Logs, 6.Errors, 7.Documents; the names itself
indicates the details to be stored in respective folders.

Note : Installation of libraries and PDM devices libraries, and hardware updates must be already done
as per the installation procedure given for PCS7 V7.1.

Retrieve Project Backup :

1. In SIMATIC Manager, select the menu command File > Retrieve. The "Retrieve" dialog box opens.
2. Click "Browse" and select the project backup you want to retrieve from the list.
3. Click "OK. The project retrieval starts on the selected location.
4. After retrieval is completed a window pops-up asking to open the retrieved project. Click "OK".

Note : After opening the project the popup will prompt for Migration, Click NO on this window, as
shown in fig below.

Checking of Retrieved project:

Following checks must be done in the retrieved project before performing any updates in project:

Hardware Configuration Checking :

This step ensures whether all the configured hardware is available in the retrieved project.
1. Open Hardware Configuration of the AS system.
2. Check all the modules / IM's and PDM devices are available as per the Excel file " Hardware Details"
with respect to site project in PCS7 V6.1
3. Check all the MLFB Nos. of each IM/CPU/Module/PDM devices etc in detail.
4. Check all the IM address with respect to above mentioned file data.
5. Check the Profibus speeds of all the master Profibus loops in their properties.
6. Check whether the download button in configuration is active.

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Note : If download button is not active then save as compile the project and note down the errors and
logs. These errors must be corrected to proceed further.

7. Check this checkpoints for all the AS systems (AS1, AS2, AS3).
8. Any deviations must be noted down, and rectified with proper solution.

Hurdles :
1. If the Images for PDM devices are not displayed and only boxes are displayed then copy the
respective BMP file of the devices type in the folder path
c:\Programfiles\Siemens\Step7\S7Data\NSBMP\

2. Its possibility that the PDM devices may not be shown in Hardware configuration. For this step
just install the hardware updates and open / retrieve the project again.
3. Double click on the PDM device to show its detail info.
4. In case PDM devices is shown in hardware, but showing no details then it can be resolved in
following ways :
 Direct upload from PDM device at site.
 Reconfiguring the PDM devices having same address details (Not Recommended).

Caution : Don't “SaveAS” the Project or Hardware Configuration if the device/devices are missing or
are having the errors, else the particular device will be automatically removed. This will
further create error in project. Just Manually rectify the error.

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Adaptations in the PCS 7 Project on the ES

Updating Operator Stations with the Project Migrator :

Using the Project Migrator the OS pictures and libraries are updated.
Carry out the following steps for Each OS and client project :

1.

Select the menu command Start > SIMATIC > WinCC > Tools > Project Migrator.
The "CCMigrator" dialog box opens, displaying "Step 1 of 3".
2. Click "Next". "Step 2 of 3" opens.
3. In the OS project path, select the MCP file.
OS projects are located in the PCS 7 project path under "wincproj".
4. Check the following settings :
– "Pictures and libraries" check box: Selected (default)
– "Configuration data" check box: Deactivated (grayed out)
– "RT data" check box: Deactivated (grayed out)
– "dBase archives" check box: Deactivated (grayed out)
5. In "Step 3 of 3", click "Finish". The update is performed automatically.
6. Repeat these steps for each OS station and for client as well.

Note :
1. Do not delete any @plds, since that step is only required for SINGLE OS clients supported in earlier
versions.
2. Also no need to Run OS project editor.
3. Do not update picture objects using tool.
4. For additional information refer document "Process Control System PCS 7 Software update
without utilization of new functions (PCS 7 V6.x or higher to V7.1) : - Adaptation of OS-relevant
settings".

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Hurdles :
1. If a popup as shown below - "No target OS station", prompts then close the project and restart the
PC.

Plant Hierarchy Checking :

This step is to ensure any loss of assignments/S88 batch structure in plant hierarchy:

1. Open the project in plant view.

2. Check the flow of plant hierarchy is in coordination with site project.
3. Right Click on the hierarchy folders, select the S88 Type definition, and check for proper object type
assignments as per PCS7 V6.1 project.
4. Note : This checking can be easily done in Process object view, on Hierarchy folders tab.
5. Check AS-OS assignments of folders. (AS / OS assignments in Process object view).
Right now no assignments have been given for OS part. But AS assignments are given to respective
folders.
6. Select the Options > Plant Hierarchy > Check Consistency command. The program checks the PH.

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7. The "Check Consistency - Log" dialog box opens. Correct any errors that were found. For more
information about the possible errors, click the "Help" button in the "Check Consistency – Log" dialog
box.

Hurdles :
1. As shown in above fig, for S88 inconsistency error, ignore it since its showing the inconsistency with
respect to other AS in multi-project. But later while doing modification it should be kept in mind to
structure the s88 type for the same level of hierarchy folder.
2. For names with parenthesis error just rename it removing the parenthesis, else it can also be
ignored.

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Adaptations in NetPro/HW Config :

In NetPro, check whether all of the connection and configuration data are configured for the target
stations.
1. Select the PCS 7 project in SIMATIC Manager.
2. For PCS7 V8.0 replace the CP in OS hardware configuration.

3. Select the menu command Options > Configure Network. NetPro opens.
4. Select the menu command View > Cross-Project Network View. as shown in below fig.

5. The cross-project network view is displayed. This allows to toggle directly between all projects in
the multiproject.
6. Check the connections to the various stations: AS-OS, AS-AS, ES-AS.

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7. If required necessary changes can be made when the "cross-project network view" is deactivated.
8. For time synchronization, check the time settings of the network adapters (e.g. CP 1613) in the ES
and OS. Double-click the network adapter of the OS/ES. Time-of-day mode must be selected for
time synchronization on the "Options" tab, as shown in below fig.

9. Perform a "Save and Compile" operation with the "Save and Compile All" option.

10. Remember station name for OS servers should contain “_” and should be in capital letters.

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Conversion of the CFC/SFC Charts :

1. Open a CFC chart and move any block it contains. This change immediately starts the conversion
dialog.
2. Click "Yes". The "Convert Format" message window opens.
3. Click “Yes".
4. Click "OK".
5. Execute a complete compilation of the S7 program.
6. Repeat this step for all AS systems (AS1, AS2, AS3).

Hurdles :
1. For "Unable to copy/move..." error as shown in below fig, click "OK" on the popup window and do
the necessary changes in symbol table and restart the cfc conversion.

2. Tags which were not assigned names in symbol table, are made as textual interconnection, as
shown in fig below

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3. All the channel drivers for DI, DO, AI, AO and for PA devices which existed in minor quantity in
project are deleted.
(viz : CH_DI, CH_DO, PA_AI, PA_AO)

4. Now save as Re-organize the project to avoid Errors.

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Conversion of the Batch Data :

Conversion of the batch data is done automatically during migration of the project. Follow the steps
given below for compile and download of batch objects and restore of recipes.

1. Select the main project folder in left top corner of Simatic manager screen. (Here WPB)
2. Right click and select Simatic Batch.
3. It will be popup for batch migration, click "OK". It will start migrating as shown below in fig

4.

After migration completes simatic batch control center will open.

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5. Select Options > Restore. Now give the path of the Batch backup file taken initially.

6. Now it will pop-up for User name and password. Enter the details (You can enter Your PC user name
and Password)
7. Now In menu Options > select Role management. Configure the user as shown below in fig. for
Super User.

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8. Now Right click on process Cell > here in fig WPB, and select Update Process Cell.
It will take a long time. have patients and do not click or terminate any process.

9. Now check for all the Recipes, Material and Libraries.

10. To take backup of migrated batch data, select Options > Backup as shown in fig below.

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Testing of the Migrated Project in lab

Preparations :
Following preparations must be done before testing of the project:
1. Arrangement of PLC with the same MLFB no as available on site.
2. Proper installation of switches and network topology of terminal and plant bus as per the file "
Configuration file".
3. Save As Reorganize the project.

Procedure :
1. Make changes in the hardware configuration as per the hardware available for testing. Do not delete
the Modules from hardware configuration, but instead disconnect the Profibus master links as
shown in below fig.
2. Download the AS program in all the three AS station i.e. AS1, AS2, AS3.
3. Download the OS program in all the OS server and the client station.
4. For troubleshooting and problems solution faced during testing refer the details below.
5. Perform the checking as per the checklist.
6. Before Activating the project on OS stations do the below listed check points.
7. Check the Batch Recipes and client PC's runtime after processing OS servers in runtime.

Check points for Settings on the OS Servers and clients stations :

Before activating the projects downloaded to the various OS servers and clients, check some of the
settings in each OS as a safety precaution.
1. Open the "Redundancy" editor in WinCC Explorer.
2. Check all settings.
3. Click "OK".
4. Open the "Time Synchronization" editor in WinCC Explorer.
5. Check all of the settings in the dialog box.
6. Click "OK".
7. Repeat steps 1 through 6 for the second OS server and all other redundant OS servers.
8. For client stations, the valid steps are 4 through 6. Do this for each client station.
9. Activate process mode on the OS servers and on client stations.

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PCS7 MIGRATION V6.1 TO V8.0 WITH BATCH Fox Control

Testing Hurdles :
1. If the CPU selected is not of the same type then error can occur while downloading to the PLC,
depending upon its No of DB's support capacity. Change the CPU as per Capacity in HW Config & in
the AS rack.

2. Downloading Failed for OS server as shown in below fig.

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PCS7 MIGRATION V6.1 TO V8.0 WITH BATCH Fox Control

Check the following points to ensure proper downloading in OS servers:

1. All PCS on client server network should be able to ping each other by their PC name.
2. Enter the name of all PCs on same network with their IP address under file lmhost.sam & host lying
under this path “C:\WINDOWS\system32\drivers\etc\” by opening them in notepad. Format for
entering IP address to be followed as shown below

3. Do the same setting on each PC configured over same network.

Precaution: If later by any means, IP address of any PC got changed, necessary changing in above file
is must in order to ping PC with its name.

4. Check for the Password of PC's. Both ES and OS PC's must have same User name and Passwords.
5. The Path in OS PC is accessible and allows to read / write at that location.
6. The Folder in which downloading is being down is mapped as a network drive in ES PC.
7. The Terminal Bus is configured in Simatic shell.

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