Adding Process Objects to Existing PCS 7 Projects and CPU 410-5H

To add Process Objects (PO) to an existing SIMATIC PCS 7 project, determine whether your automation system utilizes modular S7-400 controllers or the CPU 410-5H Process Automation controller. For modular S7-400 systems, purchase software AS RT PO expansion licenses (e.g., 6ES7658-2BA00-0YB0 for 100 POs) and transfer them into Automation License Manager (ALM) on the Engineering Station. For the CPU 410-5H, PO execution capacity is governed by the physical System Expansion Card (SEC). Purchase a CPU 410 PO upgrade license, load the license key into ALM, and execute 'PLC -> Update System Expansion Card' in SIMATIC Manager to expand hardware capacity online without replacing the physical card.

Process Object Expansion Architecture in PCS 7

In SIMATIC PCS 7, system capacity is managed technologically through Process Objects (PO). As plants expand and new equipment modules (reactors, pumps, valves, loops) are added, the automation controller requires additional Process Object licensing to allow CFC compilation and downloading.

The engineering workflow for adding PO capacity depends directly on controller hardware architecture: modular S7-400 controllers (such as CPU 414-3, CPU 416-3, and CPU 417-4H) utilize floating software runtime licenses managed in Automation License Manager, whereas the dedicated CPU 410-5H controller embeds runtime capacity directly inside its physical System Expansion Card (SEC).

Modular S7-400 vs CPU 410-5H System Expansion Card

Understanding how the two controller families manage PO licenses is vital for planning:

Modular S7-400 Controllers: In legacy modular systems, AS RT PO licenses exist as software license keys stored on the Engineering Station. During CFC compilation, SIMATIC Manager tallies all technological blocks (MotL, VlvL, PIDConL, SFC), books them against available ALM license keys, and assigns them to the CPU chart container. Adding POs simply involves transferring new license keys to the ES hard drive.
CPU 410-5H Process Controller: In CPU 410-5H systems, PO capacity is enforced by the hardware System Expansion Card plugged into the rear of the CPU. The CPU operating system continuously verifies that active technological blocks do not exceed the SEC hardware limit. Expanding capacity does not require replacing the physical SEC hardware; instead, a software upgrade license is loaded into the card electronically via SIMATIC Manager.

Equipment Schedule and Process Object Upgrade Licenses

The table below details official Siemens order numbers for expanding AS Process Object capacity across modular and CPU 410 platforms.

Controller PlatformLicense Package DescriptionMLFB / Order NumberDelivery MediumTechnological CapacityModular S7-400SIMATIC PCS 7 AS RT PO (100 PO)6ES7658-2BA00-0YB0Software License (USB/OSD)Adds 100 software AS RT POs to ALMModular S7-400SIMATIC PCS 7 AS RT PO (500 PO)6ES7658-2BB00-0YB0Software License (USB/OSD)Adds 500 software AS RT POs to ALMCPU 410-5HCPU 410 PO Upgrade (100 PO)6ES7653-2CC00-0XB0Electronic SEC UpgradeExpands SEC hardware capacity by 100 POsCPU 410-5HCPU 410 PO Upgrade (500 PO)6ES7653-2CD00-0XB0Electronic SEC UpgradeExpands SEC hardware capacity by 500 POsCPU 410-5HCPU 410 System Expansion Card 500 PO6ES7653-2CA00-0XB0Physical Hardware CardBase hardware card with 500 PO capacity

[!IMPORTANT]
Commercial Accuracy and Procurement Disclaimer: Verify exact MLFB order numbers, hardware firmware revisions, and required > upgrade tiers with authorized Siemens representatives prior to procurement. Software tools like CDT serve as planning aids and > do not replace certified manufacturer commercial quotations.

Step-by-Step Procedure to Add POs to S7-400 and CPU 410-5H

Follow the applicable procedure below based on your controller hardware:

Method A: Adding POs to Modular S7-400 Systems

Connect the USB license token to the Engineering Station.
Open Automation License Manager (ALM): transfer the SIMATIC PCS 7 AS RT PO license keys to local drive C:.
In SIMATIC Manager, select the CPU charts folder in Component View: select Options -> Charts -> Process Objects -> Display booked process objects to verify that available capacity has increased.

Method B: Adding POs to CPU 410-5H via System Expansion Card Upgrade

Transfer the purchased CPU 410 PO Upgrade license key into Automation License Manager on the ES.
In SIMATIC Manager Component View, highlight the target CPU 410-5H.
Select menu PLC -> Update System Expansion Card.
The wizard connects to ALM, validates the upgrade license key, and transfers the capacity increase directly into the physical SEC over the Industrial Ethernet Plant Bus.
The SEC capacity updates online immediately without stopping the CPU or cycling power.

Verification

Verify Process Object expansion through the following checks:
1. In SIMATIC Manager, select PLC -> Module Information: under the Performance Data / System Expansion Card tab, confirm that 'Licensed Process Objects' reflects the upgraded total.
2. Open Process Object View (View -> Process Object View): verify that 'Available POs' is positive.
3. Compile CFC charts with newly added motors, valves, or loops: verify that compilation finishes with zero PO limit warnings.
4. Perform a CFC delta download: confirm that the controller accepts technological changes smoothly.

Limitations and Operational Precautions

For CPU 410-5H systems, SEC upgrade licenses are permanently bound to the specific physical card's serial number during the upgrade process. Once applied, an SEC upgrade cannot be returned to ALM or transferred to a different CPU. In redundant CPU 410-5H installations, both CPU A and CPU B must have identical SEC capacities; running mismatched SEC capacities prevents H-system synchronization.

Engineer FAQ

Do I have to stop the CPU 410-5H to upgrade the System Expansion Card?

No. The 'Update System Expansion Card' function executes online while the CPU 410-5H is in RUN mode without interrupting active process control.

Can I upgrade an SEC beyond the maximum capacity of CPU 410-5H?

The standard CPU 410-5H supports up to 2,600 Process Objects. Upgrading beyond this limit requires an engineering evaluation from Siemens technical support.

What happens if I download charts exceeding the SEC capacity on CPU 410-5H?

The CFC compiler prevents delta downloads, and SIMATIC Manager issues an error stating that the booked POs exceed the capacity of the System Expansion Card.