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Architectural and Licensing Differences: SIMATIC S7-417-5H vs AS 410-5H Process Controllers

Architectural and Licensing Differences: SIMATIC S7-417-5H vs AS 410-5H Process Controllers

The primary architectural difference between the classic SIMATIC S7-417-5H and the AS 410-5H controller is that the CPU 410-5H is an all-in-one hardware platform whose memory and performance capacity are scaled entirely via a System Expansion Card (SEC), whereas the S7-417-5H relies on fixed hardware memory architectures and RAM/Flash memory cards. Furthermore, the CPU 410-5H natively supports Type Change in RUN (TCiR), integrated dual PROFINET IO interfaces with redundancy (S2 and System Redundancy R1), and conformal coating as standard. In CPU 410-5H, Process Object (PO) counting on the controller is managed by the physical SEC (from 100 up to 2600 POs / 2k+ unlimited), while the S7-417-5H requires AS Runtime PO engineering licenses managed via Automation License Manager without hardware card enforcement.

Table of Contents

Hardware Architecture and Controller Positioning

Siemens designed the SIMATIC S7-400 family to evolve from general-purpose automation controllers into dedicated, high-performance process controllers:

SIMATIC S7-417-5H (Order No. 6ES7417-5HT06-0AB0)

The S7-417-5H represents the top tier of the classic S7-400H product line. It features 32 MB of integrated work memory (16 MB code, 16 MB data) and requires external SIMATIC Memory Cards (RAM or Flash) for load memory. It was designed for both STEP 7 standalone automation and SIMATIC PCS 7 systems up to V8.x/V9.x.

SIMATIC CPU 410-5H (Order No. 6ES7410-5HX08-0AB0)

Introduced with SIMATIC PCS 7 V8.0 SP1, the CPU 410-5H is engineered exclusively for process automation. Instead of purchasing multiple hardware variants (412, 414, 416, 417), Siemens provides a single, high-performance CPU hardware unit. Its memory capacity, execution speed, and process object capacity are governed entirely by a removable System Expansion Card (SEC) plugged into the rear of the CPU.

System Expansion Card (SEC) Mechanism and PO Scaling Rules

The System Expansion Card (SEC) is an essential hardware component without which the CPU 410-5H cannot boot:

  1. Initial Sizing: SECs are available factory-configured for specific PO capacities: 100, 500, 1000, 1600, or 2k+ (unlimited, rated up to 2600 POs).
  2. Online PO Upgrades: Using Automation License Manager (ALM) in PCS 7 V8.1 or higher, an installed SEC can be upgraded online in increments of 100 or 500 POs without replacing the physical card or interrupting controller execution.
  3. Capacity Thresholds: Once an SEC reaches 2600 POs (or is ordered as 2k+), the controller's PO licensing limitation is cancelled, allowing the CPU to load as many blocks as fit within physical memory and scan time limits.
  4. Redundant Configurations: In an S7-400H redundant automation system, both CPUs must have identical SEC cards with matching PO capacity ratings.

Key Functional Innovations: Type Change in RUN and PROFINET

The CPU 410-5H introduces fundamental process automation capabilities not possible on the classic S7-417-5H:

1. Type Change in RUN (TCiR)

On classic controllers (S7-417-5H), modifying a block interface (adding an input or output parameter) or upgrading a library block (e.g., from APL V7 to APL V8) required stopping the controller (CPU STOP). On the CPU 410-5H, the operating system and CFC compiler support Type Change in RUN, allowing block interface changes and library updates to be downloaded while continuous process operations remain active.

2. Native Redundant PROFINET IO

The CPU 410-5H integrates dual 2-port Industrial Ethernet interfaces supporting PROFINET IO with system redundancy (S2 and R1 topologies) directly on the CPU, eliminating the mandatory requirement for external CP 443-1 communication processors for plant-wide fieldbus networking.

3. Harsh Environment Ruggedization

All CPU 410-5H units come standard with conformal coating (ISA-S71.04 severity level G1/G2/G3 and extended operating temperature ranges), whereas standard S7-417-5H units require specialized SIPLUS variants for harsh chemical or temperature environments.

Comparative Technical Specifications and Licensing Matrix

The following table compares the technical, functional, and licensing characteristics of the S7-417-5H and CPU 410-5H:

Feature / SpecificationClassic S7-417-5HModern CPU 410-5H Process ControllerPrimary Order Number (MLFB)6ES7417-5HT06-0AB06ES7410-5HX08-0AB0System Expansion Card (SEC)Not supported; fixed hardwareMandatory hardware card defines PO capacityWork Memory Architecture32 MB fixed (16 MB code / 16 MB data)48 MB dynamic high-speed work memoryLoad Memory RequirementExternal RAM / Flash Memory CardIntegrated non-volatile Flash load memoryType Change in RUN (TCiR)No (Requires CPU STOP for interface edits)Yes (Interface edits loaded in RUN)Integrated PROFINET PortsNone (requires external CP 443-1)2x 2-port PROFINET IO with System RedundancyPO Scaling MechanismAS RT PO software licenses in ALMHardware SEC capacity + AS RT PO softwareMaximum PO ThresholdLimited by memory and cycle timeHardware limit cancelled at 2600 POs (2k+)Conformal CoatingOptional (requires SIPLUS order)Standard on all production units

Always validate hardware configurations and license requirements against authorized Siemens distributor quotations.

Verification

To verify CPU configuration and SEC licensing status:
1. In STEP 7 / PCS 7 HW Config, open module properties for the CPU and verify that the firmware version and configured PO count match the hardware.
2. In Automation License Manager, connect to the CPU online to verify the active SEC PO capacity and validate license availability.
3. In SIMATIC Manager, perform a target compile and check the PCS 7 Process Object statistics (Target System -> Charts -> Process Objects).
4. Verify that the loaded PO count does not exceed the physical SEC rating.

Limitations and Operational Precautions

  • CPU 410-5H is exclusively released for SIMATIC PCS 7 (as of V8.0 SP1); it cannot be configured as a standard standalone controller in pure STEP 7 Classic without PCS 7 engineering tools.
  • In redundant S7-400H configurations, both CPU 410-5H units must have identical SEC PO ratings; mismatched SEC capacities prevent redundant synchronization.
  • Distinguish hardware SEC capacity from AS RT PO software runtime licenses; both requirements must be satisfied for licensing compliance.
  • Always validate final license quantities, SEC capacities, and MLFBs against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Why is the CPU 410-5H hardware less expensive than the S7-417-5H?

The CPU 410-5H utilizes modern, high-volume standardized electronics where base hardware costs are decoupled from performance. The commercial investment is distributed across the required System Expansion Card (SEC) based on actual process object requirements.

What happens if I download more process objects than the SEC allows?

The PCS 7 CFC compiler alerts you during compilation. If you attempt an online download exceeding the SEC limit, the CPU rejects the download, preventing unauthorized capacity overruns.

Can an SEC be swapped from one CPU 410-5H to another in the field?

Yes. The SEC can be transferred to a replacement CPU 410-5H chassis during maintenance, immediately transferring all licensed PO capacity to the new hardware.

Technical References

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Related Tags

  • CPU 410-5H
  • S7-417-5H
  • System Expansion Card
  • Process Objects
  • Type Change in RUN
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