AS 410-5H System Expansion Card (SEC) Online PO Upgrade from Laptop with Higher PCS 7 Version

Upgrading the Process Object (PO) capacity of an AS 410-5H System Expansion Card (SEC) in a legacy PCS 7 V8.0 plant using an engineering laptop running PCS 7 V8.2 is technically viable and does not corrupt the customer's offline project. The online SEC upgrade procedure in Automation License Manager (ALM) communicates directly with the physical expansion card over Industrial Ethernet and does not modify controller user code or HW Config. Crucial prerequisites mandate that the physical CPU 410-5H operates on Firmware V8.1 or higher, the SEC is Hardware Release 2, and no controller downloads are initiated from the higher-version laptop. The PO expansion can be transferred in RUN mode without stopping the automation process.

Online SEC Upgrade Mechanism in Automation License Manager

The SIMATIC PCS 7 CPU 410-5H platform decouples controller hardware from system performance. Controller capacity (from 100 to 2,600 Process Objects) is determined by the System Expansion Card (SEC) inserted into the CPU chassis. Expanding capacity is executed via CPU 410 Expansion Packs through Automation License Manager (ALM).

The upgrade procedure generates a cryptographic License Request File (*.req) on the target AS, which is submitted to the Siemens License Management Portal to generate an activation Release File (*.rel). ALM transfers this .rel file directly into the non-volatile EEPROM of the SEC without recompiling or altering the user logic.

Cross-Version Safety: Performing Upgrades with Higher-Version Laptops

When a plant's resident Engineering Station runs PCS 7 V8.0 (which lacks online SEC upgrade wizards requiring V8.1+), an engineer can safely connect a laptop running PCS 7 V8.2 / ALM V6.0:

Action on Higher-Version LaptopImpact on AS ControllerImpact on Customer V8.0 MultiprojectRead PO Information via ALMSafe: queries SEC read-only diagnostic registers.None: no offline project modification.Transfer PO Activation File (*.rel)Safe: updates SEC licensed PO limit in RUN mode.None: SEC capacity increases; existing code untouched.CFC / HW Config Download (PROHIBITED)Critical Hazard: Overwrites controller with V8.2 system blocks, requiring CPU stop and project migration.Customer V8.0 ES will be blocked from subsequent download changes.

Hardware Release and Firmware Prerequisites (Firmware V8.1 / SEC Release 2)

Before purchasing and transferring PO expansion packs, two hardware prerequisites must be satisfied:

CPU 410-5H Firmware: The physical CPU must run Firmware V8.1 or higher. If the CPU is currently running Firmware V8.0, a firmware upgrade must be performed prior to SEC expansion. On a standalone single CPU, firmware updates require a CPU STOP; on redundant AS 410-5H pairs, firmware updates can be executed in RUN.
SEC Hardware Release: The System Expansion Card must be Hardware Release 2 (FS 02) or higher. Release 1 cards manufactured during initial V8.0 deliveries do not support online cryptographic flashing and must be physically exchanged.

Step-by-Step Online SEC Upgrade Workflow

To safely execute the upgrade using the higher-version laptop:

Step 1: Connect Target AS in ALM on Laptop

Connect the laptop to the plant bus network via Industrial Ethernet.
Open Automation License Manager (ALM V6.0).
In ALM, select Edit -> Connect Target System -> Connect AS....
Enter the CPU 410-5H IP address and check 'Enable expert mode'.

Step 2: Generate License Request File

Right-click the connected CPU 410 -> select Create License Request File....
Save the resulting *.req file to the laptop desktop.

Step 3: Redeem on Siemens License Portal

Log into the Siemens Web License Manager (www.siemens.com/automation/license).
Upload the *.req file and enter the License Key Certificate numbers from the purchased CPU 410 Expansion Packs.
Download the generated License Release File (*.rel).

Step 4: Transfer Activation File to CPU

In ALM, right-click the AS -> select Transfer PO Activation File....
Select the *.rel file: ALM writes the cryptographic authorization to the SEC in RUN mode.
Disconnect the laptop: the customer's V8.0 ES can now download changes with expanded PO headroom.

Verification

To verify successful PO capacity expansion:

In ALM, right-click the CPU 410-5H -> select Display PO Information.
Confirm that Total Process Objects reflects the upgraded limit (e.g., upgraded from 1,000 to 1,600 POs).
Check the CPU Diagnostic Buffer (Ctrl + D): confirm an entry logs successful capacity upgrade without error.
On the customer's PCS 7 V8.0 Engineering Station, compile CFC changes: verify compilation proceeds without PO overrun warnings.
Confirm the controller continues executing in RUN mode without plant interruption.

Limitations and Operational Precautions

Operational boundaries for SEC upgrades:

Do Not Rename AS Station: Do not alter the AS name, IP address, or project structure between generating the .req file and applying the .rel file; cryptographic validation will fail.
Redundant AS Symmetry: For redundant AS 410-5H systems, order two identical Expansion Packs and upgrade both SECs to maintain exact PO symmetry.
Maximum 2,600 PO Ceiling: A single CPU 410-5H cannot exceed 2,600 POs under any circumstances.

Engineer FAQ

Can a laptop with PCS 7 V8.2 upgrade the SEC of a PCS 7 V8.0 plant?

Yes. The online SEC upgrade communicates exclusively through Automation License Manager (ALM) to the expansion card EEPROM, without altering controller software or project databases.

Does upgrading the SEC require stopping the AS controller?

No. Flashing the PO activation file (*.rel) into the SEC can be performed while the CPU 410-5H operates continuously in RUN mode.

What happens if the physical CPU 410-5H is still running Firmware V8.0?

Online SEC expansion requires Firmware V8.1 or higher. The CPU firmware must be updated to V8.1+ before the SEC upgrade can be executed.

How can I check if the SEC is Hardware Release 2?

In ALM, connect the target AS and select 'Display PO Information' to view the SEC hardware revision, or visually inspect the product release marking on the physical SEC card.