CPU 410-5H System Expansion Card (SEC) PO Upgrade Rules in PCS 7 V8.0 vs V8.1

In SIMATIC PCS 7 V8.0, expanding the Process Object (PO) capacity of a CPU 410-5H controller cannot be executed online via Automation License Manager (ALM) network transfer because online CPU expansion capability was introduced only starting with SIMATIC PCS 7 V8.1. In PCS 7 V8.0, the hardware System Expansion Card (SEC) defines fixed controller PO limits (from 100 POs up to 2600 POs), and capacity increases require physically replacing the SEC card with a higher-capacity model or upgrading the engineering station to PCS 7 V8.1 or higher. Starting with PCS 7 V8.1, engineers can order CPU 410 Expansion Packs (100 PO or 500 PO) and execute seamless, online, bumpless capacity upgrades via ALM without stopping the controller.

SIMATIC CPU 410-5H System Expansion Card (SEC) Architecture

The SIMATIC PCS 7 CPU 410-5H Process Automation controller (6ES7410-5HX08-0AB0) introduced a unified controller hardware concept for process industries. Rather than requiring distinct hardware tiers (such as CPU 414, 416, or 417), a single high-performance CPU 410 hardware platform is deployed across all plant scales. Controller performance, work memory size, and technological capacity are defined exclusively by a plug-in hardware token named the System Expansion Card (SEC) inserted on the rear of the CPU module.

The SEC determines the maximum allowable AS Process Objects (PO) the controller can execute, ranging from CPU 410-5H PO 100 (6ES7653-2BA00-0XB5) for small package units up to CPU 410-5H PO 2600+ (6ES7653-2BB00-0XB5) for massive continuous facilities. If a plant expands its process units and instantiates additional technological blocks in CFC, the controller monitors PO utilization against the SEC limit. Exceeding this limit triggers engineering compile locks or license shortage alarms.

Why Online PO Upgrades Fail in PCS 7 V8.0 Environments

When engineers operating PCS 7 V8.0 purchase CPU 410 Expansion Packs and attempt to transfer PO licenses via Automation License Manager across the network, the transfer fails because of engineering software version boundaries:

Absence of Online SEC Upgrade Mechanisms in PCS 7 V8.0: In PCS 7 V8.0, the CPU 410-5H operating system firmware (V8.0) and STEP 7 V5.5 SP3 engineering drivers lacked the cryptographic handshake and flash-write routines required to re-program the physical SEC card across Industrial Ethernet. The SEC was treated strictly as a read-only hardware dongle.
Online License Upgrade Introduced in PCS 7 V8.1: Siemens introduced the Online SEC Upgrade function in SIMATIC PCS 7 V8.1 (with CPU 410 firmware V8.1+). This feature allows ALM to communicate directly with the CPU over the network, verifying cryptographic certificates and incrementing the hardware PO counter inside the SEC without halting plant operations.
Physical Replacement Mandatory in V8.0: For systems remaining on PCS 7 V8.0, expanding controller PO capacity requires purchasing a physical replacement SEC card with the desired total PO count, shutting down the CPU, swapping the card, and executing a cold restart.

CPU 410-5H SEC Types, Expansion Packs, and Version Support Matrix

The following table summarizes SEC hardware types, expansion packages, and version prerequisites:

Product NameOrder Number (MLFB)Process Object CapacityUpgrade Capability in V8.0Upgrade Capability in V8.1+System Expansion Card PO 1006ES7653-2BA00-0XB5100 AS RT POsBase hardware tokenUpgradeable online via ALMSystem Expansion Card PO 5006ES7653-2BB00-0XB5500 AS RT POsBase hardware tokenUpgradeable online via ALMSystem Expansion Card PO 2600+6ES7653-2BC00-0XB52600+ AS RT POs (Max)Base hardware tokenMaximum capacity reachedCPU 410 Expansion Pack 100 PO6ES7653-2CC00-0XA0+100 PO IncrementalUnsupported (Fails)Supported (Bumpless Online)CPU 410 Expansion Pack 500 PO6ES7653-2CD00-0XA0+500 PO IncrementalUnsupported (Fails)Supported (Bumpless Online)CPU 410 Upgrade via USB / ALMOnline Network TransferNetwork HandshakeNot supported in V8.0Native in ALM V5.3 SP1+

Step-by-Step Procedure to Expand CPU 410 Capacity (V8.0 vs V8.1+)

To resolve PO capacity limits on CPU 410-5H controllers:

Resolution Pathway for PCS 7 V8.0 Installations (Physical Hardware Swap):
- Audit current PO consumption: In SIMATIC Manager, select the CPU and open PLC -> Process Objects.
- Order a physical replacement System Expansion Card with higher capacity (e.g., replace PO 500 with 6ES7653-2BC00-0XB5 for PO 2600+).
- Schedule a plant maintenance shutdown.
- Power down the S7-400 rack; remove the CPU 410-5H from its subrack.
- Carefully remove the old SEC card from the rear slot and insert the new SEC card.
- Re-seat the CPU in the rack, power up, and download the hardware configuration.
Alternative: Upgrade Engineering Station to PCS 7 V8.1 or V8.2:
- Upgrade the Engineering Station to PCS 7 V8.1 SP1 or V8.2.
- Update CPU 410-5H firmware to V8.1 or higher.
- Order the electronic CPU 410 Expansion Pack (6ES7653-2CC00-0XA0 for 100 POs or 6ES7653-2CD00-0XA0 for 500 POs).
Online License Upgrade Execution in PCS 7 V8.1+ via ALM:
- Open Automation License Manager (ALM) on the Engineering Station.
- Connect ALM to the CPU: Select Edit -> Connect Target System -> Connect AS.
- Enter the CPU IP address; ALM establishes a cryptographic connection and displays the active SEC serial number and PO capacity.
- Drag the CPU 410 Expansion Pack license from the local drive and drop it onto the connected CPU.
- ALM flashes the expansion into the SEC memory; the CPU immediately accepts the increased PO limit in RUN mode without interrupting production.

Verification

Verify expanded Process Object capacity:
1. In SIMATIC Manager, select the CPU and select PLC -> Process Objects.
2. Confirm that the total licensed Process Object count reflects the newly installed capacity (e.g., expanded from 500 to 1000 POs).
3. Open CFC; execute Chart -> Compile -> Changes Only; confirm that compilation succeeds without license shortage warnings.
4. Check the CPU diagnostic buffer; confirm zero licensing mismatch entries.

Limitations and Operational Precautions

Single SEC per CPU: A CPU 410 cannot operate without a physical System Expansion Card installed. Never remove an SEC card while the controller is powered.
Redundant H-System Symmetry: In redundant S7-410H configurations, both CPUs must be fitted with SEC cards of identical PO capacity. Mismatched SECs block H-redundancy coupling.
Commercial Accuracy Disclaimer: Verify SEC order numbers (6ES7653-2...) and PO expansion rules against official Siemens catalog CA 01 and authorized distributor quotations.

Engineer FAQ

Can I upgrade CPU 410 PO licenses online in PCS 7 V8.0?

No. Online PO expansion via Automation License Manager requires PCS 7 V8.1 or higher and CPU 410 firmware V8.1+. In V8.0, physical SEC replacement is required.

Does online PO expansion in PCS 7 V8.1 stop the running controller?

No. In PCS 7 V8.1+, PO expansion via ALM is 100% bumpless and takes effect in RUN mode without interrupting controller execution.

What happens if my CFC charts exceed the licensed PO capacity on the SEC?

CFC compilation or downloading will flag an error indicating that licensed Process Objects have been exceeded, blocking changes until capacity is upgraded.

Can an SEC card be transferred from a defective CPU to a replacement CPU?

Yes. If a CPU 410 hardware unit fails, remove the SEC card and plug it into the replacement CPU 410; all PO licenses and MAC addresses are retained on the SEC.