Diagnosing Missing AS RT Process Object Licenses and Unbooked PO Discrepancies in PCS 7

In SIMATIC PCS 7, when the Multiproject License Information dialog reports a discrepancy—such as 1,217 AS RT POs configured, only 711 booked, 1,100 licenses installed in Automation License Manager (ALM), and 'Currently available' showing 0—the deficit occurs because the total configured PO demand (1,217) exceeds the total installed license entitlement (1,100), driving the available pool to zero. The discrepancy between booked (711) and configured (1,217) POs typically arises when AS controllers were memory-reset (MRES / Urlöschen) or replaced without using the official 'Transfer back Process Objects' function, or when test controllers were loaded without returning licenses. To resolve this, audit each AS station in PCS 7 License Information, transfer back orphaned POs from disconnected or reset stations, and procure required AS RT PO upgrade license packages through an authorized Siemens distributor.

Executive Summary

Process Object (PO) licensing in SIMATIC PCS 7 regulates controller execution capacity across distributed Automation Stations. In multi-AS plants, control engineers occasionally face confusing license accounting metrics in SIMATIC Manager: installed license quantities appear booked, but available pools display zero while configured project counts exceed the installed total. Because PCS 7 enforces a check-out / check-in booking model across the Engineering Station and target controllers, abrupt CPU hardware replacements or controller memory resets can isolate booked licenses in database limbo. Understanding how AS RT POs are booked, tracked, and returned prevents commissioning halts and licensing compliance infractions.

Architecture and Fundamental Mechanics

The accounting mechanics of PCS 7 AS Runtime Process Objects operate through specific database and controller tracking structures:

The AS RT PO Booking Mechanism:
* In classic S7-400 systems (and software-managed PO environments), AS RT PO licenses reside in Automation License Manager (ALM) on the Engineering Station.
* When CFC charts are compiled and downloaded to an AS, SIMATIC Manager determines the number of technological blocks instantiated (motors, valves, controllers, dosing blocks) and 'books' that exact number of POs against the ES license pool.
* The booked licenses are tagged to the hardware station's unique subnet and MAC address.
The Zero-Availability Condition:
* In the reported scenario, 1,100 PO licenses are installed on the ES, but the multiproject requires 1,217 POs.
* Because total demand (1,217) exceeds capacity (1,100), the ES cannot satisfy the remaining 117 POs. Consequently, Currently available drops to 0.
* The remaining 506 POs (the difference between 1,217 configured and 711 currently booked) cannot be booked because the ES pool is exhausted.
Orphaned Booked Licenses:
* If an engineer executes a CPU memory clear (MRES) or swaps a CPU without first returning the booked POs in SIMATIC Manager, the ES database still considers those 711 POs assigned to that hardware node.
* The physical CPU loses its memory state, but the ES licensing database retains the debit. Until the engineer explicitly executes 'Transfer back Process Objects', those licenses remain locked and cannot be reallocated.

Step-by-Step Implementation Procedure

Follow these procedures to audit, recover, and reconcile AS RT Process Object licenses in SIMATIC Manager:

Open PCS 7 License Information:
* In SIMATIC Manager, right-click the root Multiproject folder and select PCS 7 License Information.
* Review the summary table displaying Configured POs, Booked POs, Installed Licenses, and Available Licenses.
Audit Individual AS Stations:
* In the left pane of the License Information dialog, expand the multiproject to view individual AS controllers.
* Check the booked count for each AS station against its actual CFC chart configuration.
* Identify any offline, decommissioned, or test AS stations that still hold booked POs.
Transfer Back Orphaned PO Licenses:
* Select the AS station that was reset or replaced.
* Click Transfer back Process Objects (or Return POs).
* Confirm the transaction. The booked POs will be credited back to the master license pool on the Engineering Station.
Reconcile S7-410-5H System Expansion Cards (If Applicable):
* If using CPU 410-5H controllers, note that PO capacity is governed by the physical System Expansion Card (SEC) inserted into the CPU.
* Verify that SEC hardware capacity matches the AS configuration; hardware SEC POs do not debit the ES software PO pool.
Procure Additional AS RT PO Licenses to Cover Deficits:
* If the plant genuinely requires 1,217 POs and installed licenses are only 1,100, a deficit of 117 POs exists.
* Consult an authorized Siemens distributor or check the Siemens Industry Mall for AS RT PO expansion packages (available in packages of 100 POs or 1,000 POs, such as order numbers in the 6ES7653-2... series for CPU 410 or standard AS RT PO packages).
* Transfer the newly acquired license keys into Automation License Manager on the ES.
Execute Incremental AS Download:
* Open CFC and compile the charts.
* Download changes to the AS stations; SIMATIC Manager will book the remaining POs cleanly from the restored pool.

Verification

In SIMATIC Manager, reopen PCS 7 License Information. Confirm that Booked POs matches the actual controller count, that Configured POs does not exceed Installed Licenses, and that Currently available reflects a positive number of spare Process Objects.

Limitations and Operational Precautions

Operating an AS controller with a persistent PO deficit triggers periodic licensing warnings in SIMATIC Manager and may restrict future online delta compilation downloads. Always return PO licenses before executing hardware memory resets or replacing CPU controllers.

Engineer FAQ

What blocks consume AS Runtime Process Objects?

Technological blocks with alarm capabilities (motors, valves, PID controllers, dosing blocks) consume 1 PO each; channel drivers and basic logic gates consume 0 POs.

Why did 'Currently available' show 0 when 711 POs were booked from 1,100?

Because the configured demand in the multiproject was 1,217 POs, which exceeds the 1,100 license total, exhausting all available license capacity.

How do you recover POs from a physically destroyed CPU?

In SIMATIC Manager License Information, select the offline station and use 'Transfer back Process Objects' to release the software booking in the ES database.