C135 PCS 7 (PCS7)
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Downloading Programs to AS Before Installing AS RT PO Licenses in SIMATIC PCS 7

Downloading Programs to AS Before Installing AS RT PO Licenses in SIMATIC PCS 7

Yes, it is technically possible to download a CFC program to a SIMATIC PCS 7 automation station (AS) even if AS Runtime Process Object (AS RT PO) licenses are missing or insufficient. During compilation and download, the engineering system evaluates the number of consumed Process Objects (blocks with S7_m_c := 'true'). If the required PO count exceeds the licenses installed in Automation License Manager (ALM), Step 7 displays a warning dialog: 'The license PCS 7 AS RT PO is missing or insufficient. Do you want to continue downloading?'. Acknowledging 'Yes' allows the download to complete, and the CPU transitions to RUN mode. However, missing licenses cause cyclical license violation messages in WinCC OS Alarm Logging and trigger demo mode notifications. Note that for CPU 410-5H, the hardware System Expansion Card (SEC) PO capacity imposes a hard firmware limit that will reject downloads if exceeded.

Table of Contents

PCS 7 Process Object (PO) Licensing Architecture: Software vs Hardware Limits

In SIMATIC PCS 7, runtime licensing for controller execution is governed by Process Objects (PO). A Process Object represents an engineering unit of technological control—typically an instance of an Advanced Process Library (APL) block or custom function block marked for Operator Control and Monitoring (S7_m_c := 'true') that possesses alarm capability (ALARM_8P) or operator parameters (e.g., MotL, VlvL, PIDConL, MonAnL).

Engineers must strictly distinguish between two licensing layers:

  1. Software License (PCS 7 AS RT PO): A countable, cumulative floating license installed on the Engineering Station (ES) via Automation License Manager (ALM). Available in packages of 100, 1000, or 10,000 POs, it covers the legal entitlement to execute technological control on S7-400 controllers.

  2. Hardware Capacity License (System Expansion Card / SEC): For the CPU 410-5H platform, hardware execution capacity is physically metered by the microchip hardware dongle (SEC) plugged into the rear of the CPU. SEC capacities range from 100 PO to 2600+ PO.

Compiler and Download Mechanics When PO Licenses Are Insufficient

When an engineer compiles CFC charts or downloads to the controller (Target System > Download), the engineering system calculates the total consumed Process Objects in the S7 Program:

  • If the ES has adequate AS RT PO licenses in ALM, the download proceeds silently.
  • If the required PO count exceeds the ALM license tally (or if ALM has zero AS RT PO licenses), Step 7 halts the sequence and issues a prominent warning message:

'The license "PCS 7 AS RT PO" is missing or insufficient. Configured: X POs, Licensed: Y POs. Do you want to continue the download?'

  • If the engineer selects 'Yes', the compiler does not abort. Machine blocks, instance DBs, and runtime sequences are transferred to the CPU memory, and the CPU completes its restart transition into RUN mode.

Runtime Controller Behavior and WinCC OS License Violation Alarms

Operating a PCS 7 controller with insufficient AS RT PO licenses produces the following system responses:

  • Deterministic Control Logic: The S7-400 CPU does not stop, disable I/O modules, or freeze PID calculation loops. Process safety and technological control logic remain fully operational.

  • WinCC OS Alarm Annunciation: The AS-OS communication driver reports the licensing deficit to WinCC OS. In the WinCC AlarmControl overview, system messages appear cyclically:

'License error: SIMATIC PCS 7 AS RT PO license count exceeded.'

  • ALM Audit Logging: Automation License Manager records a license shortfall in its internal compliance journal, logging the discrepancy for software compliance audits.

S7-400 Standard/High-Availability CPUs vs CPU 410-5H SEC Capacity Constraints

The consequences of insufficient licensing differ fundamentally depending on the controller hardware platform:

  • Standard S7-400 / S7-400H (e.g., CPU 417-4H, CPU 416-3): These legacy and classic CPUs rely purely on software license accounting in ALM on the ES. Downloading with 0 or insufficient ALM licenses is always permitted by acknowledging the warning dialog.

  • CPU 410-5H Process Automation: The CPU 410-5H firmware enforces a hard hardware capacity limit. The SEC plugged into the CPU defines the physical boundary. If the CFC chart PO count exceeds the SEC hardware limit, the download fails unconditionally with a fatal error: The maximum number of Process Objects supported by the System Expansion Card has been exceeded. To download, the SEC must be upgraded via the CPU 410 Expansion Pack or logic must be reduced.

Comparative Licensing Matrix: AS RT PO Licenses vs CPU SEC Capacity

The following table compares the licensing mechanics, download behaviors, and operational impacts across controller families in PCS 7:

Parameter / AttributeStandard S7-400 / S7-400HCPU 410-5H (ALM Software PO)CPU 410-5H (SEC Hardware Dongle)License Storage LocationALM on Engineering StationALM on Engineering StationPhysical Hardware SEC in CPULicense TypeCountable Floating (Cumulative)Countable Floating (Cumulative)Hardware Capacity DongleDownload Blocked on Shortage?No (Warning Dialog, Can Bypass)No (Warning Dialog, Can Bypass)Yes (Hard Fatal Download Error)CPU Operating ModeRemains in RUNRemains in RUNDownload Rejected / Retains Prior CodeOS System AnnunciationCyclical WinCC License AlarmsCyclical WinCC License AlarmsN/A (Cannot download overrun)Resolution MethodTransfer PO Licenses via ALMTransfer PO Licenses via ALMOrder CPU 410 Expansion Pack MLFB

Commercial Accuracy Disclaimer

Commercial Accuracy Disclaimer: Software order numbers (MLFBs), package structures, and hardware capacity prerequisites vary across PCS 7 versions and hardware platforms. System integrators must confirm exact software entitlements and licensing requirements against the official Siemens Catalog CA 01 and obtain an authorized Siemens distributor quotation prior to purchasing.

Never infer licensing quantities solely from I/O counts or tag estimates. Always calculate exact PO consumption within the PCS 7 Engineering System using the Process Object View prior to purchasing license packages or CPU 410 Expansion Packs.

Step-by-Step Procedure to Check PO Consumption and Manage Downloads

Follow this procedure to audit Process Object consumption and handle downloads safely:

  1. Check Consumed POs in SIMATIC Manager:
    - Open the PCS 7 Multiproject in SIMATIC Manager.
    - Select the Plant Hierarchy folder or target AS station.
    - Click menu Options > Charts > Process Objects... (or open Process Object View -> General tab).
    - Review the dialog displaying: 'Configured Process Objects' and 'Licensed Process Objects'.

  2. Inspect Installed Licenses in ALM:
    - Launch Automation License Manager on the Engineering Station.
    - Select the target drive where engineering licenses are installed (e.g., C:).
    - Verify the license key SIMATIC PCS 7 AS RT PO and confirm the total installed count.

  3. Executing Download During Commissioning:
    - In CFC, initiate download (Target System > Download > Changes only).
    - When the PO warning dialog appears, click Yes to continue download if commissioning in a staging or FAT environment.
    - For CPU 410-5H, verify online CPU diagnostic buffer (Ctrl+D) to ensure the SEC limit has not been breached.

  4. Procure and Transfer Missing Licenses Prior to SAT/Handover:
    - Before final plant handover, procure the required cumulative AS RT PO expansion packs and transfer them via ALM to clear all OS alarms.

Verification

Verify system behavior and license status through the following validation checks:

  1. Perform a Changes Download to the AS. When prompted with the PO warning, confirm download execution.
  2. Confirm the S7-400 CPU transitions to RUN mode and executes cyclic logic without faults.
  3. Open WinCC OS Runtime and inspect the incoming system alarm banner. Verify that the license warning message appears indicating the PO deficit.
  4. Transfer the appropriate PCS 7 AS RT PO license key to the ES using ALM, recompile/download, and verify that the OS license alarm clears.

Limitations and Operational Precautions

  • Plant Handover Compliance: Operating production facilities with unlicensed software violates commercial software agreements and can jeopardize official Siemens warranty coverage and support contracts.
  • OS Client Distraction: Continuous license warning messages in WinCC clutter the alarm journal, potentially distracting operators from critical process alarms during plant upsets.
  • CPU 410 Firmware Inflexibility: Because CPU 410-5H enforces SEC limits in hardware, attempting a cold start or full download that exceeds the SEC rating will leave the CPU in STOP until the logic is reduced or the SEC upgraded.

Engineer FAQ

What defines a Process Object (PO) in PCS 7?

In PCS 7, a Process Object is typically any function block instance that has Operator Control and Monitoring attributes (S7_m_c := 'true') and generates alarms via ALARM_8P (e.g., motors, valves, analog monitors, controllers), or SFC charts/types.

Do simple driver blocks like FbAnIn or logic gates count as Process Objects?

No. Basic channel driver blocks (FbAnIn, FbDiIn), standard logic gates (AND, OR), mathematical blocks, and interlock blocks (Intlk02) do not count as Process Objects and do not consume PO licenses.

Can AS RT PO licenses be transferred between Engineering Stations?

Yes. AS RT PO licenses are standard floating licenses managed by Automation License Manager (ALM) and can be moved between stations via USB or network transfer.

What happens if an SEC card is removed from a running CPU 410-5H?

Removing the SEC card from an active CPU 410-5H causes an immediate fatal hardware fault, dropping the CPU into STOP mode and triggering redundancy failover in an S7-400H pair.

Are OS RT PO licenses separate from AS RT PO licenses?

Yes. AS RT PO licenses cover controller execution in the S7-400 CPU. OS RT PO licenses cover visualization, tag management, and alarm processing on the WinCC OS Server.

Technical References

Related Articles

Related Tags

  • Licensing
  • AS RT PO
  • Process Objects
  • CPU 410-5H
  • System Expansion Card
  • ALM
  • CFC Download
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