Evaluating SEC Hardware Release Identification and CPU Firmware Dependencies for AS 410 Upgrades

Successfully executing an online Process Object (PO) upgrade on an AS 410-5H controller requires verifying two strict hardware dependencies: CPU 410-5H Firmware V8.1 or higher and System Expansion Card (SEC) Hardware Release 2 (FS 02) or higher. First-generation SEC cards (FS 01) lack the cryptographic EEPROM sectors required to accept online .rel activation files and must be physically replaced with higher-capacity cards. The hardware release can be confirmed online via Automation License Manager (ALM) by querying 'Display PO Information' or by inspecting the physical product label. If firmware updates are required on standalone controllers, they mandate a CPU STOP before online PO expansion can proceed.

Hardware Prerequisites for AS 410 Capacity Expansion

The SIMATIC PCS 7 CPU 410-5H (6ES7410-5HX08-0AB0) relies on the System Expansion Card (SEC) to establish its memory bounds and maximum Process Object (PO) count. While modern documentation describes seamless online PO expansion in RUN mode, early hardware revisions installed during PCS 7 V8.0 rollouts enforce specific compatibility barriers that must be audited prior to procuring expansion licenses.

Identifying SEC Hardware Release (FS 01 vs FS 02+)

System Expansion Cards are categorized into two major hardware generations:

SEC Hardware GenerationFunctional State (FS)Online PO Expansion CapabilityUpgrade MethodologyFirst Generation (Legacy)FS 01Unsupported: Lacks dynamic cryptographic flashing firmware.Physical Replacement Mandatory: Must purchase new physical SEC with required capacity.Second Generation (Modern)FS 02 or higherFully Supported: Supports online transfer of *.rel activation files in RUN.Online Expansion Pack: Order PO expansion licenses (100 / 500 PO) and transfer via ALM.

Methods to Audit SEC Hardware Release

Online via ALM (No Hardware Disassembly): Connect to the AS controller in Automation License Manager -> right-click CPU -> Display PO Information. The dialog reports the SEC serial number and Hardware Version (FS).
Physical Visual Inspection: Extract the SEC from the rear chassis slot (during planned maintenance): the label printed on the card indicates FS 01, FS 02, or FS 03.

CPU Firmware Upgrade Requirements and Operational Constraints

In addition to SEC Release 2, the CPU 410-5H must run Firmware V8.1 or higher:

If the controller operates on Firmware V8.0, the internal operating system cannot execute the cryptographic authentication algorithms required by ALM.
Standalone CPU 410: Updating firmware from V8.0 to V8.1+ mandates putting the CPU into STOP mode. The firmware update clears the controller memory, requiring a complete download of HW Config, NetPro, and CFC charts.
Redundant AS 410-5H Pair: Updating firmware can be executed without stopping the plant process using the redundant operating system update procedure (updating standby CPU, switching roles, updating partner CPU).

Procurement Schedule for SEC Cards and Expansion Packs

The following Equipment Schedule specifies the relevant order numbers for hardware and licensing:

Hardware Expansion Cards (Physical Replacement for FS 01):
- SEC PO 1000 (Physical Card FS 02+):             6ES7653-2CE00-0XB5
- SEC PO 1600 (Physical Card FS 02+):             6ES7653-2CF00-0XB5
- SEC PO 2600 (Maximum Physical Card FS 02+):     6ES7653-2CG00-0XB5

Runtime Expansion Packs (Online Flashing for FS 02+):
- CPU 410 Expansion Pack 100 POs (Runtime Lic):   6ES7653-2DB00-0AX5
- CPU 410 Expansion Pack 500 POs (Runtime Lic):   6ES7653-2DC00-0AX5

[!IMPORTANT]
Commercial Accuracy Disclaimer: If an audit reveals the existing SEC is Hardware Release 1 (FS 01), online PO expansion packs cannot be used. The plant must procure a replacement physical SEC card with the desired PO capacity. For redundant AS 410-5H systems, two identical SEC cards or two identical sets of expansion packs are mandatory to preserve fault-tolerant symmetry. Final license quantities and MLFBs must be validated against the applicable Siemens ST PCS 7 Catalog and authorized distributor quotations.

Verification

To verify SEC compatibility and successful PO expansion:

In ALM, connect the AS with Expert Mode enabled -> select Display PO Information.
Confirm that Hardware Version indicates FS 02 or higher.
Confirm that CPU firmware indicates V8.1.x or V8.2.x.
After transferring the .rel activation file, verify that Total Process Objects reflects the updated licensed capacity.
In STEP 7, open CPU Module Information (Ctrl + D): verify that the diagnostic buffer records zero licensing faults.

Limitations and Operational Precautions

Operational boundaries when planning SEC upgrades:

Audit Before Purchase: Always verify the SEC hardware release (FS) before ordering Expansion Packs; purchasing online expansion licenses for an FS 01 card results in unusable software entitlements.
Single CPU Maintenance Window: If a single AS 410 on Firmware V8.0 requires a firmware update to enable SEC expansion, schedule a plant shutdown for the mandatory CPU STOP.
SEC Custody: Never swap SEC cards between different controllers while powered; always follow official Siemens hot-swapping guidelines.

Engineer FAQ

Can an SEC with Hardware Release 1 (FS 01) be upgraded online?

No. First-generation FS 01 cards lack the internal non-volatile EEPROM sectors required for cryptographic online license activation. They must be physically replaced with an FS 02+ card.

How can I verify the SEC hardware version without removing the CPU from the rack?

Connect to the AS in Automation License Manager with Expert Mode enabled, right-click the CPU 410-5H, and select 'Display PO Information' to view the hardware functional state.

Does updating CPU 410 firmware from V8.0 to V8.1 cause a CPU STOP?

Yes, on a non-redundant (single) controller, updating firmware forces a CPU STOP and clears internal memory. On a redundant AS 410-5H pair, firmware can be updated in RUN.