How to Fix HW Config Error 1230 - 2000 'Unable to Create the Object' When Inserting CPU 410-5H in PCS 7 V8.1

In SIMATIC PCS 7 V8.1, HW Config errors '1230: 2000 Unable to create the object' or '2772:103 An error occurred creating the hardware' when inserting a CPU 410-5H (6ES7410-5HX08-0AB0) rack into a project indicate that the STEP 7 Hardware Catalog lacks the required Hardware Support Package (HSP), the CPU 410 engineering components were omitted during initial PCS 7 setup, or obsolete power supply modules are selected. To resolve this, update the Hardware Catalog via 'Options > Install Hardware Updates', install the dedicated CPU 410-5H HSP, verify power supply compatibility (replacing obsolete PS 405 modules with approved successors such as 6ES7405-0KA01-0AA0), and insert the station using the PCS 7 'Preconfigured Station' wizard.

Root Causes of HW Config Error 1230: 2000 and 2772:103

The SIMATIC CPU 410-5H Process Automation controller (6ES7410-5HX08-0AB0) is a high-performance CPU designed specifically for PCS 7 systems. Because it utilizes a dynamic System Expansion Card (SEC) architecture for Process Object capacity scaling, its hardware configuration profiles differ significantly from classic S7-400 CPUs:

Error 1230: 2000 (Unable to create the object): Occurs when an engineer attempts to drag a CPU 410-5H from the hardware catalog into an empty rack slot, but the underlying STEP 7 COM object registration or hardware definition database file (.dat / .xml) is corrupt, missing, or blocked by Windows registry permissions.
Error 2772:103 (An error occurred creating the hardware): Typically triggered when attempting to insert a 'Preconfigured Station' where referenced hardware elements (such as obsolete power supplies or incompatible sync modules) cannot be instantiated in the active hardware database.
Installer Omission: During custom installation of PCS 7 V8.1, if the engineer unchecks or omits the 'SIMATIC CPU 410-5H Support Package', the base STEP 7 installation will not contain the device descriptors required to create the controller object.

Hardware Catalog Updates and CPU 410 Hardware Support Packages (HSP)

To ensure the Engineering Station possesses all required device descriptions for the CPU 410-5H:

Launch HW Config and Check Catalog Version:
* Open HW Config in any project.
* Check the catalog tree under SIMATIC 400 > CPU 400 > CPU 410.
* If CPU 410-5H is missing or missing firmware version profiles (e.g., V8.1 / V8.2), the catalog must be updated.
Download and Install HSP:
* In HW Config, select menu Options > Install Hardware Updates....
* Select Download from Internet (or browse to a locally extracted HSP folder).
* Click Execute. Locate HSP 0244 (or applicable CPU 410 HSP package).
* Check the package, click Download, and then click Install.
* Note: All open STEP 7 applications must be closed during the HSP installation process.
Re-Registering Corrupted Components:
* If HSP installation reports success but Error 1230 persists, insert the PCS 7 V8.1 installation DVD/USB, choose Modify/Repair, and explicitly select the SIMATIC S7-400 CPU 410-5H software component.

Power Supply Module Compatibility and Replacement Standards

A frequent hidden trigger of Error 2772:103 during station creation is the selection of legacy, obsolete power supply modules:

The Obsolete Hardware Trap: Legacy projects often reference the discontinued DC 24V power supply module PS 405 10A (6ES7405-0KA00-0AA0), which was declared obsolete and is not validated for pairing with the modern high-inrush current demands of CPU 410-5H.
Approved Successor Hardware:
For DC 24V systems: Deploy the current PS 405 10A (6ES7405-0KA01-0AA0) or redundant PS 405 10A R (6ES7405-0KR02-0AA0).
For AC 120/230V systems: Deploy PS 407 10A (6ES7407-0KA02-0AA0) or redundant PS 407 10A R (6ES7407-0KR02-0AA0).
In HW Config, deleting the unassigned or obsolete power supply before inserting the CPU eliminates conflicts in the backplane power-budget calculation tables.

Clean Station Insertion Workflow Using Preconfigured Stations

To avoid manual hardware linking errors and ensure all internal H-Sync and rack profiles are created flawlessly, use the Preconfigured Station workflow:

Open SIMATIC Manager:
* Right-click the Multi-project folder (or sub-project).
* Select Insert New Object > Preconfigured Station....
Select CPU 410 Station Template:
* In the wizard dialog, select SIMATIC PCS 7 Box / AS Station.
* Choose AS 410 Single Station or AS 410 Redundant Station (H).
* Select the appropriate firmware revision (Firmware V8.1) and System Expansion Card (SEC) tier.
Compile and Save:
* Open the newly generated station in HW Config.
* Assign the physical rack slots, insert approved power supply modules, and configure the integrated PROFINET ports.
* Execute Station > Save and Compile. The station compiles cleanly with 0 Errors.

Comparison of Hardware Support Package States and Error Signatures

The table below outlines common HW Config error codes encountered during S7-400 and CPU 410-5H hardware engineering.

Error CodeError DescriptionPrimary Root CauseVerified Resolution Pathway1230: 2000Unable to create the objectMissing CPU 410 HSP / Corrupt COM DLLReinstall CPU 410 package / Install HSP2772:103Error occurred creating hardwareIncompatible/obsolete module in templateRemove obsolete PS module; update template256:107Internal error in F-ToolS7 F Systems compiler license/file lockReinstall S7 F Systems / Run reset_wincc13:4428Firmware version mismatchCatalog lacks matching firmware profileUpdate Hardware Catalog via Kompatool8251:24Power budget exceeded on rackToo many high-draw modules on backplaneUpgrade to 10A/20A power supply module

Verification

To confirm that CPU 410-5H hardware configuration is resolved:
1. In HW Config, verify that the CPU 410-5H (6ES7410-5HX08-0AB0) appears in Slot 3 (or Slot 4) of the UR2/CR3 rack without error alerts.
2. Double-click the CPU 410-5H: confirm that the Properties window opens correctly, displaying the PN-IO, Interface, and Cycle/Clock Memory tabs.
3. Select Station > Check Consistency. Verify that the compilation log window reports: Check consistency: 0 Error(s), 0 Warning(s).
4. Perform Station > Save and Compile. Confirm that hardware system data blocks (SDBs) generate successfully into the block folder.
5. In SIMATIC Manager, verify that the CFC chart folder and symbol table are successfully created under the S7 Program container.

Limitations and Operational Precautions

Never attempt to force an incompatible legacy power supply into a CPU 410-5H rack; inadequate backplane power stability can cause controller warm-restart failures during heavy I/O polling.
CPU 410-5H requires a valid physical System Expansion Card (SEC) inserted into the rear of the CPU module before power-up; without the SEC card, the CPU will remain in STOP mode.
When updating Hardware Support Packages (HSP), always ensure that all engineering team members install the identical HSP version to prevent multi-project synchronization lockouts.
Verify final hardware ordering numbers (MLFBs) and firmware revisions against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Can CPU 410-5H run in PCS 7 V8.0?

CPU 410-5H was introduced in PCS 7 V8.0 SP1 with dedicated hardware support packages. However, PCS 7 V8.1 or higher is strongly recommended to utilize full firmware capabilities and dynamic Process Object expansion.

What is the order number for the successor to the obsolete PS 405 10A?

The legacy power supply 6ES7405-0KA00-0AA0 is replaced by approved successor module 6ES7405-0KA01-0AA0.

Why did repairing PCS 7 installation fix Error 1230: 2000?

The PCS 7 installer re-registers the STEP 7 ActiveX and COM automation libraries (s7hcompx.dll) and restores missing XML schema definitions that HW Config relies on to instantiate complex hardware objects.