How to Recover AS Runtime Process Object Licenses After Unbooked CPU Replacement in PCS 7

When a controller CPU is replaced in SIMATIC PCS 7 without first executing the "Book Back AS RT PO" procedure, the Automation License Manager (ALM) displays the Process Object licenses with an empty battery symbol, and a warning dialog appears during compilation or download. This occurs because AS Runtime Process Object (AS RT PO) licenses are cryptographically bound to the unique hardware signature of the physical controller and memory card. While this missing license condition generates nuisance warning popups during engineering downloads, it does not trip the operating AS controller to STOP or impair running plant operations. Restoring the licenses to a healthy state requires submitting an official License Restoration Request to Siemens Technical Support with your original License Certificate (CoL).

Architecture of AS Runtime Process Object (PO) Licensing

In SIMATIC PCS 7, software utilization is metered through Process Objects (POs):
- What is a Process Object? A Process Object corresponds to an automated technological device in the plant—typically any block that can generate alarms and interface with the operator station (such as MotL, VlvL, PIDConL, or MonAnL).
- AS RT PO Accounting: Each physical controller requires an AS Runtime PO License covering the total number of instantiated process objects running in its user program.
- Hardware Binding: To prevent illicit duplication, AS RT PO licenses are transferred from the engineering station's Automation License Manager (ALM) and booked directly into the target CPU hardware:
- On classic S7-400 CPUs: Bound to the CPU serial number and physical Flash/RAM memory card.
- On CPU 410-5H: Bound to the System Expansion Card (SEC) and internal CPU hardware registers.

Why CPU Replacement Without Book-Back Invalidates PO Licenses

Before physically removing a failed or modernized CPU from an automation rack, the standard procedure requires using SIMATIC Manager to execute PLC -> Book Back AS RT PO Licenses, which transfers the license credits back into ALM:
* The Failure Mechanism: If a technician swaps the CPU hardware without booking back the licenses, the newly installed CPU possesses a different hardware serial number.
* The Empty Battery Symbol: When SIMATIC Manager attempts to verify licenses during project compilation or download, it queries the CPU. Discovering a hardware signature mismatch, SIMATIC Manager displays an empty battery icon next to the license entry, indicating "Defective / Lost License".
* Single Component Rule: Siemens documentation states that if only the CPU is replaced while reusing the identical memory/SEC card (or vice versa), the system recognizes the AS as the previous target system. However, if hardware recognition fails due to firmware differences or multi-component replacement, the licenses become orphaned.

Operational Impact on Running Controllers: Debunking the CPU STOP Myth

A widespread fear among plant engineers is that an AS RT PO license error will force the running controller into STOP mode:
- No Automatic Controller Trip: Siemens PCS 7 controllers do not stop due to missing, unbooked, or expired runtime PO licenses. The controller operating system prioritizes plant safety and continuous production above licensing enforcement.
- Engineering-Layer Warnings: The consequences are confined strictly to the engineering environment:
- An acknowledgment dialog pops up whenever an engineer compiles or downloads to the AS.
- On CPU 410-5H controllers, an internal diagnostic flag or warning LED may illuminate to signal a license discrepancy.
- Production Continuity: Running chemical batches, PID control loops, and field interlocks continue executing with complete deterministic reliability.

Method: Restoring Lost AS RT PO Licenses via Siemens Technical Support

Because AS RT PO licenses cannot be re-generated manually once lost in unbooked hardware, execute the official restoration procedure:

Step 1: Locate the Certificate of License (CoL)

Retrieve the original physical paper or digital delivery Certificate of License (CoL).
Locate the License Key Number and Delivery Note Number printed on the certificate.
Note: If the paper certificate is missing, contact your Siemens Regional Sales Account Representative to query your company's order history records.

Step 2: Open an Official Siemens Support Request (SR)

Navigate to the Siemens Industry Online Support (SIOS) portal.
Select Support Request -> Create New Request.
Under Product, enter: SIMATIC PCS 7 - Automation License Manager (ALM).
In the problem description, select: Defective / Lost License.
Attach:
- A scanned copy or PDF of the original Certificate of License (CoL).
- An ALM error log or screenshot showing the empty battery symbol and CPU serial number.
- The original purchase order or delivery note number.

Step 3: Apply the Replacement License via ALM

Siemens Technical Support will verify entitlement and dispatch a secure replacement license key (authorization file).
Open Automation License Manager (ALM) on the engineering station.
Connect the replacement license file using the instructions provided by Siemens Support.
In SIMATIC Manager, execute PLC -> Book AS RT PO Licenses to bind the restored credits cleanly to the active controller.

Verification

To verify that the licensing status is fully restored:
- Open SIMATIC Manager and select PLC -> Manage AS RT PO Licenses: confirm that the licensed PO count matches the plant demand with zero error warnings.
- Verify in ALM: confirm that the license displays a solid green battery or checkmark symbol indicating valid status.
- Perform a CFC Change Download to the AS controller: verify that the download executes immediately without prompting license error confirmation dialogs.
- Inspect the CPU face: confirm that diagnostic fault LEDs related to licensing warnings are extinguished.

Limitations and Operational Precautions

Mandatory CoL Requirement: Siemens Technical Support cannot generate replacement runtime licenses without verifiable proof of purchase (the Certificate of License or official Siemens invoice number). Always store physical license certificates in fireproof document archives.
System Expansion Card (SEC) Handling on CPU 410-5H: When replacing a CPU 410-5H, always power down the rack, remove the SEC card from the old CPU, and insert that exact SEC card into the replacement CPU. The SEC retains the PO capacity and eliminates the need for license book-backs.
Avoid Trial License Overwrites: Do not attempt to temporarily resolve the popup by installing trial licenses; trial licenses expire after 14 to 21 days, generating recurring expiration notices.

Engineer FAQ

Will the AS controller shut down if I ignore the license warning?

No. The AS controller will never enter STOP mode due to an AS RT PO license discrepancy. Plant control continues uninterrupted.

What causes the 'empty battery' icon in SIMATIC Manager?

The empty battery icon indicates that the license assigned to that controller is recognized as missing, orphaned, or bound to a hardware serial number that is no longer accessible.

Can I book back licenses from a CPU that has experienced a catastrophic electrical failure?

No. If the physical CPU and memory card are completely destroyed and cannot power up, online book-back is impossible. You must recover the licenses through Siemens Technical Support using your Certificate of License.

Does CPU 410-5H use the same book-back mechanism as classic S7-400 CPUs?

CPU 410-5H uses a dynamic System Expansion Card (SEC) architecture. Process objects are permanently activated on the SEC card. Moving the SEC card to the replacement CPU instantly restores all PO capacity without requiring an ALM book-back.

Technical References

Siemens Industry Online Support: Restoration / Repair of Defective or Lost Licenses in ALM.
SIOS Entry 109742323: PCS 7 Compendium Part A - Configuration Guidelines (Section: AS-OS Licensing).
SIOS Entry 109809264: SIMATIC Process Control System PCS 7 CPU 410-5H Process Automation Manual.
Siemens Support FAQ: Which Actions Lead to a Loss of AS RT PO Licenses in PCS 7?

Related Tags

Licensing
AS RT PO
CPU 410-5H
ALM
SIMATIC Manager
Hardware Replacement
Industrial Automation

How to Recover AS Runtime Process Object Licenses After Unbooked CPU Replacement in PCS 7