Online Process Object Upgrades for CPU 410-5H Using Automation License Manager in SIMATIC PCS 7

In SIMATIC PCS 7, upgrading the Process Object (PO) capacity of an S7-400 controller using an AS System Expansion Card (SEC) for CPU 410-5H (6ES7410-5HX08-0AB0) can be executed online in RUN mode without stopping the controller or interrupting production. Generating the PO activation request file in Automation License Manager (ALM) is a non-invasive read-only query that does not stop the CPU, and transferring the resulting activation license to the SEC dynamically increases the PO capacity limit in RUN. However, online SEC upgrades via ALM require ALM V5.3 SP1 or higher and CPU 410 firmware V8.1 or higher. In legacy PCS 7 V8.0 environments where the Engineering Station ALM lacks CPU 410 target connectivity, engineers can connect an external laptop equipped with ALM V5.3+ to the CPU plant bus and execute the online SEC upgrade in RUN mode without modifying the project.

CPU 410-5H System Expansion Card (SEC) Architecture

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.

In traditional SIMATIC S7-400 systems (such as CPU 414, 416, or 417), memory and processing capacities were hardwired into physical hardware variants. The CPU 410-5H Process Automation controller revolutionized this architecture by establishing a single, high-performance universal hardware platform.

The operational capacity of a CPU 410-5H—specifically the number of permitted Process Objects (PO), ranging from a base of $100\text{ PO}$ up to $2600+\text{ PO}$ (or unlimited)—is determined entirely by the plug-in System Expansion Card (SEC).

An SEC card performs two core hardware licensing functions:
1. Hardware Capacity Licensing: Establishes the upper bound of Process Objects that the CPU operating system will permit to run simultaneously.
2. Dynamic Scale-Out: Enables plant owners to expand controller capacity incrementally as the plant grows without purchasing new controller hardware or rebuilding racks.

Online PO Capacity Expansion in RUN Mode

A critical architectural advantage of the CPU 410-5H is the ability to upgrade its Process Object capacity without transitioning the CPU to STOP mode:

Will Generating the Activation File Request Stop the CPU?

No. In Automation License Manager (ALM), selecting Target System > Connect Target System > CPU 410-5H and requesting the activation file is a strictly read-only diagnostic query. ALM reads the SEC card's unique hardware serial number, current PO count, and firmware revision. The running process is $100\%$ unaffected.

Will Transferring the PO Upgrade Stop the CPU?

No. When the signed activation license file (purchased from Siemens) is transferred back to the CPU via ALM, the CPU 410 operating system dynamically updates its internal licensed PO ceiling in non-volatile memory in RUN mode. In redundant S7-400H pairs, ALM coordinates with the operating system to update both SEC cards across the fiber-optic synchronization link without interrupting the plant.

Step-by-Step SEC Upgrade Workflow via ALM

To perform an online Process Object expansion on an operational CPU 410-5H:

Step 1: Generate the License Request File

Open Automation License Manager (ALM) on the Engineering Station.
Select menu Target System > Connect Target System > CPU 410-5H.
Enter the Industrial Ethernet IP address of the target CPU.
Select the CPU and choose License > Request Activation File....
Save the generated .req file to your local drive.

Step 2: Upload to Siemens Activation Portal

Navigate to the online Siemens Web License Manager (siemens.com/automation/license).
Log in and enter your purchased Certificate of License (CoL) License Key and the generated .req file.
The portal processes the cryptographic pairing and downloads the signed activation file (.act).

Step 3: Transfer the Activation File to the Controller in RUN

In ALM, reconnect to the CPU 410-5H target system.
Select License > Install Activation File....
Browse to the downloaded .act file and click Install.
The progress bar confirms transfer to the SEC card.
In the ALM status window, verify that the 'Licensed Process Objects' total increases immediately to the new capacity.

Handling Legacy PCS 7 V8.0 and ALM Version Constraints

A major challenge arises on older installations running PCS 7 V8.0:
- Online SEC expansion via ALM was officially introduced in PCS 7 V8.1 (specifically requiring ALM V5.3 SP1 or higher and CPU 410 firmware V8.1 or higher).
- On a native PCS 7 V8.0 Engineering Station, ALM lacks the menu option Target System > CPU 410-5H, and attempting to read the SEC upgrade USB returns an unreadable license error.

Field Engineering Workaround (Zero Plant Downtime):

To upgrade the CPU 410 SEC card without upgrading the entire PCS 7 V8.0 plant software:
1. Obtain an engineering laptop running PCS 7 V8.1 / V8.2 or a standalone installation of ALM V5.3 SP1+.
2. Connect the laptop's network adapter directly to the plant bus Industrial Ethernet switch.
3. Assign a static IP address on the plant bus subnet.
4. Launch ALM on the laptop: Use Target System > Connect Target System > CPU 410-5H to communicate directly with the controller.
5. Execute the .req generation and .act installation entirely from the laptop.
6. The CPU 410-5H updates its hardware capacity in RUN mode.
7. The existing PCS 7 V8.0 Engineering Station can now compile and download additional charts up to the newly expanded PO limit without any software modifications.

CPU 410-5H SEC Process Object Scaling Matrix

The following matrix details the available System Expansion Card capacity tiers for CPU 410-5H:

System Expansion Card PackageStandard Order Number (MLFB)Base PO CapacityUpgrade Increment AvailableOnline Upgrade Supported in RUNSystem Expansion Card 100 PO6ES7653-2BA00-0XB5100 Process ObjectsExpandable in +100 / +500 stepsYes (Firmware V8.1+)System Expansion Card 500 PO6ES7653-2BB00-0XB5500 Process ObjectsExpandable in +100 / +500 stepsYes (Firmware V8.1+)System Expansion Card 1000 PO6ES7653-2BC00-0XB51000 Process ObjectsExpandable in +100 / +500 stepsYes (Firmware V8.1+)System Expansion Card 1600 PO6ES7653-2BD00-0XB51600 Process ObjectsExpandable up to 2600+ POYes (Firmware V8.1+)System Expansion Card 2600+ PO6ES7653-2BE00-0XB52600+ PO (Full Scale)Maximum rated hardware capacityFactory FullSEC PO Upgrade +100 PO6ES7653-2CC00-0XB5+100 PO ExpansionDynamic add-on packYes (Firmware V8.1+)SEC PO Upgrade +500 PO6ES7653-2CD00-0XB5+500 PO ExpansionDynamic add-on packYes (Firmware V8.1+)

Verification

To confirm that the AS SE PO upgrade was successfully applied:
1. In ALM, select the connected CPU 410-5H under Target Systems.
2. Check the Licensed POs field: Confirm that it reflects the expanded capacity (e.g., increased from 500 to 1000 PO).
3. In SIMATIC Manager, select the CPU and choose PLC > Module Information.
4. Check the Performance / Capacity tab: Verify that the controller recognizes the updated System Expansion Card capacity.
5. In SIMATIC Manager, select the Charts folder and click Options > Process Objects > Process Objects (AS)...: Confirm that the total available PO limit reflects the newly purchased capacity.

Limitations and Operational Precautions

Observe the following engineering precautions:
- Redundant Pairs Require Matching SEC Cards: In an S7-400H redundant configuration, both CPU 410-5H controllers must have identical SEC card capacities. When upgrading, purchase and apply matching upgrade packs for both Rack 0 and Rack 1.
- AS RT PO vs CPU SEC PO: Do not confuse AS Runtime Process Object software licenses in ALM with the physical System Expansion Card hardware capacity. Both must satisfy the project's compiled PO count.
- SEC Physical Handling: Never remove the physical System Expansion Card from the CPU while power is applied or while the CPU is in RUN mode. Hardware capacity expansion is performed electronically via software.

Engineer FAQ

Will my plant shut down when I install the SEC PO upgrade on CPU 410-5H?

No. The CPU 410-5H operating system was specifically engineered to dynamically expand its Process Object license capacity online in RUN mode without stopping or disrupting control.

Why does ALM on my PCS 7 V8.0 station fail to see the CPU 410 target system?

Target system connectivity for CPU 410 SEC cards requires ALM V5.3 SP1 or higher, which was introduced in PCS 7 V8.1. You can perform the upgrade by connecting an external laptop with ALM V5.3+ directly to the CPU.

What happens if my compiled project exceeds the SEC Process Object limit?

The CFC compiler will complete the compilation, but the AS download loader will abort the download with an error stating that the maximum licensed Process Objects on the CPU have been exceeded.