C135 PCS 7 (PCS7)
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Replacing CPU 410-5H Controllers and Transferring System Expansion Cards in SIMATIC PCS 7

Replacing CPU 410-5H Controllers and Transferring System Expansion Cards in SIMATIC PCS 7

When replacing a SIMATIC PCS 7 CPU 410-5H controller, the hardware System Expansion Card (SEC) can be removed from the original CPU and installed directly into the replacement CPU. The SEC contains the hardware processing entitlement, retaining the controller's total Process Object capacity including any previously loaded expansion packs. However, engineers must distinguish hardware SEC capacity from software AS Runtime PO licenses managed in Automation License Manager; before replacing a operational CPU, any booked software POs should be booked back to the Engineering Station to preserve software license counts.

Table of Contents

Distinguishing Hardware SEC Capacity from Software AS RT PO Licensing

A critical compliance requirement in SIMATIC PCS 7 engineering is maintaining the distinction between controller hardware capacity and software runtime licensing:

  1. Hardware Capacity: System Expansion Card (SEC):
    * The SEC is a proprietary hardware card plugged into the rear slot of the CPU 410-5H.
    * It dictates the physical processing capacity of the controller, scaling from 100 Process Objects (PO) up to 2600+ PO (or unlimited in specific versions).
    * It also determines whether the CPU operates as standard or fault-tolerant (CPU 410-5H) or compact (CPU 410E).
    * The hardware capacity resides permanently on the SEC. When capacity expansion packs (CPU 410 Expansion Packs) are loaded, the updated PO entitlement is written directly into the cryptographic memory of the SEC card.
  2. Software Licensing: AS Runtime Process Objects (AS RT PO):
    * AS RT PO licenses are software floating licenses managed on the Engineering Station (ES) via Automation License Manager (ALM).
    * When an AS program is compiled and loaded, software POs are "booked" from the ES pool to the controller.
    * A redundant AS 410-5H pair requires only a single AS RT PO software license pool covering the application program.

Physical Architecture and Data Retention of the System Expansion Card

The System Expansion Card contains a secure cryptographic EEPROM that stores:

  • Controller Hardware Serial Pairing and Authorization Keys.
  • Maximum Allowed Hardware PO Limit (e.g., 500 PO, 1000 PO, 1600 PO, 2600+ PO).
  • Fail-Safe (F-Systems) Runtime Authorization Flags.

Because all capacity entitlements are stored in non-volatile memory on the SEC, the card can be extracted from a defective CPU and inserted into a replacement CPU 410-5H of the same or newer firmware revision. The new controller immediately recognizes the full hardware PO capacity embedded on the transferred SEC.

+-------------------------------------------------------------------+
|               CPU 410-5H Hardware Replacement Flow                |
+-------------------------------------------------------------------+
|  Original Defective CPU 410-5H                                    |
|         |                                                         |
|         |-- [Step 1: If CPU is responsive, book back AS RT POs]   |
|         |                                                         |
|         v                                                         |
|  Power Down Rack -> Extract SEC Card from Rear Slot               |
|         |                                                         |
|         v                                                         |
|  Insert Transferred SEC Card into Replacement CPU 410-5H          |
|         |                                                         |
|         v                                                         |
|  Seat Replacement CPU in Rack -> Power On                         |
|         |                                                         |
|         v                                                         |
|  New CPU Reads SEC: Full Hardware Capacity Retained               |
|         |                                                         |
|         v                                                         |
|  Download HW Config & Program -> Re-Book AS RT POs from ES        |
+-------------------------------------------------------------------+

Step-by-Step CPU 410 Replacement and SEC Transfer Procedure

Follow this structured procedure when replacing a CPU 410-5H:

Step 1: Book Back Software POs (If CPU is Responsive)

  1. If the old CPU is still accessible via the plant bus, open SIMATIC Manager on the ES.
  2. Select the Multiproject or target AS project.
  3. Select Options -> Charts -> Book back Process Objects (PO)....
  4. Follow the wizard to return the booked software AS RT POs from the CPU back to the central ALM license repository on the ES.

Step 2: Hardware Decommissioning and SEC Extraction

  1. Disconnect power to the S7-400 rack power supply module.
  2. Disconnect Ethernet plant bus cables and sync modules (if redundant 410-5H).
  3. Loosen the mounting screw and extract the defective CPU 410-5H from the rack.
  4. On the rear/underside of the CPU, locate the System Expansion Card slot.
  5. Carefully press the ejector latch and pull out the SEC card. Store it in an anti-static pouch.

Step 3: SEC Insertion and Replacement CPU Installation

  1. Unbox the replacement CPU 410-5H.
  2. Ensure the replacement CPU does not contain another SEC card.
  3. Insert the original SEC card firmly into the rear slot of the replacement CPU until the latch clicks.
  4. Slide the replacement CPU into the target rack slot and secure the mounting screw.
  5. Reconnect network cables, sync submodules, and power up the rack.

Step 4: Hardware and Program Download

  1. In SIMATIC Manager, verify controller communication via PLC -> Display Accessible Nodes.
  2. Check CPU firmware revision: ensure the replacement CPU firmware is equal to or higher than the predecessor.
  3. Download the Hardware Configuration (HW Config -> PLC -> Download).
  4. Download the CFC program (Charts -> Compile and Download Objects). The ES will automatically re-book the required AS RT PO software licenses.

Managing AS Process Object Book-Back in Automation License Manager

If the original CPU suffered a catastrophic hardware failure and cannot communicate:

  • The SEC card retains its hardware capacity without issue.
  • However, the software AS RT PO licenses booked to the destroyed CPU remain registered as "in use" in the ES project database.
  • To recover software licenses from a destroyed controller, utilize the License Recovery procedure in SIMATIC Manager or contact Siemens Technical Support with the hardware failure report to re-credit lost floating license keys in Automation License Manager.

Verification

Confirm proper hardware recognition and capacity allocation:

  1. CPU Diagnostic Buffer and Module Information:
    * In SIMATIC Manager, select the replacement CPU and press Ctrl + D.
    * Under the General tab, verify the controller serial number and firmware version.
    * Select the Performance / Capacity or Process Objects tab:
    • Confirm that the Maximum Process Objects value matches the rating of the transferred SEC (e.g., 1000 PO or 2600 PO).
  2. Automation License Manager Check:
    * Open ALM on the ES.
    * Verify that the active AS RT PO license count reflects the current plant utilization.
  3. RUN Mode Transition:
    * Switch the CPU mode switch to RUN.
    * Confirm that the CPU transitions to RUN with a steady green LED, zero system fault (SF) indications, and healthy cyclic execution.

Limitations and Operational Precautions

  • Distributor Quotation Disclaimer: All procurement recommendations, spare CPU order numbers, and SEC expansion packs must be validated against the current Siemens ST PCS 7 catalog and confirmed through an authorized Siemens distributor quotation.
  • Firmware Compatibility: Never downgrade CPU 410 firmware below the minimum version required by your installed PCS 7 release (e.g., CPU 410-5H firmware V8.2 requires PCS 7 V9.0 or higher; running in older PCS 7 releases requires specific compatibility modes).
  • Power Interruption Hazard: Never insert or extract the System Expansion Card while the CPU is powered on; doing so can permanently damage the EEPROM and destroy the hardware license.
  • SEC Cannot Be Shared: An SEC card cannot be duplicated or shared across multiple CPUs; each operational CPU requires its own physical SEC card.

Engineer FAQ

  • Can an SEC card be transferred from a defective CPU 410-5H to a brand-new CPU?
    Yes, the SEC can be transferred directly to a replacement CPU 410-5H, immediately enabling the full hardware PO capacity on the new unit.
  • Does the SEC retain POs added via expansion packs?
    Yes, when CPU 410 Expansion Packs are applied, the additional PO capacity is permanently written into the cryptographic memory of the SEC card.
  • What is the difference between SEC capacity and AS RT PO software licenses?
    The SEC card enables the hardware controller's physical processing limit (e.g., 1000 PO), while AS RT PO is a software floating license managed via ALM in the ES.
  • What happens if I power on a CPU 410-5H without an SEC card installed?
    The CPU will not transition to RUN mode and will generate a system fault (SF) indicating that no valid System Expansion Card is present.
  • What should I do if the defective CPU cannot be powered on to book back software POs?
    The transferred SEC will still work in the new CPU, but software PO recovery in ALM may require using the emergency recovery procedure or contacting Siemens support.
  • Can I use a CPU 410-5H in PCS 7 V7.0 or V8.0?
    The CPU 410-5H was introduced in PCS 7 V8.1; utilizing it in older environments requires specific hardware upgrade packages or configuring it under spare-part compatibility modes.
  • Does a redundant AS 410-5H pair require one or two SEC cards?
    Each physical CPU in an AS 410-5H redundant pair requires its own identical physical SEC card with matching PO capacity.
  • Does a redundant AS pair require two sets of AS RT PO software licenses?
    No, official Siemens licensing rules mandate only one common pool of software AS RT PO licenses for a redundant controller pair.
  • How do I verify the PO capacity currently loaded on an SEC card?
    Connect online in STEP 7, open Module Information (Ctrl+D), and inspect the Process Objects tab to view total authorized SEC capacity.
  • Can an SEC card from a CPU 410E be used in a standard CPU 410-5H?
    The SEC card dictates the identity; installing a CPU 410E SEC card into a 410-5H hardware unit will restrict the controller to CPU 410E limits (max 200 PO).

Technical References

  • Siemens Industry Online Support (SIOS) Portal: Process Automation with SIMATIC PCS 7 CPU 410-5H Manual (Entry ID: 96839331).
  • SIMATIC PCS 7 Licenses and Configuration Limits Manual, Siemens AG.
  • SIMATIC S7-400 CPU 410-5H System Expansion Card Handling Guidelines.

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Related Tags

PCS 7, CPU 410, CPU 410-5H, System Expansion Card, SEC, Process Objects, Licensing, Hardware Replacement

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