Resolving AS Process Object License Shortages and CPU 410-5H SEC Capacity Limits in PCS 7

In SIMATIC PCS 7, encountering the error 'insufficient process objects' during a delta download despite having valid licenses in Automation License Manager (ALM) occurs primarily due to the architectural separation between software AS RT POs and controller hardware capacity. On standard S7-400 CPUs, software AS RT Process Object licenses in ALM govern capacity, and license key corruption (check via ALM -> Check) can block downloads. However, on CPU 410-5H controllers, PO capacity is governed strictly by the physical System Expansion Card (SEC) plugged into the CPU, not by ALM licenses on the ES. If a CPU 410-5H exceeds its SEC capacity (default 100 POs), an SEC PO Upgrade must be ordered and loaded directly into the CPU.

Executive Summary

During software commissioning and expansion of automation multiprojects in SIMATIC PCS 7 V8.x or V9.x, engineers frequently add technological function blocks (motors, valves, analog monitors) to CFC charts and attempt a delta download (Changes only) to the automation station. A perplexing error occurs: the engineering system rejects the download, reporting that there are insufficient process objects available, even though the engineer inspects the Automation License Manager (ALM) on the Engineering Station and confirms that hundreds of AS RT PO licenses are present and unassigned. This article explains the two-tier licensing model in PCS 7, contrasts classical S7-400 software PO accounting with CPU 410-5H hardware System Expansion Card (SEC) capacity, and details how to verify, diagnose, and expand PO entitlements.

Architecture and Fundamental Mechanics

PCS 7 Process Object Accounting, Classical AS RT POs, and CPU 410-5H System Expansion Card Mechanics:

What Constitutes an AS Process Object (PO):
In PCS 7, a Process Object (PO) represents a basic unit of automation functionality.
Technological control blocks from the Advanced Process Library (APL)—such as MonAnL, PidConL, VlvL, MotL, and DoseL—consume exactly 1 AS Process Object per instance.
Basic logic blocks (AND, OR), mathematical blocks, and Basis Library diagnostic blocks (MOD_D16_, RACK, OB_BEGIN) do NOT consume Process Objects.
Classical S7-400 Controller PO Licensing (CPU 414 / 416 / 417):
For standard S7-400 controllers, PO licensing is managed entirely on the Engineering Station via software license keys in ALM.
Package SIMATIC PCS 7 AS Runtime Process Objects (Count relev.) (e.g. 6ES7653-2BA00-0XB5) provides additive PO capacity.
During CFC compilation and download, STEP 7 queries ALM to book the required PO count.
If a license key in ALM is marked as 'defective' or corrupted, the booking engine fails, reporting an PO shortage.
CPU 410-5H Controller Hardware Licensing (System Expansion Card - SEC):
The high-performance controller CPU 410-5H operates on a fundamentally different, hardware-embedded capacity model.
The CPU 410-5H hardware itself has an unlimited maximum performance, but its authorized technological capacity is governed by the physical System Expansion Card (SEC) inserted into the rear of the CPU.
Out of the box, a standard CPU 410-5H is equipped with an SEC licensed for 100 POs.
Crucial Rule: Standard AS RT PO licenses stored in ALM on the Engineering Station CANNOT expand a CPU 410-5H! The CPU 410-5H completely ignores ES-side ALM licenses during delta download.
If the CFC charts assigned to a CPU 410-5H contain 150 technological blocks, attempting a delta download fails with 'insufficient process objects' because the SEC ceiling (100 PO) is exceeded.
Expanding CPU 410-5H Capacity via PO Upgrades:
To expand capacity, engineers must purchase CPU 410 PO Upgrade Packages (e.g. +100 PO, +500 PO).
The upgrade entitlement is loaded into ALM on the ES, and then transferred into the physical CPU 410-5H using the 'CPU 410 Expansion' utility in SIMATIC Manager while the controller remains in RUN mode.

Step-by-Step Implementation Procedure

Determine Controller Type and License Architecture:
* In SIMATIC Manager, check whether the failing AS station utilizes a standard S7-400 CPU (e.g. CPU 416-3) or a CPU 410-5H.
* Check the compiled PO consumption: in Plant View or Component View, select the Charts folder -> Options -> Charts -> Book Process Objects....
* Review the dialog: note 'Configured Process Objects' vs 'Licensed Process Objects'.
If Using Standard S7-400 CPUs (ALM Software License Check):
* Open Automation License Manager (ALM) on the Engineering Station.
* Locate SIMATIC PCS 7 AS Runtime Process Objects (Count relev.).
* Right-click the license key and select Check.
* If the status reports 'Defective', contact Siemens Technical Support with your Certificate of License to request an activation code.
* If the license count is genuinely exceeded, transfer additional PO keys from the master license USB drive.
If Using CPU 410-5H (System Expansion Card SEC Upgrade):
* In SIMATIC Manager, select the CPU 410-5H station -> PLC -> Display Available Technical Capabilities... (or CPU 410 Expansion).
* Inspect the hardware capacity: verify the maximum PO limit stamped on the SEC (e.g. 100 PO).
* If the compiled project requires 250 POs, procure a CPU 410 PO Upgrade Package (e.g. 500 PO upgrade).
* In ALM, transfer the CPU 410 Upgrade license to the ES.
* In SIMATIC Manager, select PLC -> Upgrade Technical Capabilities... and follow the online wizard to transfer the PO entitlement directly to the CPU 410-5H System Expansion Card without stopping the controller.
Execute Delta Download:
* In SIMATIC Manager, select PLC -> Download.
* Select Changes only.
* The compiler verifies that the licensed PO capacity now matches or exceeds the configured PO count, completing the download smoothly.

Verification

In SIMATIC Manager, open Options -> Charts -> Book Process Objects; confirm that 'Configured POs' <= 'Licensed POs'.
Trigger a delta download to the CPU; verify that the download completes with zero license error dialogs.
For CPU 410-5H, open PLC -> Display Available Technical Capabilities; confirm that the SEC reports the upgraded PO capacity.

Limitations and Operational Precautions

Do not confuse AS Process Objects (AS RT PO) with OS Process Objects (OS RT PO); each subsystem maintains independent accounting. Standard AS RT PO licenses (6ES7653-2BA...) cannot be used to upgrade a CPU 410-5H System Expansion Card; CPU 410-5H strictly requires dedicated CPU 410 PO Upgrade packages. Always validate final license quantities and MLFBs against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Why does PCS 7 say 'insufficient process objects' when ALM has plenty of licenses?

If using a CPU 410-5H, PO capacity is governed by the physical System Expansion Card (SEC) in the CPU, which cannot use standard ALM licenses.

What is the default PO capacity of a CPU 410-5H?

A standard CPU 410-5H ships with a base System Expansion Card licensed for 100 Process Objects.

How do you upgrade the PO capacity of a CPU 410-5H?

Purchase a CPU 410 PO Upgrade package and transfer it to the CPU's SEC using the 'Upgrade Technical Capabilities' wizard in SIMATIC Manager.

Can a CPU 410-5H PO upgrade be loaded without stopping the controller?

Yes, the SEC upgrade wizard supports online capacity expansion while the CPU 410-5H remains in RUN mode.

What blocks consume AS Process Objects?

Technological control blocks such as MonAnL, PidConL, VlvL, MotL, and DoseL consume 1 PO each. Basic logic blocks do not consume POs.

Technical References

Process Objects

AS RT PO

CPU 410-5H

System Expansion Card

SEC Upgrade

Automation License Manager

Delta Download

PCS 7 V8.2

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Resolving AS Process Object License Shortages and CPU 410-5H SEC Capacity Limits in PCS 7