C135 PCS 7 (PCS7)
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Resolving Error D22F When Booking Back AS Process Objects on CPU 410-5H in PCS 7

Resolving Error D22F When Booking Back AS Process Objects on CPU 410-5H in PCS 7

In SIMATIC PCS 7, attempting to book back Automation Station Process Objects (AS RT PO) from a CPU 410-5H fails with error 0xFFDF_D22F ('The connected CPU rejected the download order: Order system data block contains invalid parameters') when the controller remains in RUN mode. To prevent memory inconsistencies during license ledger updates, the CPU 410 operating system strictly requires the controller to be transitioned to STOP mode before executing the PO book-back routine. Transitioning the CPU to STOP or executing a memory reset (MRES) clears error D22F and successfully returns software POs to the Engineering Station.

Table of Contents

Mechanisms of AS Process Object Booking and Ledger Accounting

SIMATIC PCS 7 manages software controller licensing through the AS Runtime Process Object (AS RT PO) system:

  • The Central License Ledger: The Engineering Station (ES) holds commercial floating license keys in Automation License Manager (ALM) authorizing a specific number of Process Objects (e.g., 500 PO, 1000 PO, 2000 PO).
  • The Booking Process: When an engineer compiles and downloads an automation station program (CFC -> Compile -> Chart as Program), the PCS 7 compiler calculates the total technological blocks instantiated (motors, valves, controllers, analog monitors) and "books" the required quantity of POs from the ES ledger into the target CPU.
  • The Book-Back Process: When decommissioning an automation station, migrating logic to another CPU, or reallocating licenses across a multiproject, the engineer executes the Book Back Process Objects function (Options -> Charts -> Book back Process Objects (PO)...), returning the booked license tokens from the CPU back to ALM on the ES.

Root Cause Analysis of Error 0xFFDF_D22F

When initiating the book-back wizard, engineers frequently encounter the fatal abort:

F: The connected CPU rejected the download order (0xFFDF_D22F: [S7DOS] (D22F)
The order system data block contains invalid parameters. Download aborted.

Following this failure, subsequent program downloads to the CPU 410-5H are rejected until a memory reset (MRES) is performed. The underlying technical causes include:

  1. CPU Operating in RUN Mode: The CPU 410-5H operating system strictly prohibits structural system data block (SDB) deletions and license ledger modifications while cyclic user programs are executing in RUN or RUN-P. The CPU rejects the book-back SDB write command with error D22F.
  2. SDB Parameter Conflict: The book-back utility constructs a specialized system data block that resets internal license allocation counters. If active execution threads hold locks on technological instances, the parameter validation check fails.
  3. Firmware Execution Restrictions: In CPU 410 firmware releases (e.g., V8.1 and V8.2), automated background memory resets triggered by the wizard can fail if the operating mode switch is not physically placed in STOP.

Step-by-Step Procedure to Safely Book Back Process Objects

Follow this verified procedure to return AS Process Objects to the ES without encountering error D22F:

Step 1: Transition Controller to STOP Mode

  1. Ensure the plant process controlled by the CPU 410-5H is safely shut down and placed in a safe isolation state.
  2. In SIMATIC Manager, select the CPU and execute PLC -> Operating Mode....
  3. Select STOP and confirm the prompt, or physically toggle the CPU mode switch to STOP.
  4. Confirm that the yellow STOP LED illuminates steady.

Step 2: Execute Memory Reset (MRES) if Previously Blocked

  1. If the CPU previously aborted with error D22F and is rejecting downloads:
    * Perform an overall reset (MRES): Toggle the mode switch to MRES, hold for 3 seconds until the STOP LED flashes slowly, release, and immediately toggle back to MRES.
    * The STOP LED flashes rapidly while memory is purged, then returns to steady yellow.
    * Note: An MRES clears the user program memory but does not destroy license entitlements on the SEC or in the ES database.

Step 3: Execute the Book-Back Wizard

  1. In SIMATIC Manager, select the Charts folder of the target AS project.
  2. Select Options -> Charts -> Book back Process Objects (PO)....
  3. In the wizard, select the option to return booked process objects from the automation station to the local license repository.
  4. Confirm target communication. The wizard connects to the CPU (now in STOP), clears the internal license counter SDB, and re-credits the floating AS RT PO licenses back to Automation License Manager on the ES.
  5. Confirm that the wizard finishes with Booking back successfully completed.
+-------------------------------------------------------------------+
|               Safe AS RT PO Book-Back Architecture                |
+-------------------------------------------------------------------+
|  Engineer attempts book-back while CPU is in RUN mode             |
|                             |                                     |
|                             v                                     |
|  CPU Operating System Rejects SDB: Error 0xFFDF_D22F Manifests   |
|                             |                                     |
|                             v                                     |
|  Step 1: Physically or Software-Switch CPU 410-5H to STOP         |
|                             |                                     |
|                             v                                     |
|  Step 2: If locked, execute MRES to clear corrupted SDB buffer    |
|                             |                                     |
|                             v                                     |
|  Step 3: Run "Options -> Charts -> Book back Process Objects..."   |
|                             |                                     |
|                             v                                     |
|  Result: AS RT POs successfully re-credited to ALM on ES          |
+-------------------------------------------------------------------+

Distinguishing SEC Hardware Capacity from Book-Back Operations

A vital distinction must be maintained between software licenses and hardware cards:

  • System Expansion Card (SEC) Capacity: The physical SEC card plugged into the rear of the CPU 410-5H dictates the controller's maximum hardware PO capacity (e.g., 500 PO, 1000 PO, 2600+ PO). Booking back POs does not alter, erase, or reduce the hardware capacity of the SEC card.
  • Software AS RT PO Licenses: The book-back operation exclusively returns the software license tokens tracked by Automation License Manager on the Engineering Station.

Handling License Recovery Following Controller Failure

If a CPU 410-5H suffers a catastrophic hardware failure and cannot be powered on to execute the book-back wizard:

  1. Same CPU Re-Download: If the exact same CPU is repaired or memory-reset, downloading the project again will recognize the previously booked CPU identifier without deducting additional PO licenses from ALM.
  2. Defective Hardware Recovery: If the physical CPU is permanently decommissioned without booking back, the software PO licenses remain recorded as "in use" in the project database. To recover these lost licenses, execute the Process Object Recovery function in SIMATIC Manager or contact Siemens Technical Support with the official License Certificate of License (CoL) to request license replacement.

Verification

Confirm that the book-back procedure completed successfully:

  1. Automation License Manager Inspection:
    * Open ALM on the Engineering Station.
    * Locate the AS RT PO license key.
    * Confirm that the License Key Count has increased by the number of POs returned from the controller.
  2. SIMATIC Manager PO Counter Check:
    * In SIMATIC Manager, select the Multiproject root.
    * Right-click and inspect project properties or check PO utilization.
    * Verify that the target AS displays 0 PO booked and that the central pool displays the returned capacity as available.

Limitations and Operational Precautions

  • STOP Mode Requirement: Never attempt to book back AS Process Objects on a running production plant; placing the CPU in STOP halts all cyclic automation logic.
  • Commercial Accuracy Compliance: Never claim that memory resets destroy commercial license ownership; software entitlements are legally tied to the Certificate of License, and hardware capacity resides permanently on the SEC.
  • Redundant System Handling: In redundant AS 410-5H pairs, book-back operations must be executed with both CPU units placed in STOP mode.

Engineer FAQ

  • What causes error 0xFFDF_D22F during PO book-back?
    The CPU 410-5H was in RUN mode; the controller operating system rejects system data block updates and license modifications unless placed in STOP mode.
  • Does performing an overall reset (MRES) destroy my AS Process Object licenses?
    No, an MRES clears the user program memory in the CPU, but software licenses remain registered in the ES database and hardware capacity remains intact on the SEC.
  • Can I book back Process Objects from a running controller without stopping the plant?
    No, the CPU must be in STOP mode to modify the internal license allocation system data blocks.
  • What is the difference between booking back POs and downloading a project?
    Downloading books POs from the ES license pool to the controller; booking back returns unused POs from the controller back to the ES pool.
  • What happens to the System Expansion Card (SEC) when POs are booked back?
    Nothing; the SEC card retains its full permanent hardware PO capacity rating regardless of software book-back operations.
  • What should I do if a CPU is destroyed and I cannot perform a book-back?
    Use the SIMATIC Manager PO License Recovery utility or open a Siemens Support Request with your Certificate of License to re-credit lost licenses in ALM.
  • Why did subsequent downloads fail after error D22F appeared?
    Error D22F leaves an incomplete system data block in the CPU download buffer; executing a manual MRES clears the buffer and restores normal download capabilities.
  • Can I book back POs on a CPU 410-5H running PCS 7 V8.0?
    The CPU 410-5H was introduced with PCS 7 V8.1; running in V8.0 requires specific hardware update packages and service packs, but STOP mode rules remain identical.
  • Does booking back POs affect the WinCC OS server licenses?
    No, AS Process Objects (AS RT PO) license automation station execution, while OS Process Objects (OS RT PO) license WinCC tags and faceplates independently.
  • Where in SIMATIC Manager is the book-back command located?
    Select the AS Charts folder, then navigate to Options -> Charts -> Book back Process Objects (PO)....

Technical References

  • Siemens Industry Online Support (SIOS) Portal: How do you book back process objects in SIMATIC PCS 7? (Entry ID: 38817815).
  • SIMATIC PCS 7 Licenses and Configuration Limits Manual, Siemens AG.
  • Process Automation with SIMATIC PCS 7 CPU 410-5H Operating Manual, Siemens AG.

Related Articles

Related Tags

PCS 7, CPU 410, Process Objects, AS RT PO, Error D22F, Book Back, Automation License Manager, Licensing

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