Resolving License Not Sufficient for Configured Process Objects Errors and ALM PO Discrepancies

In SIMATIC PCS 7, the error 'The license available is not sufficient for the configured process objects' during controller download indicates that technological blocks (S7_m_c = true) exceed licensed Process Objects (POs) or license booking is desynchronized. If the Automation License Manager (ALM) displays available AS RT POs but SIMATIC Manager reports zero, the primary causes are: an active Trial License capping capacity at 250 POs, a license version mismatch (e.g., V9.0 key on PCS 7 V8.0), unreturned POs booked by another ES, or on CPU 410-5H, licenses left on the ES instead of transferred to the System Expansion Card (SEC).

Executive Summary

During controller downloads in SIMATIC PCS 7 (including V8.0, V8.2, and V9.x), engineers frequently encounter a blocking license exception: 'The license available is not sufficient for the configured process objects(1)'. Confused engineers open the Automation License Manager (ALM) and observe that valid AS RT PO license keys (such as AS RT PO 1000) are installed. However, inspecting 'Object Properties -> PCS 7 License Information' in SIMATIC Manager indicates zero available process objects. This discrepancy stems from license version incompatibilities, trial license priority overrides, or misunderstandings of the CPU 410-5H System Expansion Card (SEC) architecture. This guide provides the diagnostic workflow to resolve PO licensing blocks.

Architecture and Fundamental Mechanics

The SIMATIC PCS 7 Process Object (PO) licensing model governs both controller execution (AS RT PO) and human-machine visualization (OS RT PO):
1. Process Object Booking Mechanism (Standard S7-400):
- On standard S7-400 controllers (e.g., CPU 416, CPU 417), AS RT PO licenses reside in ALM on the Engineering Station.
- When an AS program is compiled and downloaded, STEP 7 calculates the total number of blocks with S7_m_c = 'true' (technological blocks).
- STEP 7 'books' these POs from the ALM license container. If the project is moved to another ES, the booked POs remain associated with the original ES until 'booked back'.

System Expansion Card (SEC) Architecture (CPU 410-5H):
- On the CPU 410-5H, AS RT PO licenses do NOT reside on the ES hard drive. They MUST be loaded directly onto the physical System Expansion Card (SEC) inserted into the CPU.
- If an engineer purchases an AS RT PO expansion and leaves the license key on the ES C: drive in ALM, the CPU 410-5H cannot access it, reporting 0 available POs.
Trial License Interference:
- When a temporary 'PCS 7 Engineering Trial' license is installed, ALM assigns it evaluation priority. Trial mode imposes an absolute cap of 250 Process Objects and restricts commercial pool allocation. Even with 10,000 commercial POs installed, the trial license forces a license violation.
Version Incompatibility:
- License keys are strictly version-specific. An AS RT PO V9.0 license cannot license an engineering environment running PCS 7 V8.0. In PCS 7 V8.0, a V9.0 key is treated as unrecognized, resulting in 0 available POs.

Step-by-Step Implementation Procedure

Inspect PCS 7 License Information in SIMATIC Manager:
a. In SIMATIC Manager, right-click the root Multiproject or AS project folder and select 'Object Properties'.
b. Switch to the 'PCS 7 License Information' tab.
c. Review the table: note 'Configured Process Objects' vs. 'Licensed Process Objects' and 'Available Process Objects'.
d. Confirm whether the shortage affects the AS (controller) or OS (WinCC).
Audit Installed Licenses in Automation License Manager (ALM):
a. Open Automation License Manager (ALM) on the Engineering Station.
b. Inspect the C: drive license repository.
c. Search for any license containing the word 'Trial' (e.g., PCS 7 Engineering Trial). If present, right-click and move it to a USB drive or delete it.
d. Right-click the commercial AS RT PO license (e.g., AS RT PO 1000) and select 'Check' to confirm the license key is not corrupted.
e. Verify the exact license version: confirm that the license version matches the installed PCS 7 software release (e.g., V8.0 vs. V9.0).
Transfer POs to System Expansion Card (For CPU 410-5H Only):
a. If using a CPU 410-5H, open ALM and select Edit -> Connect Computer... or browse to the target CPU 410-5H.
b. Select the CPU's System Expansion Card (SEC) as the target drive.
c. Drag and drop the AS RT PO expansion license from the ES hard drive directly onto the SEC.
d. Confirm the SEC updates its total licensed capacity.
Re-book Process Objects from Master ES:
a. If the project was copied from another ES, open the project on the original master ES.
b. In SIMATIC Manager, perform a dummy change (e.g., insert and delete an empty chart), compile, and download to book the POs back into the master pool.
c. Archive the project and transfer it cleanly to the target ES.
Restart ES and Execute Download:
a. Restart the Engineering Station to clear cached licensing daemons.
b. Open SIMATIC Manager and execute PLC -> Download.
c. The download proceeds without licensing error prompts.

Verification

In SIMATIC Manager, open Object Properties -> PCS 7 License Information: confirm that 'Available Process Objects' reflects the full licensed capacity minus active configured POs.
In ALM, confirm that the AS RT PO license reports 'In Use' with active booked counts.
Execute an incremental download to the CPU: verify that the download completes with zero licensing exception prompts.
In the CPU Diagnostic Buffer, confirm no license shortage or PO violation events are recorded.

Limitations and Operational Precautions

Continuing an AS download when a license shortage warning is displayed activates a temporary grace period in the controller; after the grace period expires, the CPU enters an un-downloadable license fault state until sufficient POs are added. Never treat estimated I/O counts as actual PO consumption; actual PO consumption must be calculated via SIMATIC Manager. License expansion packages and System Expansion Cards should be procured through an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why does ALM show 1000 POs while SIMATIC Manager shows 0?

The installed license version may not match the PCS 7 release (e.g., V9.0 license on V8.0), a Trial license is overriding commercial keys, or the license must be transferred to the CPU 410 SEC.

How does a Trial license affect Process Object capacity?

A PCS 7 Trial license caps total capacity at 250 Process Objects and overrides commercial floating licenses until removed from ALM.

Do I need AS RT PO licenses for S7-300 controllers in PCS 7?

PCS 7 does not support S7-300 as an automation system; standard PCS 7 AS RT PO licensing applies exclusively to S7-400 and CPU 410 controllers.

What blocks consume AS RT Process Objects?

Technological blocks with Operator Control and Monitoring (OCM) attributes (S7_m_c = true), such as MotL, VlvL, and PIDConL. Pure channel drivers and mathematical blocks consume 0 POs.

Can booked POs be returned if I delete blocks from my program?

Yes. Deleting technological blocks and recompiling the CFC charts automatically books those Process Objects back into the available license pool upon download.