C135 PCS 7 (PCS7)
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6 Cielo Ciencia y Tecnología
·Publicada en C135 PCS 7 (PCS7)

Resolving Missing AS RT PO Expansion and Activating CPU 410-5H System Expansion Cards

Resolving Missing AS RT PO Expansion and Activating CPU 410-5H System Expansion Cards

On a SIMATIC PCS 7 CPU 410-5H controller, Process Object (PO) capacity is governed by the hardware-bound System Expansion Card (SEC), not by software license keys transferred via Automation License Manager (ALM). To expand PO capacity (e.g., stepping up from 500 to 750 or 1000 POs), you cannot use the standard 'License Key Transfer' function. Instead, you must use ALM to connect to the CPU, generate an activation request file (.act), submit it to the Siemens online activation portal alongside the purchased SEC Step-Up certificate, and download the resulting release file (.rea) back into the CPU 410 via ALM.

Table of Contents

Executive Summary

The SIMATIC PCS 7 CPU 410-5H represents a paradigm shift in controller capacity management: a single physical CPU hardware type covers the entire performance spectrum, with process object (PO) capacity determined exclusively by the plugged-in System Expansion Card (SEC). When plant expansions require increasing controller PO limits (e.g. moving from 500 to 750 or 1000 POs), engineers frequently encounter confusion when attempting to use traditional ALM 'License Key Transfer' commands. Attempting to transfer an activation request file (.act) results in the error 'This automation system is not a valid target for the license key'. This article details the cryptographic SEC Step-Up procedure, activation file workflows, and troubleshooting steps to restore expansion capacity.

Architecture and Fundamental Mechanics

Architectural Mechanics of CPU 410-5H System Expansion Cards (SEC):

  • Hardware-Bound Capacity vs Software Licensing:
  • Traditional S7-400 CPUs (e.g., CPU 416-3, CPU 417-4) utilize software AS RT PO licenses stored in Automation License Manager on the Engineering Station. During compilation or download, the ES books POs from ALM into the project.

  • The CPU 410-5H fundamentally alters this: controller PO capacity is embedded in the physical microchip of the System Expansion Card (SEC) inserted into the rear of the CPU module. The CPU firmware directly queries the SEC hardware at startup and runtime.

  • The SEC Step-Up Cryptographic Mechanism:

  • The SEC capacity cannot be altered by simple software license transfers because the SEC contains a tamper-proof cryptographic hardware signature tied to its unique serial number.

  • To expand capacity, an engineer must execute a 3-way challenge-response upgrade:

    1. Request File (.act): Generated by ALM connected online to the CPU 410. It contains the encrypted identity, current PO level, and hardware serial of the SEC.
    2. Certificate of License (CoL): The purchased Siemens SEC Step-Up product providing a License Key number and Delivery Note number.
    3. Release File (.rea): Generated exclusively by the Siemens Activation Server upon uploading the .act file and CoL entitlement. It contains the cryptographically signed authorization token.

  • Why Direct ALM Transfer Fails:

  • In ALM under Edit -> Connect Target System -> Connect CPU 410, the .act file is displayed in the file list. However, selecting Transfer triggers 'This automation system is not a valid target for the license key' because the .act file is an outgoing request payload, not an executable license token. The CPU 410 accepts only .rea files via the dedicated 'Upgrade...' function.

Step-by-Step Implementation Procedure

Step-by-Step Procedure to Perform CPU 410-5H SEC Step-Up Activation:

  1. Establish Physical and Network Connection:
    - Connect the Engineering Station (or a field service laptop) to the Industrial Ethernet or PROFINET interface of the CPU 410-5H.
    - Verify network accessibility via STEP 7 or pinging the CPU IP address.
  2. Connect Target System in Automation License Manager:
    - Launch Automation License Manager (ALM) with administrative privileges.
    - Select menu Edit -> Connect Target System -> Connect CPU 410.
    - Enter the target CPU IP address or select the interface. ALM connects online to the controller and reads the SEC serial number, hardware version, and current PO count.
  3. Generate the Activation Request File (.act):
    - In the ALM CPU 410 view, click the Upgrade... button (or right-click the CPU node -> Upgrade).
    - Select Save request file....
    - Choose a secure local folder on the PC and save the resulting .act file (named after the SEC serial number).
  4. Submit Request File to Siemens Online Activation Server:
    - On an internet-connected PC, navigate to the Siemens Industry Online Support (SIOS) Activation Portal (accessible via standard Siemens licensing portal links).
    - Select the option to perform an SEC CPU 410 Step-Up.
    - Enter the License Key and Delivery Note numbers from your purchased SEC Step-Up Certificate of License (CoL).
    - Upload the .act file generated in Step 3.
    - Submit the transaction; the Siemens activation server validates the entitlement and immediately provides the cryptographic release file (.rea) for download.
  5. Apply the Release File (.rea) to the CPU 410:
    - Return to ALM on the PC connected to the AS 410-5H.
    - Select menu Edit -> Connect Target System -> Connect CPU 410.
    - Click Upgrade... -> select Load release file....
    - Browse to the downloaded .rea file and confirm the transfer.
    - ALM writes the cryptographic authorization token directly into the SEC chip. The CPU updates its internal PO limit immediately (supportable in RUN mode without restarting the controller).

Verification

Verification Procedure:
1. ALM SEC Status Check: In ALM, reconnect to the CPU 410 via Connect Target System. Verify that the displayed Process Object capacity reflects the upgraded value (e.g. 750 or 1000 POs).
2. SIMATIC Manager Verification: In SIMATIC Manager, select the AS project -> select menu Options -> PCS 7 License Information. Verify that the AS Process Objects capacity matches the new SEC limit.
3. Online CPU Diagnostics: In STEP 7 HW Config, open the CPU 410-5H Module Information -> check the Diagnostic Buffer. Confirm no SEC capacity warnings (Event ID 16#45...) are logged.

Limitations and Operational Precautions

Operational Precautions and SEC Guardrails:
- One-to-One Hardware Binding: A release file (.rea) is cryptographically tied to the single SEC serial number from which the .act file was generated. It cannot be loaded into another SEC or shared across multiple controllers.
- Redundant AS Pairs (410-5H): In a high-availability redundant AS pair, both CPU 410-5H controllers must have identical SEC capacities. If stepping up capacity, separate SEC Step-Up packages must be purchased and activated independently for both SEC cards.
- Physical Removal Warning: Never remove or insert a System Expansion Card while the CPU is powered. Doing so will immediately cause the CPU to transition to DEFECTIVE/STOP mode.
- Procurement Verification: Always verify specific SEC Step-Up catalog numbers (MLFBs) and target capacities with an authorized Siemens distributor or through the Siemens Industry Mall before ordering.

Engineer FAQ

Why did ALM say 'This automation system is not a valid target for the license key'?

You attempted to use the standard 'Transfer' button on an .act request file. .act files cannot be transferred directly; you must use the 'Upgrade...' wizard to load a validated .rea release file provided by Siemens.

Can the SEC Step-Up be performed while the CPU 410-5H is in RUN mode?

Yes. The SEC upgrade procedure is designed to allow online capacity expansion without interrupting process automation execution, provided the engineering connection is stable.

What should I do if I lost the .act file before receiving the release file?

Simply reconnect ALM to the CPU 410-5H via 'Connect Target System' and click 'Upgrade... -> Save request file...' again to regenerate a fresh .act file.

Does the CPU 410-5H consume AS RT PO licenses from the ES ALM?

No. The CPU 410-5H utilizes hardware capacity embedded in its SEC card. It does not pull AS RT PO runtime license keys from the Engineering Station ALM.

If a CPU 410 fails and is replaced, can I move the SEC to the spare CPU?

Yes. The SEC card can be physically transferred from the defective CPU to the replacement CPU 410-5H while the rack is powered off, preserving all licensed PO capacity.

Technical References

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Related Tags

  • CPU 410-5H
  • System Expansion Card
  • SEC Step-Up
  • Process Objects
  • Automation License Manager
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