Understanding AS RT PO License 6ES7653-2BB00-0XB5 on CPU 410-5H and OS PO Correlation

If your SIMATIC PCS 7 CPU 410-5H controller already has an activated System Expansion Card (SEC) with 1000 Process Object (PO) capacity, you do NOT need to purchase an additional 'AS RT PO' software license (6ES7653-2BB00-0XB5) to download your 1000 PO program. On CPU 410-5H, AS Process Objects are hardware-bound and reside directly on the physical SEC card. However, AS PO capacity does NOT provide OS runtime licenses. To operate the plant from WinCC, you must purchase OS Server runtime licensing with sufficient 'OS RT PO' licenses (e.g. an OS Server base package plus OS RT PO 1000) for each OS Server node.

Executive Summary

A frequent and costly commercial misconception during the commissioning of SIMATIC PCS 7 (V8.0 through V9.1) systems is the confusion between automation controller Process Objects (AS PO) and operator station Process Objects (OS PO), particularly regarding the CPU 410-5H. When an engineer holds a CPU 410-5H equipped with a 1000 PO System Expansion Card (SEC) and an AS Engineering license on the ES, uncertainty often arises as to whether catalog number 6ES7653-2BB00-0XB5 (CPU 410 SEC PO 1000) must be purchased a second time as a software license key in Automation License Manager. This article establishes the definitive manufacturer licensing boundaries between SEC hardware capacity, AS POs, and OS RT POs.

Architecture and Fundamental Mechanics

Licensing Architecture: CPU 410-5H SEC Capacity vs. OS Process Objects:

CPU 410-5H Hardware-Bound Process Objects (SEC):
Traditional S7-400 controllers (CPU 416, CPU 417) utilize floating software AS RT PO licenses stored in ALM on the Engineering Station. During compilation, the ES books POs from ALM into the project.
The CPU 410-5H operates on a fundamentally different hardware capacity model: the Process Object entitlement is embedded inside the microchip of the physical System Expansion Card (SEC) inserted into the CPU.
Catalog number 6ES7653-2BB00-0XB5 represents the physical System Expansion Card for 1000 POs (or its expansion token). If the CPU 410-5H was already purchased with this 1000 PO SEC card installed, the controller is already fully authorized to execute up to 1000 AS Process Objects. No software key is needed in ALM on the ES to permit downloading.
Distinct Separation Between AS POs and OS POs:
AS Process Objects (AS PO): Count technological control blocks configured in the AS program (e.g., motor blocks MotL, valve blocks VlvL, PID controllers PIDConL, interlocks). Elementary logic gates (such as AND, OR, ADD) do NOT consume POs.
OS Process Objects (OS PO): Count technological objects compiled into the WinCC OS project that are visualized, monitored, or controlled on operator faceplates (blocks with attribute S7_m_c := 'true').
Crucial Rule: AS PO capacity confers zero entitlement for OS operation! Operating an OS requires separate 'OS Software Server' runtime licenses and 'OS RT PO' additive licenses installed on each OS Server in Automation License Manager.
Multi-Controller and Redundancy Rules:
On redundant CPU 410-5H controllers, each physical CPU must have its own SEC card of matching capacity.
On OS Servers, each independent server (or server pair) must be licensed for the total OS POs assigned to its process area.

Step-by-Step Implementation Procedure

Step-by-Step Procedure to Audit and Verify PO Capacities:

Verify CPU 410-5H SEC Capacity Online:
- Open Automation License Manager (ALM) on the Engineering Station.
- Select menu Edit -> Connect Target System -> Connect CPU 410.
- Enter the CPU IP address; ALM reads the SEC status directly from the hardware.
- Confirm that 'Current PO Capacity' indicates 1000 PO.
Audit AS Process Object Consumption in SIMATIC Manager:
- In SIMATIC Manager Component View, select the AS project or Charts folder.
- Select menu Options -> PCS 7 License Information.
- Under 'AS Process Objects', review:
- Configured Process Objects (e.g. 650 POs).
- Licensed Capacity (1000 POs from SEC).
- If configured POs $\le$ SEC capacity, downloading to the AS will succeed without purchasing additional software licenses.
Calculate and Procure Required OS Runtime Licenses:
- In the same 'PCS 7 License Information' window, inspect the OS Process Objects tab.
- Review the total number of WinCC Process Objects required for the OS Server project.
- Procure the appropriate WinCC OS Server runtime package:
- SIMATIC PCS 7 OS Software Server (includes base 100 POs).
- Additive OS RT PO expansion packages (e.g. PO 1000) to cover total project OS PO demand.
Transfer OS License Keys to Target OS Server:
- Open ALM on the target OS Server.
- Transfer the OS Server runtime and OS RT PO license keys to the local C: drive.
Compile and Download:
- Download charts to the CPU 410-5H (verifying 0 license errors).
- Download WinCC project to the OS Server and activate Runtime.

Verification

Verification Procedure:
1. AS Download Verification: In SIMATIC Manager, execute a program download to the CPU 410-5H. Confirm that the download completes with zero license deficiency warnings.
2. CPU Diagnostic Buffer Check: In HW Config, check CPU 410-5H Module Information -> Diagnostic Buffer. Confirm no SEC capacity overrun events are registered.
3. OS Runtime License Check: On the OS Server, open ALM. Verify that the 'OS Software Server' and 'OS RT PO' licenses report status 'In use' without entering WinCC Demo Mode.

Limitations and Operational Precautions

Operational Precautions and Commercial Guardrails:
- Hardware vs Software Distinction: Never purchase software AS RT PO licenses (6ES7653-2BA00-0XB5) for a CPU 410-5H; CPU 410 controllers exclusively use System Expansion Cards (6ES7653-2BB00-0XB5).
- No Automated 1:1 PO Assumption: While many continuous process projects have approximately comparable AS and OS PO counts, never assume they are strictly equal. Always check actual counts in 'PCS 7 License Information'.
- Commercial and Procurement Verification: Catalog numbers, SEC step-up packages, and OS RT PO packages vary by PCS 7 version. Always validate exact MLFBs and PO counts against the official Siemens ST PCS 7 catalog and an authorized Siemens distributor quotation.

Engineer FAQ

Do I need to buy an AS RT PO software license if my CPU 410 already has a 1000 PO SEC?

No. On CPU 410-5H, AS Process Object capacity resides in the hardware SEC card. If your CPU has a 1000 PO SEC, it is already authorized to execute 1000 POs without additional software keys on the ES.

What is the catalog number 6ES7653-2BB00-0XB5?

It is the Siemens order number (MLFB) for the CPU 410 System Expansion Card with 1000 Process Objects capacity.

Does having 1000 AS POs mean I automatically have 1000 OS POs?

No. AS POs and OS POs are completely separate licenses. The OS Server requires its own OS Server runtime and OS RT PO licenses to operate.

Where can I see the exact number of AS and OS Process Objects consumed?

In SIMATIC Manager, select the project and open menu Options -> PCS 7 License Information.

Do basic logic blocks like AND or OR consume Process Objects?

No. Elementary boolean logic and math blocks do not consume Process Objects. Only technological blocks (motors, valves, controllers, interlocks) consume POs.