Upgrading Process Objects (PO) on SIMATIC PCS 7 CPU 410-5H Redundant Systems - ALM Online Upgrade Requirements

To increase the Process Object (PO) capacity of a SIMATIC PCS 7 CPU 410-5H controller (such as expanding beyond the default 100 POs when a program utilizes 103 POs), engineers must apply a CPU 410 Expansion Pack (e.g., 100 PO package 6ES7653-2CA00-0XE0). In an S7-400H redundant configuration, both CPUs must be upgraded with identical PO expansion packages. If an engineer inserts the license USB and cannot see the 'activation file' or the menu command 'Edit -> Connect target system -> Connect/disconnect AS 410' in Automation License Manager (ALM), two critical prerequisites are typically missing: First, the Online Upgrade feature requires PCS 7 V8.1 or higher (with ALM V5.3 SP1+) and CPU 410 firmware V8.1; it does not exist in PCS 7 V8.0. Second, SIMATIC Manager must be completely closed before opening ALM to release database locks on the AS communication channels.

The CPU 410-5H System Expansion Card (SEC) Licensing Architecture

The SIMATIC PCS 7 CPU 410-5H (6ES7410-5HX08-0AB0) introduces a unified hardware concept for process automation. Instead of manufacturing dozens of distinct CPU models with fixed memory limits, Siemens produces a single ultra-high-performance hardware controller whose memory, performance, and Process Object (PO) capacity are defined by a physical System Expansion Card (SEC) inserted in the CPU rear slot.

The base CPU 410-5H comes pre-configured with a default capacity of 100 Process Objects. When the technological program in CFC expands beyond 100 POs (for example, utilizing 103 POs), the CPU will report a license violation during compilation or download. To scale the system, engineers purchase CPU 410 Expansion Packs (6ES7653-2CA00-0XE0 for 100 POs, or 6ES7653-2CC00-0XE0 for 500 POs) to upgrade the hardware capacity of the SEC.

Why the 'Connect Target System' Option Disappears in ALM

When engineers attempt to perform an SEC upgrade using Automation License Manager (ALM), they frequently report that the USB drive appears 'void' (no license file visible) or that the menu command Edit -> Connect target system is completely absent.

Diagnostic SymptomRoot CauseRequired RemediationMissing 'Connect target system' Menu in ALMRunning PCS 7 V8.0; Online Upgrade was introduced in PCS 7 V8.1Upgrade engineering software to PCS 7 V8.1+ / ALM V5.3 SP1+Menu Present but Grayed OutSIMATIC Manager or HW Config is running in the backgroundClose SIMATIC Manager completely; reopen ALMNo 'Activation File' Visible on USBSEC licenses are ALM license keys, not loose Windows filesView USB drive inside ALM tree view, not Windows File ExplorerConnection Refused to AS 410PG/PC Interface misconfigured or CPU firmware < V8.1Verify Set PG/PC Interface points to active network NIC (BCE/Softnet)

In ALM, license entitlements are stored in a hidden, secure directory structure (AX NF ZZ). Attempting to browse the USB drive in standard Windows Explorer will show an empty folder. The expansion keys can only be viewed and transferred inside ALM.

Prerequisites and Step-by-Step Workflow for Redundant CPU 410 Online Upgrade

In a fault-tolerant S7-400H redundant configuration, each CPU possesses its own physical SEC. Therefore, a redundant pair requires purchasing two identical expansion packages (6ES7653-2CA00-0XE0 x 2).

Mandatory Prerequisites:

SIMATIC PCS 7 V8.1 or higher (ALM V5.3 SP1 or higher).
CPU 410-5H Firmware V8.1 or higher.
Hardware configured with Firmware V8.1+ in HW Config.
System Expansion Card product release version 2 or higher.

Upgrade Workflow:

Transfer Licenses to Workstation: Insert both USB sticks. Open ALM. Drag the CPU 410 Expansion Pack (PO 100) licenses from the USB drives onto the local hard drive C:.
Close Competing Applications: Close SIMATIC Manager, CFC, and HW Config.
Connect to AS 410 in ALM: In ALM, select Edit -> Connect target system -> Connect/disconnect AS 410.
Establish Communication: Enter the IP address of the first CPU 410-5H (Master). ALM interrogates the CPU and displays the SEC serial number and current capacity (100 PO).
Execute Upgrade: Select the CPU in ALM, right-click, and select Upgrade. ALM transfers 100 POs from drive C: directly into the SEC memory in RUN mode without CPU restart.
Repeat for Standby CPU: Disconnect from CPU 1, connect to the IP address of the second CPU 410-5H (Standby), and transfer the second 100 PO expansion license.

Verification

Verify SEC upgrade completion and PO availability using these checks:

ALM Capacity Inspection: In ALM, query the target AS 410. Confirm that the current capacity displays 200 PO on both controllers.
SIMATIC Manager Module Information: Open SIMATIC Manager, select the CPU, and press Ctrl+D. Open the Performance Data or System Expansion Card tab. Verify that licensed POs show 200.
CFC Program Download Test: Compile the CFC charts. Confirm that the compiler calculates 103 POs against an available budget of 200 POs, allowing delta download in RUN mode with zero licensing warnings.

Limitations and Operational Precautions

When upgrading CPU 410 Process Objects, adhere to these licensing rules:

Symmetry Enforcement: In an H-system, if CPU A has 200 POs and CPU B has 100 POs, the controllers will refuse to synchronize redundancy, triggering an operational fault.
Irreversible Assignment: Once a CPU 410 Expansion Pack is transferred into an SEC, the license is permanently bound to that specific SEC hardware serial number and cannot be moved back to a USB drive or transferred to another CPU.
Distinction Between AS PO and OS PO: CPU 410 Expansion Packs upgrade AS Runtime Process Objects. They do not provide WinCC OS Runtime Process Objects, which must be licensed separately via WinCC OS PO packages.
Commercial Procurement and Licensing Disclaimer: Expansion packages (6ES7653-2CA00-0XE0) must be procured through official Siemens channels. Always verify total plant PO counts with an authorized Siemens distributor before purchase.

Engineer FAQ

Can I upgrade CPU 410 POs while the plant is operating in RUN mode?

Yes. The CPU 410-5H Online Upgrade feature was specifically designed to allow expanding Process Object capacity on live, running automation systems without requiring a CPU stop.

What happens if my program exceeds the SEC PO count?

If the program uses more POs than licensed on the SEC (e.g., 103 used vs 100 available), CFC will issue severe compilation warnings and may block downloading new charts to the controller.

Can I use a single 100 PO license to upgrade both CPUs in an H-system?

No. Each physical CPU 410-5H contains its own independent System Expansion Card (SEC). A redundant system requires purchasing two separate expansion pack licenses.