Adding Interlock Bypassed Indicators to CEMAT Motor Block Icons in PCS 7

To display an interlock bypassed indicator on a CEMAT Minerals motor block icon without losing tag connections during screen updates, create a custom block icon template file named '@PCS7Typicals_Custom.pdl' in the WinCC GraCS directory rather than directly editing the factory '@PCS7Typicals.pdl'. In the custom template, copy the target drive icon (e.g., @C_DRV_1D/1), assign a unique variant type (such as @C_DRV_1D/25), and embed an Extended Status Display or bitmap layer linked to the drive's maintenance status tag (.STATUS3 or .MAINT). Assign this new type in the CFC block properties and run 'Create/Update Block Icons' to preserve dynamic tags permanently.

CEMAT Block Icon Architecture and Typical File Integrity

In SIMATIC PCS 7, block icons represent technological field devices on WinCC operator process screens. The automatic generation and synchronization of these icons is driven by template files located in the project's GraCS directory. In standard systems, this is @PCS7Typicals.pdl or @PCS7Typicals_APL.pdl; in cement and mining installations, it is governed by @PCS7Typicals_CEMAT.pdl.

When engineers attempt to customize block icons—such as adding a visual indicator (a yellow hand or wrench icon) to warn operators that an electrical or process interlock is bypassed—they often edit the factory template directly or paste unconfigured graphic objects into process screens. This causes dynamic tag links to vanish as soon as the SIMATIC Manager block icon generator runs.

Why Dynamic Tags Disappear During Direct Template Edits

Understanding the WinCC Block Icon Generator rules prevents tag loss:

Template Overwriting by Project Editor: Whenever the WinCC OS Project Editor runs, factory files beginning with @ (such as @PCS7Typicals.pdl) are completely overwritten by pristine versions from the Siemens installation directory. Any direct modifications made to factory files are deleted.
Relative Tag Resolution: Inside a typical picture, dynamic tag properties must use relative tag syntax (beginning with a dot, e.g., .STATUS3 or .STATUS1). If an icon is copied across screens without proper grouping, the wizard strips the dynamic dialog because the parent group properties (type, tag, tagstructure) are missing or unlinked.
Custom Typicals Priority: SIMATIC Manager searches for custom templates adhering to the naming convention @PCS7Typicals_<CustomName>.pdl (e.g., @PCS7Typicals_CEMAT_Plant.pdl) and merges them into the block icon catalog without risk of overwriting.

CEMAT Status Word Bitmasking for Interlock Bypassing

In CEMAT Minerals (C_DRV_1D), status reporting is handled by 32-bit double words. The table below illustrates the structure of CEMAT status words and how bypass indicators should be extracted.

Status TagMonitored AttributeRelevant Bit PositionVisual Indicator Meaning.STATUS1Operational Drive StateBit 0 (Running), Bit 1 (Stopped)Motor running forward / reverse / idle.STATUS2Fault and Trip ConditionsBit 4 (Overload), Bit 5 (Electrical Trip)Drive tripped on mechanical/electrical fault.STATUS3Maintenance & Bypass FlagsBit 12 (Interlock Bypassed)Interlock bypassed (Display Hand/Wrench Icon).STATUS3Operating ModeBit 8 (Local Mode), Bit 9 (Single Mode)Drive decoupled from plant automation sequence.MAINTCollective Maintenance WordBit 0 (Bypass Active)Maintenance interlock bypass active on upstream modules

Comparison of Standard vs Custom Block Icon Customization

The table below contrasts standard CEMAT block icon behavior with properly engineered custom block icons.

Engineering DimensionStandard @PCS7Typicals_CEMAT.pdlCustom @PCS7Typicals_Custom.pdlUpgrade SafetyOverwritten during SP / Hotfix installation100% Retained during updates and Project Editor runsVariant DifferentiationRestricted to standard variants (@C_DRV_1D/1, /2)Supports user-defined variants (e.g., @C_DRV_1D/25)Bypass VisualizationHidden or restricted to faceplate sub-dialogsProminent visual badge (Hand/Wrench) directly on screenTag PreservationTags strip if pasted manually without wizardAutomated relative tag resolution via Create/Update Block IconsSiemens StandardStandard baseline templateRecommended Siemens Best Practice for plant typicals

Step-by-Step Procedure to Add Bypass Indicators to CEMAT Icons

Follow this procedure to permanently add an interlock bypass badge to CEMAT motor block icons:

Create Custom Typicals Picture:
- In WinCC Graphics Designer, open @PCS7Typicals_CEMAT.pdl.
- Save the file as @PCS7Typicals_Custom.pdl inside the project's GraCS directory.
Customize the Drive Block Icon:
- Locate the target motor icon (e.g., @C_DRV_1D/1). Select and duplicate it (Ctrl + D).
- Open object properties of the duplicated group: change property type to @C_DRV_1D/25.
- Ungroup the icon temporarily or open group editing mode.
- Insert a Status Display object (or Extended Status Display) positioned in the upper right quadrant of the motor symbol.
- Connect the status display's tag property to relative tag .STATUS3.
- Configure bitmask evaluation: when Bit 12 = 1 (or .MAINT Bit 0 = 1), display the yellow hand or wrench bitmap image.
- Regroup all objects into a single unified graphic object.
Assign New Type in CFC:
- In Continuous Function Chart, open the object properties of the target C_DRV_1D block.
- In the Attributes tab, set attribute type to @C_DRV_1D/25.
Execute Block Icon Update:
- In SIMATIC Manager, select the plant hierarchy folder and run Options -> Plant Hierarchy -> Create/Update Block Icons.
- Confirm the update: the wizard parses @PCS7Typicals_Custom.pdl and places the customized icon with dynamic tags fully resolved.

Verification

Verify custom block icon functionality through the following checks:
1. In WinCC Graphics Designer, open the target process screen: confirm that the block icon has type @C_DRV_1D/25 and dynamic tag properties point to the real motor tag.
2. Launch WinCC Runtime: verify that the motor icon displays normal idle/running colors without visual defects.
3. In the field or online test mode, activate an interlock bypass on the associated C_INTERL block: verify that the yellow hand/wrench icon immediately appears on the motor symbol.
4. Clear the bypass: verify that the bypass badge clears instantly.

Limitations and Operational Precautions

Never modify factory graphics in C:\Program Files (x86)\Siemens\WinCC\Options\PDL\.... Always maintain custom templates within the specific WinCC project GraCS folder and back them up before performing any PCS 7 software upgrade. Additionally, ensure that custom bitmap files (e.g., Bypass_Hand.emf or Wrench.bmp) are copied to the GraCS folder on all OS Servers and OS Clients to avoid missing image placeholders during runtime.

Engineer FAQ

Why did copying and pasting an icon directly onto a process picture fail?

Copying an icon directly bypasses the SIMATIC Manager Block Icon Generator. Without the wizard resolving relative tag paths (e.g., .STATUS3 to Area/Unit/Motor.STATUS3), the tags remain unbound and disappear.

How many custom typicals files can I create in a WinCC project?

SIMATIC PCS 7 allows multiple custom typical files following the naming format @PCS7Typicals_<Name>.pdl. The generator parses them in alphabetical order.