Bulk Inserting Blocks Across Multiple Existing CFC Charts in SIMATIC PCS 7 - IEA and CMT Synchronization

To insert a single function block across hundreds of existing Continuous Function Charts (CFC) in SIMATIC PCS 7 without manual copy-pasting, engineers utilize either the Import/Export Assistant (IEA) or Control Module Types (CMT) synchronization. In legacy projects based on Process Tag Types (PTT), the new block is added to the template chart in the Master Data Library and propagated via the IEA File Wizard. In modern PCS 7 (v8.1/v8.2+), adding the block to the Control Module Type in the Master Data Library and executing 'Plant Hierarchy -> Synchronize' automatically instantiates the block across all instances while preserving custom parameters.

Mass Engineering Challenges in Large PCS 7 Facilities

In enterprise process automation facilities containing hundreds of motors, valves, and analog transmitters, engineering modifications frequently require introducing a universal logic block across all existing charts:
* Adding an auxiliary interlock block (Intlk04 or Intlk08).
* Adding a runtime operating hours counter (OpTime).
* Adding a signal status filter or power monitor.

Manually opening, pasting, and interconnecting a new block across 400+ CFC charts consumes weeks of engineering time and introduces severe copy-paste errors.

Method 1 - Control Module Types (CMT) Type-Instance Synchronization

Starting in SIMATIC PCS 7 v8.1 and continuing into v8.2+, the modern, manufacturer-recommended approach for bulk engineering is Control Module Types (CMT):

[Master Data Library (MDL) -> Plant Hierarchy]
   │
   ├─► Open the Master Control Module Type (e.g., "CMT_Motor_1D")
   ├─► Insert the new Function Block from the catalog (e.g., "OpTime" FB1885)
   ├─► Connect internal algorithm pins (e.g. Motor.Running -> OpTime.Tracking)
   ├─► Mark exposed parameters / signals as Control Module Attributes
   └─► Save and Close the CMT
         │
         ▼
[SIMATIC Manager -> Multiproject Level]
   │
   ├─► Select: Plant Hierarchy -> Synchronize...
   ├─► The Synchronization Wizard analyzes all 400 instances across all AS stations
   ├─► Highlights the addition of the new "OpTime" block
   └─► Click: "Synchronize" -> Instantiates the block across all 400 charts automatically!

CMT synchronization updates the chart structure without wiping out instance-specific parameters (e.g. tag names, hardware addresses, setpoints).

Method 2 - Import/Export Assistant (IEA) for Process Tag Types

For older or migrated projects utilizing Process Tag Types (PTT):
1. Open the Process Tag Type template chart in the Master Data Library.
2. Insert the new block and configure standard interconnections.
3. Open the Import/Export Assistant (IEA) wizard (Options -> Process Tags -> Import/Export Assistant).
4. Export the existing process tag list to a .csv or .txt exchange file.
5. In Microsoft Excel, verify the column mapping for the newly introduced block parameters.
6. Re-import the file via the IEA wizard. The assistant parses the 400 charts and updates each instance with the new block.

Mass Parameterization via Process Object View (POV)

The following table compares bulk engineering methodologies in SIMATIC PCS 7:

Bulk Engineering ToolSupported PCS 7 VersionsExecution MechanismIdeal ApplicationControl Module Types (CMT)PCS 7 v8.1 / v8.2 / v9.xCentral type-instance synchronizationStandard DCS projects; updates 400+ charts in minutes.Import/Export Assistant (IEA)PCS 7 v6.x / v7.x / v8.0CSV spreadsheet export/importLegacy projects based on Process Tag Types.Process Object View (POV)All PCS 7 versionsTabular parameter grid inside SIMATIC ManagerMass parameter editing (limits, addresses, text) after creation.Manual Copy-PasteAll versionsIndividual chart editingHighly discouraged (> 5 charts); prone to typographical errors.

Verification

To confirm that the new block has been successfully instantiated across all target charts:
1. Open the Process Object View (POV) in SIMATIC Manager and navigate to the Blocks tab.
2. Filter the block list by the name of the newly inserted block (e.g. OpTime); verify that the total instance count matches the expected target (e.g. 400 instances).
3. Open 5 to 10 random CFC charts across different automation stations; verify that the new block is positioned cleanly and its internal chart interconnections are intact.
4. Execute a CFC compilation (Chart -> Compile -> Charts as Program -> Changes Only); verify that compilation finishes with 0 errors.
5. In test mode online, verify that the newly added blocks are executing within their designated cyclic interrupt OBs.

Limitations and Operational Precautions

Before performing mass CMT synchronization or IEA imports across hundreds of charts, always create a full Multiproject backup archive (.zip). Adding blocks to hundreds of charts consumes controller work memory and changes instance data block allocations. Verify remaining CPU work memory in PLC -> Module Information -> Memory before performing controller delta downloads.

Engineer FAQ

Will CMT synchronization overwrite custom parameters I entered on specific charts?

No. CMT synchronization updates only structural elements (new blocks, template connections) and respects instance-specific values (such as tag comments, setpoints, and I/O addresses).

Can I convert legacy Process Tag Types (PTT) into modern Control Module Types (CMT)?

Yes. SIMATIC PCS 7 includes a built-in migration wizard: select the PTT folder, right-click, and choose 'Migrate to Control Module Types'.

What happens if CPU work memory is insufficient for 400 new blocks?

The CFC compiler will flag an error during compilation or the download will be rejected with 'Insufficient work memory'. Check memory sizing prior to bulk expansion.

Can I bulk-delete a block across 400 charts using the same method?

Yes. Deleting the block from the Master CMT in the library and executing 'Synchronize' will automatically remove the block from all 400 instantiated charts.