Customizing Diagnostic Block Icons Using Maintenance Typicals in SIMATIC PCS 7

In SIMATIC PCS 7 Maintenance Station (MS), standard diagnostic block icons are generated from the template file '@@maintenancetypicals.pdl'. To customize diagnostic block icons without risking data loss during future system updates, engineers must never edit '@@maintenancetypicals.pdl' directly. Instead, create a user-defined template picture named '@maintenancetypicals.pdl' (e.g., '@maintenancetypicals_Plant.pdl') in the OS project directory, copy the target block icons into it, modify their visual attributes, and run 'Create/update diagnostic screens' in SIMATIC Manager.

Executive Summary

SIMATIC PCS 7 Maintenance Station provides comprehensive plant asset management by automatically generating diagnostic screens and block icons for automation system hardware, field devices, and network infrastructure. During the 'Create/update diagnostic screens' procedure, PCS 7 extracts graphical typicals from predefined WinCC Picture Description Language (.pdl) template files.

The default template file supplied with the system is @@maintenancetypicals.pdl. A common mistake among automation engineers is directly altering @@maintenancetypicals.pdl to change colors, fonts, or diagnostic representations. However, subsequent PCS 7 software updates, library upgrades, or running the OS Project Editor will overwrite this file, discarding all customizations. This guide outlines the standard naming conventions, search precedence mechanics, and exact step-by-step procedures to create resilient custom maintenance typicals in PCS 7 V8.0 through V9.1.

Architecture and Fundamental Mechanics

The PCS 7 Maintenance Station architecture relies on the Diagnostic Screen Generation Wizard (DiagGen). When an engineer executes 'Plant Diagnostics > Create/update diagnostic screens' from SIMATIC Manager, the wizard inspects the hardware configuration, PROFIBUS/PROFINET topologies, and AS diagnostic blocks (MOD_D1, RACK_410, etc.).

For every discovered hardware asset, DiagGen places a diagnostic block icon on the corresponding diagnostic overview and hierarchy screens. To determine which visual template to instantiate, the wizard scans the local OS project's GraCS (Graphics) directory using a strict precedence rule:
1. User-Defined Typicals: Files matching the pattern @maintenancetypicals*.pdl (with a single '@' prefix followed by custom text, e.g., @maintenancetypicals_Custom.pdl). If multiple custom typical files exist, they are parsed alphabetically.
2. System Default Typicals: The factory file @@maintenancetypicals.pdl (with a double '@@' prefix).

If DiagGen finds a block icon with a matching type attribute (e.g., @MS_AS, @MS_ET200M, @MS_SWITCH) in a user-defined @maintenancetypicals*.pdl file, it instantiates the user's version and ignores the standard icon in @@maintenancetypicals.pdl. Because system updates and the OS Project Editor only overwrite files with the double '@@' prefix, user-defined single '@' files remain permanently untouched.

Step-by-Step Implementation Procedure

Follow these steps to create and deploy custom diagnostic block icons in SIMATIC PCS 7 Maintenance Station:

Locate and Open the Standard Maintenance Typicals File:
- In SIMATIC Manager, navigate to your Maintenance Station OS project (or standard OS Server).
- Right-click the OS project and select 'Open Object' to launch WinCC Explorer.
- In the WinCC Explorer navigation pane, select 'Graphics Designer'.
- Open @@maintenancetypicals.pdl from the file list.
Create a User-Defined Template File:
- In Graphics Designer, select 'File > Save As...'.
- Save the file under a new name adhering strictly to the naming convention: @maintenancetypicals<Identifier>.pdl (for example, @maintenancetypicals_Site.pdl). Ensure there is only ONE leading '@' character.
Customize the Desired Block Icons:
- In @maintenancetypicals_Site.pdl, delete all block icons that you do not plan to modify (this keeps the template clean and reduces generation time).
- Select the specific block icon you wish to customize (e.g., the network switch icon @MS_SCALANCE or the distributed I/O rack icon @MS_ET200M).
- Right-click the object and select 'Configuration Dialog' or open the 'Properties' window.
- Modify graphical properties such as background color, font size, border styling, or dynamic tooltip scripts.
- IMPORTANT: Do NOT alter the object property type or the internal script connections that link diagnostic states to Maintenance Station faceplates.
- Save and close @maintenancetypicals_Site.pdl.
Execute Diagnostic Screen Generation:
- Return to SIMATIC Manager.
- Select the multiproject or the specific AS/OS station containing the Maintenance Station.
- Select 'Options > Plant Diagnostics > Create/update diagnostic screens' from the main menu.
- In the wizard dialog, select the target OS station and click 'Start'.
- DiagGen parses the custom @maintenancetypicals_Site.pdl file, identifies the updated icons, and recreates the diagnostic screens across the project.
Verify and Download to OS Runtime:
- Open the generated diagnostic screens in WinCC Graphics Designer to inspect the updated icons.
- Download the OS project to the Maintenance Station and activate runtime.

Verification

In WinCC Explorer on the Maintenance Station, open one of the generated diagnostic screens (e.g., @Diag_AS_*.pdl or @Diag_Field_*.pdl) in Graphics Designer.
Confirm that the instantiated block icons reflect your customized colors, fonts, and dimensions.
Verify object properties: ensure that the Servername, Tag, and TagHigh attributes correctly bind to the corresponding hardware diagnostic tags.
Activate WinCC Runtime, trigger a test diagnostic state (or simulate a communication fault), and verify that the customized block icon displays the correct Maintenance State (Maintenance Required, Maintenance Demanded, Unchecked) and successfully opens the diagnostic faceplate when clicked.

Limitations and Operational Precautions

Never rename or delete system tags associated with diagnostic block icons, as this breaks integration with the Maintenance Station Diagnostic Server. Customized typicals must reside in the local OS project's GraCS directory or the Master Data Library; if working in a multiproject, store custom typicals in the Master Data Library and distribute them to OS projects via project synchronization. Upgrading major PCS 7 versions may introduce new diagnostic block icon attributes; always compare custom typicals against newly released @@maintenancetypicals.pdl files after major version upgrades.

Engineer FAQ

What is the difference between @@maintenancetypicals.pdl and @maintenancetypicals.pdl?

Files prefixed with '@@' are Siemens factory templates that are automatically replaced during updates or OS compilations. Files prefixed with a single '@' are user-defined templates that are preserved permanently.

Can I create multiple custom typical files like @maintenancetypicals_1.pdl and @maintenancetypicals_2.pdl?

Yes. The DiagGen wizard parses all files matching @maintenancetypicals*.pdl in alphabetical order. If duplicate icon types exist across custom files, the last parsed file takes precedence.

Where should I store custom typicals in a multi-engineering environment?

Store custom typical files in the Master Data Library under the OS project template folder. This ensures they are consistently replicated across all engineering stations.

Why did my custom block icons disappear after running the OS Project Editor?

This occurs if you edited @@maintenancetypicals.pdl directly instead of creating @maintenancetypicals<Name>.pdl. OS Project Editor overwrites all double-at ('@@') files.

Do diagnostic block icons consume WinCC Process Object (PO) licenses?

No. Diagnostic block icons generated by Maintenance Station display hardware health and are linked to driver blocks; they do not consume additional WinCC OS RT PO licenses beyond the Maintenance Station license.