C135 PCS 7 (PCS7)
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How to Resolve Missing Block Icons and Faceplates for the PCS 7 Condition Monitoring Library

How to Resolve Missing Block Icons and Faceplates for the PCS 7 Condition Monitoring Library

In SIMATIC PCS 7, missing block icons and faceplates for add-on Condition Monitoring Library (CML) blocks such as VlvMon (valve monitoring) following an OS compile occur when the required template picture TemplateCMLib.PDL is missing from the target OS GraCS directory, or when block compilation attributes are unconfigured. The OS compiler requires the library's specific template PDL to locate block icon definitions (e.g., @VlvMon/1). Copying TemplateCMLib.PDL into the OS project's GraCS folder, verifying that 'OCM possible' and 'Create block icon' are checked in CFC block properties, and recompiling the OS resolves the issue.

Table of Contents

Architecture of Condition Monitoring Library (CML) in PCS 7

The SIMATIC PCS 7 Condition Monitoring Library (CML) is an optional software package that integrates predictive mechanical asset maintenance directly into the process control system.

CML delivers specialized algorithmic blocks running in Automation Stations (AS):
* VlvMon (Valve Monitoring): Continuously evaluates electro-pneumatic control valve health, detecting mechanical stiction, pneumatic leakage, hysteresis, and transit time degradation.
* PumpMon (Pump Monitoring): Detects cavitation, dry running, and flow anomalies on centrifugal pumps.
* SteadyState: Determines process equilibrium for stable baseline measurements.

Unlike standard APL blocks whose templates are automatically integrated during base PCS 7 installation, add-on libraries like CML require explicit template registration in the WinCC Operator Station project to enable automated block icon and faceplate generation.

Root Cause Analysis for Missing CML Block Icons

Engineers frequently install CML, instantiate VlvMon in a CFC chart, verify that the block executes in the AS, but discover that no block icon or faceplate appears on the WinCC process picture after running the OS Compiler.

Underlying Failure Mechanisms

  1. Missing Template File in WinCC GraCS: The PCS 7 block icon generation wizard relies on template pictures (@PCS7Typicals*.pdl or Template*.pdl) located in the project's GraCS directory. For CML, the template file is TemplateCMLib.PDL (or @PCS7TypicalsCMLib.pdl). If this file was not copied into the OS project's GraCS directory after installing CML, the compiler finds zero visual representations for VlvMon and skips icon creation.
  2. Missing OCM and Block Icon Flags in CFC: The VlvMon block properties must have:
    * OCM possible enabled (Operator Control and Monitoring).
    * Create block icon enabled.
  3. Mismatched Block Icon Type Index: VlvMon provides a single certified icon variant: index 1 (@VlvMon/1). If an engineer enters an arbitrary icon number in CFC block properties without corresponding graphics in the template, generation fails.
  4. Picture Property Disabled: The target process picture (.pdl) must have the attribute 'Derive block icons from the plant hierarchy' active in its Object Properties.

Step-by-Step Block Icon Generation and Recovery Procedure

To ensure CML block icons and faceplates generate successfully during compilation:

Step 1: Copy CML Templates into OS Project GraCS

  1. Navigate to the CML installation directory on the Engineering Station:
    C:\Program Files (x86)\Siemens\Step7\S7Data\CMLib\Templates (or WinCC Options folder).
  2. Locate the file TemplateCMLib.PDL (and @PCS7TypicalsCMLib.pdl if present).
  3. Copy these template files into the GraCS folder of every OS project (e.g., D:\Projects\OS_Prj\wincproj\OS\GraCS).

Step 2: Configure CFC Block Properties

  1. In SIMATIC Manager, open the CFC chart containing the VlvMon block.
  2. Right-click VlvMon and select Object Properties:
    * Check OCM possible.
    * Check Create block icon.
    * In the Block icon field, verify the index is set to 1 (or leave default).
  3. Verify that the chart resides in a Plant Hierarchy folder assigned to the target OS.

Step 3: Verify Process Picture Hierarchy Settings

  1. In Plant View, locate the process picture (.pdl) where the icon should appear.
  2. Right-click the picture and select Object Properties.
  3. On the Options tab, ensure that 'Derive block icons from the plant hierarchy' is checked.

Step 4: Run OS Compilation and Generate Icons

  1. In SIMATIC Manager Plant View, select the OS assignment folder.
  2. Select menu Plant Hierarchy -> Create/Update Block Icons....
  3. Check the compilation log (Plant Hierarchy -> Open Block Icons Log) to confirm that @VlvMon/1 was placed successfully.
  4. Compile the OS with Tags and messages enabled.

CML Block Types and Template File Reference Matrix

The following table outlines the block types, required templates, and icon variants in the PCS 7 Condition Monitoring Library:

Block TypeMonitored Mechanical AssetRequired Template FileDefault Icon TypeSupported Faceplate ViewsVlvMonControl Valves (Pneumatic)TemplateCMLib.PDL@VlvMon/1Standard, Diagnostic, Parameter, TrendPumpMonCentrifugal PumpsTemplateCMLib.PDL@PumpMon/1Standard, Characteristic, Limit, TrendSteadyStateProcess Equilibrium DetectorTemplateCMLib.PDL@SteadyState/1Standard, ParameterPrSysMonPressure System IntegrityTemplateCMLib.PDL@PrSysMon/1Standard, Diagnostic, Limit

Ensuring templates reside in GraCS guarantees seamless automated instantiation.

Verification

To verify that the CML block icon and faceplate function properly:
1. In SIMATIC Manager Plant View, open the Block Icons Log; confirm zero error lines for VlvMon.
2. Open the process picture in Graphics Designer; confirm that the @VlvMon/1 icon is rendered with valid dynamic tag connections.
3. Activate WinCC Runtime.
4. Verify that the valve monitoring icon displays dynamic stiction and wear status indicators.
5. Click the block icon: verify that the CML faceplate opens, displaying valve characteristic curves and diagnostic metrics.

Limitations and Operational Precautions

  • Condition Monitoring Library blocks require additional controller memory and cycle time; instantiate VlvMon in slower cyclic interrupt OBs (e.g., OB32 at 1000 ms or OB31 at 2000 ms) rather than fast tasks.
  • CML requires dedicated software licensing; verify license requirements against the Siemens catalog and consult an authorized distributor for official quotation.
  • If custom block icons are designed, never overwrite TemplateCMLib.PDL directly; create a custom @PCS7TypicalsCustom.pdl with priority over standard templates.
  • Running OS Project Editor does not automatically copy add-on library templates; CML templates must be copied manually after running the editor.

Engineer FAQ

Where is TemplateCMLib.PDL located on the Engineering Station?

It is typically located in C:\Program Files (x86)\Siemens\Step7\S7Data\CMLib\Templates or inside the Master Data Library of the CML installation package.

Why does the Block Icons Log report 'Icon not found in template'?

This warning occurs when the icon type specified in CFC (e.g., @VlvMon/2) does not exist in any of the @PCS7Typicals*.pdl or Template*.pdl files in the OS GraCS directory.

Can VlvMon monitor non-pneumatic motor-operated valves?

VlvMon is specifically optimized for continuous throttling pneumatic control valves equipped with positioners (e.g., SIPART PS2). For on/off motor valves, standard APL VlvMotL monitoring is typically sufficient.

Technical References

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Related Tags

  • Condition_Monitoring
  • VlvMon
  • Block_Icons
  • TemplateCMLib
  • PCS7_CML
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