Integrating Operating Hours and Motor Runtime Display into APL Faceplates in PCS 7

To monitor and display operating hours on a motor faceplate ('MotL' or 'MotSpdCL') in SIMATIC PCS 7, instantiate the APL runtime calculation block 'RunTime' (FB1860) or aggregate block 'Aggr16' (FB1803) in CFC. Connect the motor running feedback ('MotL.FbkRunOut') to the run input ('RunTime.In'), and interconnect the calculated hours output ('RunTime.Hours') to the motor block's auxiliary analog input ('UserAna1' or 'AV'). During OS compilation, the auxiliary value is linked to the motor faceplate, displaying running hours directly in the preview, standard, and maintenance views.

Executive Summary

Preventive and predictive maintenance in process industries requires continuous tracking of operating hours for rotating machinery—such as slurry pumps, cooling fans, and agitators—to trigger oil changes, bearing lubrication, and seal inspections. While the standard APL motor blocks (MotL, MotSpdCL) provide basic runtime trip timers, they do not accumulate multi-year running hours internally. Instead, the PCS 7 Advanced Process Library utilizes modular auxiliary blocks to compute runtimes and project them directly into standard operator faceplates. This guide explains the architecture, CFC wiring, and faceplate integration.

Architecture and Fundamental Mechanics

Runtime Calculation Architecture and Faceplate Auxiliary Value Mechanics:

The Runtime Meter Block (RunTime - FB1860):
Dedicated APL utility block designed to accumulate operational duration.
Evaluates execution cycles in an active cyclic OB (e.g., OB35 - 100ms).
Inputs: In (Boolean run signal, e.g., motor contactor closed).
Outputs: Hours (Accumulated hours, REAL), Minutes (Minutes portion), Days (Days portion), and TotalHours (DINT).
Auxiliary Values on APL Faceplates (UserAna1 / AV):
Technological blocks feature configurable auxiliary input pins (UserAna1, UserAna2) specifically designed to display secondary process measurements on the main faceplate.
In the faceplate XML/C-script engine, values connected to UserAna1 appear with custom engineering units (h or hrs) and configurable text labels (e.g., 'Operating Hours').
Aggregate Management (Aggr16 - FB1803):
For multi-pump duty/standby groups (up to 16 drives), Aggr16 tracks individual operating hours (RunTi01..16) and automatically selects the drive with the lowest runtime for next start.

Step-by-Step Implementation Procedure

Step-by-Step Procedure to Integrate Motor Runtime Display:

Instantiate RunTime Block in CFC:
- Open the CFC chart containing the motor block (MotL).
- From the APL library (PCS 7 AP Library -> Blocks -> Math / Count), insert RunTime (FB1860).
- Name the block instance (e.g., Pump101_RunTime).
Interconnect Running Feedback:
- Connect output MotL.FbkRunOut to input RunTime.In.
- Set RunTime.SampleTime := 0.1 (matching OB35 100ms cycle).
Link Operating Hours to Motor Auxiliary Input:
- Connect RunTime.Hours to MotL.UserAna1 (or AV).
- Open the Object Properties of MotL.UserAna1:
- Set the engineering unit to h (hours).
- Set the parameter text / identifier to Operating Hours.
Configure Maintenance View Integration (Optional):
- Connect RunTime.Hours to the Maintenance Station input pins if using PCS 7 Asset Management.
- Configure maintenance threshold limits (e.g., warning at 5,000 hours, alarm at 8,000 hours).
Compile OS and Verify Faceplate:
- Compile CFC changes and download to the AS.
- Compile the OS project (Scope: Changes only).
- Open the motor faceplate in WinCC Runtime; confirm operating hours appear in the Standard/Preview view.

Verification

To verify runtime accumulation and display:
1. Start the motor from the WinCC faceplate.
2. In CFC test mode, verify that RunTime.In = 1 and RunTime.Hours begins incrementing.
3. Open the MotL faceplate in WinCC Runtime; verify that the auxiliary value field displays the label 'Operating Hours' with live hours and unit 'h'.
4. Stop the motor; confirm that runtime accumulation freezes accurately.

Limitations and Operational Precautions

Operational precautions:
- Ensure that RunTime.SampleTime matches the actual cycle time of the calling OB; a mismatch causes calculation acceleration or drift.
- Operating hour accumulators should be retentive; verify that instance DB memory is buffered to prevent loss of hours on CPU warm restart.
- Provide an authorized reset mechanism (e.g., RunTime.RstOp := 1) with operator Level 6 security to reset hours following mechanical overhaul.

Engineer FAQ

Does the MotL block calculate multi-year operating hours internally?

No. MotL tracks short-term runtime and monitoring times; multi-year operating hours require the dedicated APL RunTime (FB1860) block.

Where do operating hours appear on the motor faceplate?

In the Standard or Preview view under the Auxiliary Values section (configured via UserAna1 or AV).

Can I reset the accumulated operating hours after motor maintenance?

Yes, by triggering the reset input (RstOp or Reset) on the RunTime block from the faceplate or CFC.

What block balances operating hours across multiple duty/standby pumps?

The APL Aggr16 (FB1803) aggregate management block.

Does adding a RunTime block consume an additional Process Object?

If OCM (S7_m_c) is enabled on RunTime for direct faceplate display, it consumes an AS/OS PO; if connected purely as an unmonitored auxiliary math block to MotL, it does not.