Resolving Custom Faceplate Open Failures on WinCC OS Clients in SIMATIC PCS 7 - ES Master GraCS Distribution

Custom faceplates failing to open on WinCC OS Clients (while working on the OS Server) and disappearing after every OS download occurs because the custom Picture Description Language (@PG_...pdl) files were manually copied directly into runtime server directories rather than the Master OS project on the Engineering Station (ES). In SIMATIC PCS 7, OS Downloads overwrite client and server project directories with the ES master image. To resolve this permanently, place all custom block icons and faceplate files into the ES Master OS project's GraCS directory, run the OS Project Editor, and perform a formal OS Download from SIMATIC Manager.

Client-Server Graphics Architecture in SIMATIC PCS 7

In SIMATIC PCS 7 multi-client architectures, Operator Stations are divided into OS Servers (which manage communications, archives, and tag databases) and OS Clients (which host operator workstations).

When an operator clicks a block icon on an OS Client:
* The click event executes a standard C-script function (APL_OpenFacePlate or SSMOpenTopField).
* The script determines the block type and requests the corresponding faceplate PDL files (e.g. @PG_CustomValve_Overview.pdl, @PG_CustomValve_Standard.pdl).
* In modern PCS 7 configurations, OS Clients read graphic screens either from their own local GraCS directory or cross-load them across the terminal bus via Server Data package assignments.

Why Manual File Copying Fails During OS Downloads

Engineers developing custom faceplates frequently test them by copying .pdl files directly into C:\...\<OS_Project>\GraCS on the live OS Server or OS Client machine.
1. The Temporary Success Trap: The faceplate opens successfully because the local folder contains the required file.
2. Download Overwrite: In SIMATIC PCS 7, the Engineering Station (ES) is the sole authoritative master. When an engineer executes PLC -> Download to update changes to an OS Server or OS Client, the download wizard synchronizes files from the ES.
3. File Deletion / Exclusion: Any file present on the runtime station that does not exist in the ES master project is either deleted or ignored, causing the faceplate to vanish on subsequent downloads.

Correct Repository Location on the Engineering Station

To ensure permanent, automated distribution across all OS Servers and OS Clients:

[SIMATIC Manager on Engineering Station (ES)]
   │
   ├─► Open Multiproject -> Master Data Library -> GraCS folder (Optional)
   │
   ├─► Open Primary OS Server Project:
   │     • Path: <Project_Path>\<OS_Server_Name>\wincproj\<OS_Name>\GraCS\
   │     • Paste custom block icons: @PCS7TypicalsProject.pdl
   │     • Paste custom faceplates:
   │         - @PG_CustomBlock_Overview.pdl
   │         - @PG_CustomBlock_Standard.pdl
   │         - @PG_CustomBlock_Parameter.pdl
   │
   ▼
[Server Data Generation & Client Synchronization]
   │
   ├─► In OS Server: Right-click Server Data -> Generate
   ├─► Open OS Client Project in SIMATIC Manager:
   │     • If client uses local GraCS: Copy custom @PG files to Client GraCS on ES
   │     • In WinCC Explorer on Client: Assign Standard Server for Graphics
   ▼
[Target Download via SIMATIC Manager]
   │  • Execute: Right-click OS Server -> PLC -> Download
   │  • Execute: Right-click OS Client -> PLC -> Download
   └─► Master files are pushed automatically to all runtime targets

OS Project Editor Configuration and Clean Client Distribution

The table below outlines how custom graphic elements must be managed to survive system updates:

Graphic File ElementMaster ES Storage LocationOS Project Editor ActionDownload Distribution MechanismCustom Block Icons@PCS7TypicalsProject.pdl in ES GraCSPreserved (Only updates standard @PCS7Typicals...)Compiled via Plant Hierarchy -> Create block icons.Custom Faceplate Views@PG_Custom...pdl in ES GraCSPreserved (Does not overwrite non-standard names)Pushed during OS Download to Server/Client.Custom Global ScriptsLibrary / PAScript on ESHeader regenerated automaticallyDistributed during OS Download.Standard Siemens PDLs@screen.pdl, @overview.pdlRestored to system default by Project EditorReplaced if modified directly; use custom views instead.

Verification

To confirm that custom faceplates persist across downloads:
1. On the Engineering Station, execute an Entire OS Download to the OS Server and the target OS Client.
2. Navigate to the OS Client runtime folder on the target machine; confirm that @PG_CustomBlock_Standard.pdl is present in the GraCS folder.
3. Activate WinCC Runtime on the OS Client.
4. Click the custom block icon; verify that the faceplate top field and standard view open instantly without error dialogs.
5. Launch apdiag.exe on the OS Client, open the Output Window, and click the faceplate again; verify that no "File not found" or PDLRT script errors are generated.

Limitations and Operational Precautions

Never modify default Siemens faceplates (such as @PG_VlvL_Standard.pdl) in place without renaming them. Running the OS Project Editor during Service Pack installations will overwrite standard Siemens PDLs with original factory versions, wiping out custom engineering modifications. Always name custom faceplates with a unique prefix (e.g. @PG_PlantValve_Standard.pdl).

Engineer FAQ

How do I diagnose why a faceplate fails to open on an OS Client?

Run apdiag.exe (located in Siemens\WinCC\uTools or bin) on the OS Client, open the Output Window, and click the block icon. The diagnostic window logs the exact missing PDL filename or script syntax error.

Can OS Clients display faceplates stored only on the OS Server?

In PCS 7, if picture caching is disabled or if the client project references server data packages properly, standard screens can be retrieved from the server. However, local client caching is recommended for fast faceplate opening.

Why does 'Create/update block icons' not update the OS Client?

Block icons are generated into process screens (.pdl) within the OS Server project. The OS Client accesses these screens via server packages or client downloads.

Do custom faceplates require regenerating C-script headers?

If custom faceplates introduce new project functions (.fct), open the Global Script C Editor on the ES and select Options -> Regenerate Header before performing an OS Download.