Resolving Inaccessible Interlocks and Groups in CEMAT V8.2 OS Faceplates

When operator faceplates in SIMATIC PCS 7 CEMAT V8.2 fail to open interlock and group diagnostic windows on OS Servers and OS Clients—while functioning perfectly on the Engineering Station (ES)—the root cause is missing CEMAT C-script project functions in the runtime project library. The CEMAT faceplate architecture relies on specialized global C-scripts located in the WinCC project Library folder (\library) that are not always automatically replicated during standard OS project downloads. Copying the entire Library folder from the Engineering Station OS project to the corresponding directories on each physical OS Server and Client, followed by regenerating script headers, restores complete interlock and group navigation.

CEMAT Faceplate Scripting Architecture

In the Siemens CEMAT Minerals & Cement DCS environment, drive and group faceplates (C_DRIVE_1D, C_GROUP, C_DAMPER) provide multi-tabbed operational interfaces. The Interlocks and Group Diagnosis tabs dynamically evaluate upstream safety interlocks (GEVT, ELON), active bypasses, and linked route states.

Unlike standard Advanced Process Library (APL) faceplates that rely on centralized DLLs, CEMAT faceplates execute custom WinCC C-project functions (e.g., C_OpenInterlock.fct, cemat_multiproject.fct). These functions reside inside the WinCC project directory structure under the local library folder.

Root Cause of Missing Interlocks on Distributed Clients

When the project functions are missing or desynchronized on client workstations:

WorkstationScript AvailabilityFaceplate Diagnostic BehaviorEngineering Station (ES)Local \library\ populated during CEMAT setup.Normal Operation: Interlock and group buttons open diagnostic popups instantly.OS Server (Server 1 / 2)Scripts may be omitted if OS project was created afresh.Faceplate background C-scripts fail silently; interlock evaluation returns 0.OS Client (Distributed)Scripts omitted; OS download wizard synchronizes PDLs but skips custom C-scripts.Fault Condition: Clicking 'Interlocks' or 'Groups' produces no response; buttons disabled.

Step-by-Step Script Replication and Header Regeneration

To resolve the missing faceplate navigation on all runtime stations:

Step 1: Copy CEMAT Library Scripts from ES

On the Engineering Station, navigate to the WinCC OS master project directory:
C:\<Project_Path>\<OS_Name>\library\
Copy all files and subfolders within the library directory (including *.fct files).

Step 2: Paste Scripts onto OS Servers and Clients

On each physical OS Server (Server 1 and Server 2), paste the copied files into:
C:\<Target_Project_Path>\<OS_Server_Name>\library\
On each physical OS Client, paste the copied files into:
C:\<Client_Project_Path>\<OS_Client_Name>\library\

Step 3: Regenerate Global Script Headers

On each target OS Server and Client workstation:

Open the local project in WinCC Explorer.
In the left project tree, right-click Global Script -> select Regenerate Header.
Wait for the confirmation dialog: 'Header files regenerated successfully'.
Check Server Data: ensure Standard Server assignments for Split Screen Manager (SSM) are correctly configured under Server Data -> Standard Server.

Verification

To verify that CEMAT faceplate diagnostics are fully restored:

Activate WinCC Runtime on the OS Client.
Open a plant process graphic containing a CEMAT drive block icon (e.g., C_DRIVE_1D).
Click the block icon to display the standard faceplate.
Click the Interlocks button: verify that the interlock matrix window opens immediately, displaying active permissives and bypassed inputs.
Click the Group button: confirm that the associated group faceplate opens without script execution errors in WinCC_Sys.log.

Limitations and Operational Precautions

Operational boundaries for CEMAT faceplates:

Repeat After OS Project Recreation: If an engineer executes 'Recreate OS Project' or re-runs the OS Project Editor with full reset, custom files in the \library\ folder may be cleared; maintain an external backup of the CEMAT script folder.
Standard Server Configuration: Ensure that OS Clients have a designated Standard Server configured for SSM and Alarm Logging in Server Data; missing standard server assignments can prevent popup window creation.
Version Alignment: Never mix CEMAT V8.0 and V8.2 script files; mismatched C-function signatures will crash script.exe during faceplate initialization.

Engineer FAQ

Why did interlocks open on the Engineering Station but not on OS Clients?

The Engineering Station had the CEMAT library installation which placed custom C-scripts in its local library directory. OS project downloads synchronize picture files (*.pdl) but do not automatically copy custom *.fct script files.

What WinCC function compiles the copied C-scripts into runtime headers?

Right-clicking Global Script in WinCC Explorer and selecting Regenerate Header compiles all *.fct files in the library folder into the internal C-runtime header files (apdef.h).

Can server data configuration cause faceplate navigation failures?

Yes. If the OS Client has 'No Standard Server' configured for Split Screen Manager (SSM), the WinCC picture tree manager cannot determine which server to query for interlock faceplate popups.

Do I need to restart WinCC Runtime after copying the scripts?

Yes, regenerating script headers and restarting WinCC Runtime ensures that the newly compiled C-functions are loaded into the runtime memory of PdlRuntimeHost.exe.