Resolving 'Insufficient Permission' When Resetting CEMAT C_RUNNT (FB1016) Operating Hours

In SIMATIC PCS 7 and CEMAT environments, receiving an 'Insufficient permission' error dialog when attempting to reset the operating hours counter on the WinCC faceplate for C_RUNNT (FB1016) occurs when the logged-in operator account lacks required WinCC User Administrator privileges or when the controller block parameter VAL_REL is not asserted in CFC. In CEMAT, resetting accumulated runtime is classified as an extended maintenance operation requiring Authorization Level 6 (Process Controlling) or Level 10 (Maintenance). Additionally, the controller block algorithm rejects reset commands if the technological release input is zero. To resolve this, grant Authorization Level 6 or 10 to the user in WinCC User Administrator and configure VAL_REL to true in CFC.

CEMAT Operating Hours Counter C_RUNNT (FB1016) Architecture

The CEMAT block C_RUNNT (FB1016) is a standardized function block utilized across cement and minerals processing plants to accumulate running hours, operational cycles, and maintenance service intervals for mechanical equipment such as kiln drives, ball mills, conveyors, and fans. The block integrates runtime hours by monitoring an active running signal (e.g., motor contactor feedback or drive running signal connected to input RUN_SIG).

On the operator station (WinCC OS), C_RUNNT presents a specialized faceplate (@PG_C_RUNNT.pdl). The faceplate displays three distinct time accumulations: total operating hours since commissioning, maintenance interval operating hours, and operating cycle counts. To prevent unauthorized operators from inadvertently clearing maintenance records, the faceplate's reset button executes a security check via the WinCC C-script cemat_user_auth.c before dispatching the reset command word to the S7 controller instance data block.

Root Causes of 'Insufficient Permission' Faceplate Errors

When an engineer or plant operator clicks the Reset button on the C_RUNNT faceplate and the system responds with the error 'Insufficient permission', technical evaluation indicates two complementary layers of authorization failure:

WinCC User Administrator Privilege Level Mismatch: In standard PCS 7 and CEMAT systems, simple setpoint adjustments require Level 5 (Process Monitoring / Basic Operation). However, resetting operating hours or clearing cumulative runtime counters is classified under Authorization Level 6 (Process Controlling / Higher Process Operation) or Authorization Level 10 (Advanced Maintenance). If the logged-in user account only holds Level 5 rights, the WinCC security function PWRTCheckPermission() immediately rejects the button click and pops up the permission alert without contacting the controller.
CFC Block Software Interlocking (VAL_REL / Value Release): Even if the operator possesses the appropriate WinCC authorization, the reset command dispatched to the AS controller will be blocked if the block input VAL_REL (Value Release) is set to 0 (FALSE) in CFC. CEMAT implements VAL_REL as a hardware/software interlock preventing runtime tampering unless maintenance mode is active or a supervisory keyswitch is engaged.
Missing Area Authorization in Picture Tree Manager: If the plant hierarchy is segregated into technological areas (e.g., Raw Mill, Kiln, Clinker Grinding), the logged-in user must possess authorization specifically for the plant section hosting that instance of C_RUNNT.

WinCC Authorization Levels and CFC Interlock Parameter Matrix

The following table summarizes the authorization levels and block parameters required to reset the C_RUNNT block:

Control ElementParameter / PrivilegeFunction / RoleRequired Value for ResetWinCC User AdminAuthorization Level 6Higher Process OperationMust be enabled for user groupWinCC User AdminAuthorization Level 10Extended Maintenance AccessRequired if configured for maintenance roleArea AuthorizationArea Rights in Picture TreePermits control in specific plant areaMust cover the C_RUNNT chart areaCFC Block InputVAL_REL (BOOL)Value Release InterlockMust be 1 (TRUE) to permit OS resetsCFC Block InputRUN_SIG (BOOL)Running signal inputWhen equipment is running, reset may be blockedFaceplate C-ScriptPWRTCheckPermission()Evaluates user token against WinCC ACLReturns TRUE (1)

Step-by-Step Procedure to Grant Reset Privileges

To resolve the permission error and permit authorized personnel to reset operating hours:

Configure User Rights in WinCC User Administrator:
- On the WinCC Engineering Station or central OS Server, open WinCC Explorer.
- Double-click User Administrator.
- Select the user account or user group experiencing the problem (e.g., Maintenance or Supervisors).
- Ensure that checkbox 6: Process Controlling (and/or 10: Maintenance) is checked.
- Under Authorizations per Area, verify that the user group is granted access to the plant section where the equipment resides.
- Save the User Administrator configuration and deploy changes to redundant OS servers.
Assert VAL_REL in CFC:
- In SIMATIC Manager, locate the CFC chart containing the C_RUNNT block (FB1016).
- Inspect block input VAL_REL.
- If VAL_REL is static 0 and not interconnected, set its parameter value to 1 (TRUE).
- If VAL_REL is interconnected to an interlock or maintenance key switch tag, ensure the condition is satisfied prior to issuing the reset.
- Compile and download CFC changes to the S7 controller.
Test Faceplate Reset Action in Runtime:
- Log into WinCC Runtime using the updated credentials.
- Open the faceplate for the C_RUNNT instance.
- Click the Reset button. Confirm that the prompt asks for confirmation without displaying 'Insufficient permission', and that the runtime accumulator resets to zero.

Verification

Verify correct permission configuration:
1. Log into WinCC Runtime with an operator holding Level 5 (Monitoring); confirm that clicking Reset produces 'Insufficient permission', proving security enforcement.
2. Log in with a maintenance technician holding Level 6 and 10; click Reset, confirm the action, and verify that operating hours reset to 0.0.
3. Check the WinCC Alarm Logging archive; confirm that an operator input message (Operating message) is logged recording the user ID, timestamp, and reset event.
4. Monitor the CFC chart online; confirm that output RUNNT resets and resumes counting when RUN_SIG goes high.

Limitations and Operational Precautions

Audit Trail Compliance: Resetting runtime counters permanently removes historical accumulation from the AS memory. Ensure totalizer values are archived or recorded prior to resetting.
Equipment Running State: Certain CEMAT versions block resetting operating hours while RUN_SIG is active; ensure the machine is stopped before initiating maintenance resets.
Redundant Server Synchronization: Always update User Administrator on the master OS server and synchronize to the standby server to avoid mismatched permissions across clients.

Engineer FAQ

Which WinCC authorization level is required to reset C_RUNNT?

By default, CEMAT requires Authorization Level 6 (Process Controlling) or Level 10 (Maintenance) to reset operating hours counters.

What is the purpose of the VAL_REL input on C_RUNNT?

VAL_REL is an interlock enable input. If VAL_REL is FALSE (0), the block algorithm suppresses reset commands dispatched from the OS faceplate.

Why can an operator reset one motor's hours but not another?

The operator likely lacks area authorization for the plant section where the second motor is assigned in the Plant Hierarchy.

Does resetting C_RUNNT affect the total lifetime operating hours?

C_RUNNT typically separates service maintenance hours from lifetime hours. Depending on parametrization, the reset button targets the maintenance interval counter.