Resolving Missing Block Icons and Invisible Faceplates After Restoring SIMATIC PCS 7 Backups on New Stations

When restored SIMATIC PCS 7 project backups exhibit completely invisible block icons and faceplates in WinCC Graphic Designer or Runtime, the root cause is missing add-on software libraries or un-registered ActiveX/OCX controls on the newly installed PC station. Standard PCS 7 installations do not include optional packages such as CEMAT, Industry Library, Power Control, or Safety Matrix. If the original project utilized custom or add-on library controls, those exact software packages must be installed on the new station, registered via regsvr32, and synchronized via the OS Project Editor.

ActiveX/OCX Dependency Architecture in SIMATIC PCS 7 Graphics

In SIMATIC PCS 7 WinCC, process visualization relies on modular component architectures:
* The Visual Container:
Process pictures (.pdl) contain references to ActiveX controls (.ocx), Extended Status Displays, and dynamic faceplate templates.
* The Registration Requirement:
For an OCX control to render in WinCC Graphic Designer or Runtime, its binary file must be present in the Windows file system (typically C:\Program Files (x86)\Common Files\Siemens\...) and registered in the Windows COM Registry (HKEY_CLASSES_ROOT\CLSID\...).
* The Invisible Rendering Symptom:
When a PDL is opened on a machine lacking the required OCX control, WinCC cannot instantiate the COM object. Instead of throwing a blocking error, Graphic Designer skips rendering the object or displays an empty bounding box, rendering block icons completely invisible.

Why Restoring a Backup on a Fresh OS Station Causes Invisible Icons

When a customer experiences an Engineering Station crash and restores an archive onto newly installed hardware:
* The Base Install Misconception:
Engineers assume installing "SIMATIC PCS 7" installs the complete ecosystem. However, PCS 7 media installs only base components (STEP 7, CFC, SFC, WinCC, APL).
* Omitted Add-On Software:
Many industrial plants utilize specialized industry libraries:
* CEMAT (6DL5436-8AX00-0XA0): Specialized minerals/cement library using proprietary OCX faceplate controls.
* PCS 7 Industry Library (IL) (6ES7658-1EX08-1YB5): Provides Comfort Panel blocks and advanced building/process controls.
* SIMATIC Safety Matrix / S7 F-Systems OS: Required for safety faceplates.
* Third-Party / Legacy Packages: PTE400, SC Library, or custom user OCX objects.
* If these add-ons are missing, compiling the OS does nothing because the compiler cannot manufacture missing Windows OCX components.

Diagnostic Matrix: Missing Library Signatures and Symptoms

The table below outlines common missing software packages and their diagnostic signatures:

Missing Add-On SoftwareAffected Objects / FaceplatesWinCC Graphic Designer SymptomWindows Registry / OCX TargetCEMAT LibraryMotor, damper, route block iconsCompletely missing or red cross boxCemat*.ocx in Common FilesPCS 7 Industry LibraryIL faceplates, Comfort Panel linksButtons and bargraphs disappearIL_*.ocx componentsS7 F-Systems / Safety MatrixF-channel, MOS, Matrix bypass iconsMissing safety badges and faceplates@pg_SWC_MOS.pdl, Safety OCXWinCC Basic Process ControlOverview area banners, alarm lineScreen headers missing or distortedOS Project Editor base templates

Identifying Installed Software and Missing Add-On Packages

To identify what is missing:
* Use Siemens 'Installed Software' Utility:
Navigate to Start -> Siemens Automation -> Installed Software (or open SIMATIC Manager -> Help -> About -> Installed Software).
Compare the list of installed packages on the new station against plant engineering documentation or the original crash dump manifest.
* Examine Graphic Designer Errors via APDIAG:
Launch apdiag.exe in the WinCC bin directory. Select Output Window. Open the problematic PDL in Graphic Designer. apdiag logs the exact CLSID and OCX filename that failed to load.

Step-by-Step Procedure to Restore Missing Libraries and OCX Controls

Identify Missing Software Packages:
Review the original project specification or inspect apdiag.exe logs to identify required add-ons (e.g., CEMAT v8.0 or Industry Library v8.0).
Install Add-On Software on the New Station:
* Insert the installation media for the identified add-on package.
* Run the setup wizard to install engineering tools, WinCC faceplates, and OCX binaries.
Manually Register OCX Controls (If Required):
If controls remain unregistered:
* Open an administrative Command Prompt.
* Navigate to the OCX directory (e.g., cd C:\Program Files (x86)\Siemens\WinCC\bin).
* Run: regsvr32 <MissingControl>.ocx.
Run the OS Project Editor:
* Open WinCC Explorer on the restored project.
* Open OS Project Editor.
* Confirm the screen resolution and layout match the plant standard. Click OK to re-import system scripts, typicals, and header PDLs.
Re-Generate Block Icons:
In SIMATIC Manager, right-click the OS Server object and select Plant Hierarchy -> Create/Update Block Icons.
Activate Runtime:
Launch WinCC Runtime and verify that all block icons and faceplates are fully rendered.

Verification

To verify that all icons and faceplates are restored:
1. Open the process graphics in WinCC Graphic Designer. Confirm that all valve, motor, and instrument block icons are clearly visible with correct graphic shapes.
2. Launch WinCC OS Runtime.
3. Click a block icon. Confirm that the corresponding faceplate opens immediately with active bargraphs, buttons, and status indicators.
4. Verify that apdiag.exe reports zero ActiveX creation errors.

Limitations and Operational Precautions

Version Parity Requirement: Ensure the installed add-on library version matches the exact library version used in the PLC project. Mixing library versions (e.g., CEMAT v8.1 on a v8.0 project) can cause faceplate tag discrepancies.
Client Station Parity: The add-on software must be installed on every participating station (Engineering Station, OS Servers, and OS Clients). Installing it only on the ES will leave client consoles blank.
Licensing Disclaimer: Add-on libraries such as CEMAT (6DL5436-8AX00-0XA0) and Industry Library (6ES7658-1EX08-1YB5) require separate engineering and runtime licenses validated against the applicable Siemens catalog and authorized distributor quotation.