Resolving MPC10-10 Block Deletion Errors and Matrix Inconsistencies in SIMATIC PCS 7

When SIMATIC PCS 7 generates the compilation error 'These blocks have been deleted already' for the Advanced Process Control multi-variable predictive controller block 'MPC10_10' (FB1130), the failure is caused by orphaned instance data blocks, corrupted model matrix files (*.mat), or timestamp mismatches between the CFC chart and master data library. To resolve this, clean up block types in CFC via 'Options' -> 'Block Types', purge orphaned instance DBs, re-import the certified MPC model configuration from the APC-Configurator, and perform an AS compilation with 'Generate entire program'.

Executive Summary

In SIMATIC PCS 7 Advanced Process Control (APC), the MPC10_10 block coordinates complex multi-variable processes involving up to 10 manipulated variables (MV) and 10 controlled variables (CV) with cross-coupling interactions. During project reorganizations, library updates, or multiproject merges, engineers frequently encounter compiler rejections stating that block instances have been deleted or that internal matrix structures cannot be addressed. This issue arises when the internal block interface GUID or associated DB allocation in the S7 program becomes desynchronized from the mathematical model files. This article details the internal mechanics of MPC blocks, provides a step-by-step restoration workflow, and covers operational safeguards.

Architectural and System Mechanics

Architecture of the SIMATIC PCS 7 Multi-Variable Predictive Controller:

Multi-Variable Matrix Processing: MPC10_10 (FB1130) executes a linear state-space prediction model. The block relies on large matrix configuration data blocks generated by the PCS 7 MPC Configurator.
Internal DB Structure: The controller maintains internal pointer vectors referencing controller gain matrices, disturbance variables (DV), and prediction horizons. If any sub-block or instance DB is deleted manually from the STEP 7 block folder, the CFC cross-reference table retains dangling memory offsets.
CFC Block Type Management: When CFC encounters a block instance whose interface timestamp differs from the block pool, it attempts to reorganize instance memory. If the master FB definition is missing or marked deleted in the current CPU catalog, compilation terminates with the error 'These blocks have been deleted already'.
License Dependencies: The MPC controller requires an engineering license in Automation License Manager (ALM) for the MPC Configurator tool.

Step-by-Step Engineering and Implementation Procedure

Step 1: Clean Up Block Types in the CFC Chart Folder

Open any CFC chart on the affected AS station in SIMATIC Manager.
Navigate to 'Options' -> 'Block Types...'.
In the 'Block types in the chart folder' pane, select FB1130 (MPC10_10).
Click 'Clean Up' to remove orphaned, unreferenced block instances and dangling DB references.

Step 2: Synchronize Block Types from the Master Data Library

Open the project Master Data Library in SIMATIC Manager.
Verify that the correct APC library version of MPC10_10 resides in the library block folder.
In the CFC editor, open 'Options' -> 'Block Types...', select FB1130 in the Master Data Library, and click 'Update...'.
Acknowledge the prompt to update all chart instances across the AS project.

Step 3: Re-Import and Compile the Model Matrix in the MPC Configurator

Double-click the MPC10_10 instance block in CFC to launch the MPC Configurator interface.
Open the verified process identification project file (*.mpc / *.mat).
Verify that all 10 MVs and 10 CVs have consistent sample times matching the cyclic execution OB (e.g., OB32 / 1 second).
Execute 'Compile and Download Model' from the configurator to rewrite the instance DB matrix tables cleanly.

Step 4: Recompile the Automation Station Program

In SIMATIC Manager, right-click the Chart folder -> 'Compile' -> 'Charts as Program'.
Select 'Entire program' and check 'Generate SCL source'.
Verify that the compile process completes with 0 errors.

Verification

To verify proper MPC10_10 block operation:
1. In CFC test mode, confirm that MPC10_10.ErrorNum = 0 and the block reports operational status.
2. Verify that manipulated variables (MV) track within designated low/high limits.
3. Open the MPC faceplate in WinCC Runtime; confirm that prediction horizons, setpoint trajectories, and matrix weights render correctly.
4. Confirm that the CPU diagnostic buffer contains zero memory access faults (OB121/OB122).

Limitations and Operational Precautions

Operational precautions:
- Multi-variable controllers place heavy mathematical loads on controller work memory and scan cycles. Always place MPC10_10 in a dedicated cyclic interrupt OB (e.g., OB32 or OB33) with a cycle time >= 1 second.
- Recompiling an entire program with 'Generate entire program' requires an AS STOP download unless managed strictly through delta compilations.
- Never delete instance DBs directly from the STEP 7 SIMATIC Manager block folder; always use CFC Block Type cleanup.

Engineer FAQ

Q: What causes the error 'These blocks have been deleted already'?

A: It occurs when a block type was removed or modified in the block folder while CFC charts still retain instance references or orphaned DB pointers.

Q: What is the function block number for MPC10_10?

A: In the standard PCS 7 APC library, MPC10_10 is implemented as FB1130.

Q: Can MPC10_10 run in OB35 (100ms)?

A: While technically possible, running high-order predictive matrix calculations at 100ms can overload the CPU communication and execution cycle. 1s or higher is recommended.

Q: Where are MPC model matrices stored in the project?

A: Matrices are compiled into dedicated data blocks and auxiliary files stored within the project directory structure.

Q: Does MPC require an additional runtime license?

A: Advanced Process Control algorithms may require specific APC / MPC engineering and runtime licenses depending on the PCS 7 version.

Technical References

Related Tags

MPC10_10, APC Library, CFC Block Types, Instance DB, Multi-Variable Control

`Multi-Variable Control`

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Resolving MPC10-10 Block Deletion Errors and Matrix Inconsistencies in SIMATIC PCS 7