C135 PCS 7 (PCS7)
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Resolving Safety Matrix Viewer Error Wrong Matrix Connected During Online Monitoring in PCS 7

Resolving Safety Matrix Viewer Error Wrong Matrix Connected During Online Monitoring in PCS 7

The error 'Wrong Matrix Connected' in the SIMATIC PCS 7 Safety Matrix Viewer during online monitoring indicates a CRC checksum mismatch between the safety program running in the AS, the WinCC OS tag database, and the local Safety Matrix file (.sfm). In PCS 7 V8.0 SP1, after modifying tags or logic in Safety Matrix, you must execute 'Transfer to F-System', compile the F-program to establish the new F-collective signature, compile the OS with 'Tags and messages' selected, and ensure the updated .sfm matrix file is copied to the OS Client project directory (\SafetyMatrix). If the client references a stale matrix file with an older CRC, online connection is blocked by safety design.

Table of Contents

Executive Summary

SIMATIC Safety Matrix provides Cause-and-Effect methodology for programming and visualizing Safety Instrumented Systems (SIS) up to SIL 3 according to IEC 61508 and IEC 61511. Operating within SIMATIC PCS 7, the Safety Matrix Viewer allows operators and maintenance engineers to monitor safety interlocks, bypasses, and emergency shutdowns online from WinCC screens. However, following routine engineering modifications—such as adding a new cause tag or updating trip limits—commissioning engineers frequently face a critical fault: when opening the matrix on an OS Client, the viewer displays error dialog Wrong Matrix Connected and refuses to establish an online monitoring session. This problem occurs because the Safety Matrix Viewer enforces strict triple-point cryptographic CRC checking across the AS controller, OS database, and local .sfm files. This technical guide explains the safety signature mechanism and provides the definitive recovery workflow.

Safety Matrix Architecture: AS F-Program, OS Database, and SFM Files

The Safety Matrix deployment spans three interrelated tiers:

  1. Safety Controller (AS F-System): The Safety Matrix compiler translates Cause-and-Effect logic into fail-safe CFC charts containing the F_SC_MA function block, which holds the active safety program and a unique collective CRC signature.
  2. Operator Station (WinCC OS): Holds communication tags and ALARM_8P message structures compiled from the matrix.
  3. Matrix File (*.sfm): An XML-based binary descriptor file located on the OS workstation that tells the Safety Matrix Viewer how to render rows, columns, and tag names.

The Safety Matrix CRC Signature Verification Mechanism

To ensure safety integrity and prevent operators from viewing stale or mismatched safety representations:

  • Upon establishing an online connection, the Safety Matrix Viewer queries the runtime CRC signature from block F_SC_MA in the AS.
  • It compares this value against the internal CRC embedded within the local .sfm file.
  • If the two checksums differ by even a single bit, the viewer raises Wrong Matrix Connected and terminates online access.

Why 'Wrong Matrix Connected' Errors Occur Post-Compilation

Three configuration oversights cause signature desynchronization:

  1. Failure to Transfer to F-System: The engineer edited the matrix and saved the .sfm file, but did not execute Transfer to F-System, leaving the AS running older logic.
  2. Missing F-Program Compilation: After transfer, the safety program was not compiled in the Safety Administration Editor, leaving the F-collective signature desynchronized from the OS compile.
  3. Stale OS Client Matrix File: In distributed client-server systems, the updated .sfm file was generated on the ES or OS Server, but was never transferred to the OS Client's local project directory.

Safety Matrix Diagnostic and Signature Synchronization Matrix

The following table compares the required status across all three safety matrix tiers:

Safety TierComponent LocationRequired Checksum / File StateFailure Symptom if MismatchedTier 1: AS ControllerF_SC_MA Block InstanceRunning compiled F-program with current CRCMatrix Viewer reports 'Wrong Matrix Connected'.Tier 2: OS ServerWinCC Tag Logging / TagsOS compiled with 'Tags and Messages'Alarms missing; tags show disconnected.Tier 3: OS Client<ProjectPath>\SafetyMatrix\*.sfm.sfm file CRC matches AS controller CRCImmediate 'Wrong Matrix Connected' abort.F-Safety ProgramSafety Administration EditorF-Collective signature clean (0 errors)CPU fails to compile safety delta download.

Step-by-Step Resolution and Signature Alignment Procedure

Method 1: Proper Transfer, Compilation, and Signature Alignment

  1. In SIMATIC Manager, open the target Safety Matrix in the Safety Matrix Editor.
  2. Navigate to Matrix > Transfer (or click Transfer to F-System).
  3. Enter the safety engineering password and confirm the transfer dialog.
  4. In SIMATIC Manager, select the AS program and open the Safety Administration Editor.
  5. Compile the safety program to calculate the updated F-collective signature.
  6. Compile the CFC charts and download changes to the AS controller.
  7. Select the OS project, right-click, and choose Compile (select Tags and messages).

Method 2: Synchronizing Matrix Files to OS Clients

  1. On the Engineering Station, navigate to the OS project folder: <ProjectPath>\SafetyMatrix\.
  2. Locate the updated .sfm file corresponding to the matrix name (e.g. Boiler_ESD.sfm).
  3. Copy Boiler_ESD.sfm across the network share to the identical folder path on the OS Server and all OS Clients.
  4. On the OS Client, launch the Safety Matrix Viewer in WinCC Runtime and click Go Online; verify successful connection.

Verification

To verify that the Safety Matrix Viewer connects and monitors online safely:

  1. Online Status Indication: In WinCC Runtime, open the Safety Matrix. Confirm that the status bar displays Online: Monitoring Active (Green).
  2. Live Cause-Effect Actuation: Force a non-critical test Cause input in S7-PLCSIM. Confirm that the corresponding intersection cell in the matrix illuminates yellow/red in real time on the viewer.
  3. CRC Signature Match: In the Safety Matrix properties window, inspect the displayed CRC checksum. Verify that it matches the F-signature shown in the Safety Administration Editor.

Limitations and Operational Precautions

  • Safety Bypassing Restrictions: Operating maintenance bypasses via the Safety Matrix Viewer requires explicit safety authorization and physical bypass keyswitch permissives conforming to plant safety procedures.
  • F-Runtime Delta Downloads: In safety-critical plants, downloading safety program modifications requires strict peer review and logging of the new F-collective CRC signature.
  • Safety Matrix License Requirement: The Safety Matrix Viewer requires a valid runtime license on every OS station where matrix monitoring is utilized.

Engineer FAQ

Why does Safety Matrix require both Transfer and CFC Compile?

Transfer converts the matrix graphical grid into CFC block calls (F_SC_MA); compiling CFC compiles those calls into executable machine code for the fail-safe CPU.

Can I edit a Safety Matrix file directly using a text editor?

No. Modifying .sfm files outside the official Siemens Safety Matrix Editor corrupts the internal cryptographic hash, permanently preventing online connection.

Where does the OS Client look for the .sfm file during runtime?

The client looks in its local project directory under <OS_Client_Project_Path>\SafetyMatrix\<MatrixName>.sfm.

Technical References

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