Restoring Missing Interlock Bypass Icons on CEMAT Motor Faceplates in PCS 7

When upgrading from the standard PCS 7 Advanced Process Library (APL) to CEMAT Minerals V8.2, the prominent interlock bypass indicator (bold letter 'B') on motor block icons disappears because CEMAT drive blocks (C_DRV_1D) handle interlock evaluation and visualization through dedicated CEMAT status words rather than APL bypass bits. To restore visible bypass indication, verify that the motor block icon variant selected in CFC corresponds to a CEMAT symbol configured with the bypass display layer, and ensure that upstream interlock blocks (C_INTERL, C_INT_L, or C_ANNUNC) have interlock bypassing authorized. Alternatively, map the CEMAT bypass status bit to the Extended Status Display in the WinCC Graphics Designer.

Visualization Architecture: APL vs CEMAT Minerals

In SIMATIC PCS 7, the Advanced Process Library (APL) and the industry-specific CEMAT Minerals library (used extensively in cement, mining, and aggregates) employ different human-machine interface (HMI) philosophies.

In APL, standard technological blocks (MotL, VlvL) display prominent operational state badges directly on block icons. When an interlock or safety signal is bypassed, APL renders a high-visibility badge (such as a bold letter 'B' or wrench symbol) in the top-right corner of the block icon to alert operators immediately.

In CEMAT Minerals V8.2, motor visualization is centered around the C_DRV_1D block. CEMAT separates operational alarms, interlocks, and maintenance flags into specialized multi-word status registers (STATUS1, STATUS2, STATUS3). If the block icon template deployed in WinCC does not link to the specific CEMAT maintenance/bypass bit, the bypass state remains invisible until an operator opens the detailed diagnostic window.

Why the APL 'B' Indicator Does Not Display in Standard CEMAT

The loss of the bypass badge during migration or new development stems from architectural differences:

Different Block Icon Templates: APL uses templates from @PCS7Typicals_APL.pdl (e.g., @MotL/1), whereas CEMAT uses specialized templates from @PCS7Typicals_CEMAT.pdl (e.g., @C_DRV_1D/1, @C_DRV_1D/2).
Different Signal Origins: In APL, parameter BypProt or Intlk08.Bypass feeds directly into the block icon's Extended Status Display. In CEMAT, interlocks originate from dedicated modules (C_ANNUNC, C_MEASUR, C_INTERL, C_INT_L), and bypass status is transmitted via the collective maintenance status word (MAINT / STATUS3).
Icon Variant Selection: Basic CEMAT block icons omit the maintenance overlay to reduce visual clutter in massive cement plants where hundreds of drives operate simultaneously.

Comparison of APL and CEMAT Bypass Visualization Mechanisms

The table below contrasts how interlock bypass status is handled and displayed across APL and CEMAT Minerals.

Visualization FeaturePCS 7 Advanced Process Library (APL)PCS 7 CEMAT Minerals V8.2Drive Block TypeMotL / MotRevLC_DRV_1D / C_DRV_2DInterlock Signal OriginDirect inputs (Intlock, Protect) or Intlk08Interlock modules (C_INTERL, C_INT_L, C_ANNUNC)Bypass ParameterBypProt (BOOL) / Intlk08.BypActBYPB_L (BOOL) or operator authorization on C_INTERLBlock Icon IndicatorBold letter 'B' or wrench icon on status badgeStatus layer icon / maintenance wrench indicatorTemplate File@PCS7Typicals_APL.pdl@PCS7Typicals_CEMAT.pdl / @Template_CEMAT.pdlStatus Word BitmaskAPL Status2 bit decoded via dynamic wizardSTATUS3 / MAINT bitmask decoded via CEMAT scripts

Step-by-Step Procedure to Restore Bypass Visualization

Follow this procedure to enable visible bypass indicators on CEMAT motor block icons:

Select the Appropriate CEMAT Block Icon Variant:
- In the CFC chart containing C_DRV_1D, open the block object properties.
- Under the Attributes tab, locate attribute type (e.g., @C_DRV_1D/1).
- Change the type attribute to an icon variant that supports maintenance/bypass visualization (such as @C_DRV_1D/2 or custom variant).
Configure Upstream CEMAT Interlock Blocks:
- Ensure that interlocks feeding C_DRV_1D use CEMAT interlock blocks (C_INTERL or C_INT_L).
- Verify that parameter BYPB_L is enabled or operator bypass authorization is permitted in the CEMAT system parameters.
Customize Extended Status Display in @PCS7Typicals_CEMAT.pdl:
- In WinCC Graphics Designer, open @PCS7Typicals_CEMAT.pdl.
- Locate the target @C_DRV_1D block icon and open its Extended Status Display properties.
- Add an icon state layer bound to the bypass bit of the motor's status tag (.STATUS3 or .MAINT).
- Assign the bitmap image depicting the bold 'B' or maintenance symbol.
Update Block Icons in Process Pictures:
- In SIMATIC Manager, select the plant hierarchy folder and run Options -> Plant Hierarchy -> Create/Update Block Icons.
- Confirm the update to apply the modified graphic template across all WinCC process screens.

Verification

Verify bypass display operation through the following steps:
1. In WinCC Runtime, open the faceplate for a test motor and activate an interlock bypass on its associated C_INTERL block.
2. Verify that the motor block icon on the process screen instantly displays the bypass indicator badge.
3. Remove the bypass condition: confirm that the badge clears immediately.
4. Verify that bypassing the interlock logs an audit entry in the WinCC Alarm Logging sequence archive.

Limitations and Operational Precautions

Modifications to @PCS7Typicals_CEMAT.pdl must be managed carefully. Never modify the factory template in the installation directory; always edit the copy residing in the local project's GraCS directory. During system upgrades or CEMAT hotfix installations, factory templates can overwrite custom modifications unless properly archived. Additionally, always follow plant management of change (MOC) procedures before modifying operator-facing safety indicators.

Engineer FAQ

Can I use standard APL block icons with CEMAT C_DRV_1D blocks?

No. APL block icons expect APL-specific structure tags (Status1, Status2, OS_Perm), whereas CEMAT uses proprietary status words. Using an APL icon with a CEMAT block results in non-functioning faceplates.