Troubleshooting Invalid and Grayed-Out Process Object Block Icons in SIMATIC PCS 7 WinCC OS

In SIMATIC PCS 7 WinCC OS Runtime, a Process Object (PO) block icon displaying in a grayed-out, hatched, or invalid status (often accompanied by an exclamation mark or broken connection badge) despite the CPU running and compilation succeeding indicates an unresolved AS-OS communication connection, mismatched WinCC structure tag prefixes, or a Quality Code failure (16#00 Bad). This occurs when the OS compilation was executed with an incorrect S7 connection unit, the technological block in CFC lacks active communication driver generation, or the WinCC Process Object runtime license limit is exceeded. To resolve this, verify Named Connections status in WinCC, check tag Quality Codes, and recompile the OS.

Process Object Block Icon Architecture and Quality Code Display

In SIMATIC PCS 7 OS (WinCC), block icons dynamically visualize technological equipment (motors, valves, analog monitors):
* Structure Tag Binding: Each block icon binds to a WinCC Structure Tag (e.g. TIC101) created during OS compilation.
* APL Quality Code Visualization: APL block icons evaluate the NAMUR Quality Code (ST) embedded in process variables.
* Invalid State Representation: If WinCC cannot communicate with the AS controller, or if the controller reports ST = 16#00 (Bad), the block icon suppresses normal operational coloring and renders as gray, hatched, or displays a yellow/red warning badge, preventing erroneous operator actions.

Root Causes of Invalid and Grayed-Out Block Icons

When a block icon displays invalid status in WinCC Runtime:
1. Wrong Connection Selected During OS Compile: In SIMATIC Manager, when compiling the OS, if the engineer selected the wrong communication unit (e.g. MPI or Industrial Ethernet instead of Named Connections), WinCC tags cannot resolve their online addresses.
2. Channel Quality Code Bad (16#00): If the physical analog sensor wire is broken or passivated, the driver block sets ST := 16#00. The block icon correctly signals to the operator that the measurement is invalid.
3. Mismatched Tag Prefix: If the block icon was copied manually and its tag property does not match the compiled structure tag name in WinCC Tag Management.
4. WinCC Runtime Process Object License Overrun: If the total number of compiled Process Objects exceeds the installed OS RT PO license, WinCC enters demo mode and suppresses dynamic updates for surplus blocks.

Diagnostic and Remediation Procedure for Block Icon Communication

Follow this procedure to restore live dynamic communication to the block icon:

[Phase 1: Inspect AS-OS Communication Connection Status]
   │  • In WinCC Explorer, navigate to: Tag Management -> SIMATIC S7 Protocol Suite
   │  • Select: "Named Connections" -> Right-click -> "Status"
   │  • Verify that the connection to the AS controller shows "Connected" (Green checkmark)
   │  • If disconnected, verify SIMATIC Shell settings and NetPro S7 connection
   │
[Phase 2: Inspect Variable Quality Code in WinCC Tag Logging / Runtime]
   │  • In WinCC Runtime, open the faceplate for the faulted block icon
   │  • Check the Status parameter:
   │      - If Quality Code displays "Bad" (16#00):
   │          Check field wiring, channel passivation, and CFC channel driver health
   │
[Phase 3: Verify and Recompile OS Connection]
   │  • In SIMATIC Manager: Select the OS object -> Right-click -> "Compile"
   │  • On the "Select network connection" page:
   │      - Ensure connection is mapped to "Named Connections"
   │  • Select scope: "Tags and messages" -> Execute compilation
   │  • Download to target OS -> Block icons immediately transition to active color!

Block Icon Status Indications and Quality Code Matrix

Evaluate block icon visual indicators against their diagnostic root causes:

Block Icon Visual AppearanceWinCC Quality CodeUnderlying Root CauseCorrective ActionGrayed Out / Hatched Lines16#00 (Bad)S7 connection down or channel passivatedCheck Named Connection status; verify field wiring.Yellow Exclamation Mark16#60 (Simulated)Signal forced in CFC or manual simulationReturn channel driver to process mode.Blue Padlock Badge16#80 (Good)Message Lock (MsgLock = 1) activeNormal operation; alarms suppressed by operator.Red Wrench IconOut of ServiceBlock in Out of Service (OosOp = 1) modeReturn block to Manual or Auto mode.Steady Green / Blue Fill16#80 (Good)Normal operational stateProcess running within normal limits.

Verification

To confirm that the block icon displays healthy operational status:
1. In WinCC Runtime, navigate to the process graphic containing the block icon.
2. Confirm that the icon displays solid, non-hatched operational colors (e.g. solid green for running, solid gray for stopped).
3. Confirm that no exclamation mark or invalid communication badges overlay the icon.
4. Click the block icon; confirm that the technological faceplate opens immediately with live dynamic values.
5. In WinCC Explorer, verify that the SIMATIC S7 Protocol Suite -> Named Connections connection status indicates zero communication errors.

Limitations and Operational Precautions

Never force Quality Codes to 16#80 (Good) in application logic to clear a grayed-out icon if the physical field sensor is truly passivated or broken. Doing so blinds operators to dangerous sensor failures and can lead to process overfilling or runaway reactions. Always resolve the physical fieldbus or transducer wiring defect.

Engineer FAQ

Why is only one specific block icon grayed out while others work?

If other icons on the same AS connection display properly, the issue is not network communication. The specific block has a broken field sensor (Quality Code 16#00), is un-interconnected in CFC, or has a mismatched tag name.

What does a hatched block icon mean in PCS 7?

Hatching indicates an invalid signal or communication failure between WinCC and the AS controller for that specific structure tag.

How do I check the Quality Code of a tag in WinCC?

Add the tag to a WinCC OnlineTrendControl or open the internal variable in the WinCC Dynamic Dialog evaluation window to read its status byte.

Does an OS compile in 'Changes Only' fix broken connections?

If the communication path in NetPro changed, an 'Entire compile' of the OS is required to update internal connection endpoints.

Technical References

Related Tags

Block Icon Status
Quality Code
Named Connections
Grayed Out Icon
Process Objects

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Troubleshooting Invalid and Grayed-Out Process Object Block Icons in SIMATIC PCS 7 WinCC OS