Troubleshooting SIMATIC PCS 7 SFC Visualization Failures on MultiClients: Missing Faceplates and Window Coordinates

When SIMATIC PCS 7 SFC Visualization suddenly stops functioning on OS MultiClients in PCS 7 V8.1 SP1 while all other WinCC graphics remain dynamic and healthy, the failure is typically caused by multi-monitor coordinate displacement, an un-reloaded WinCC Server Data package, or an expired SFC-Visualization license. If client monitor configurations or resolutions were recently modified, the SFC faceplate may open at off-screen coordinates located outside the visible physical desktop. To resolve this, reload updated Server Data packages (*.pck) on the MultiClient, verify the SIMATIC PCS 7 SFC-Visualization license in Automation License Manager, run OS Project Editor to restore system pictures (@PG_SFC.pdl), and reset cached window position coordinates.

SFC Visualization MultiClient Client-Server Architecture

In SIMATIC PCS 7, Sequential Function Charts (SFC) execute high-level batch and continuous sequencing logic directly in controller RAM. To visualize and control these state machines from the operator control room, the software package SIMATIC PCS 7 SFC-Visualization provides specialized WinCC ActiveX/OCX faceplates (@PG_SFC.pdl, @PG_SFCTYPE.pdl, and @SFC_...).

In an OS MultiClient architecture, clients do not possess direct connections to the AS controllers; they query the OS Servers via Server Data Packages (*.pck). When an operator clicks an SFC block icon, the client resolves the server prefix, loads the SFC OCX control, and establishes an asynchronous data pipe to the server's SFC runtime server process (CCSFCSrv.exe).

Root Cause 1: Multi-Monitor Window Coordinate Displacement (Off-Screen Windows)

A widespread yet frequently misdiagnosed failure during plant commissioning occurs when SFC faceplates appear to 'freeze' or never render:

The Coordinate Cache: WinCC OS remembers the last screen coordinates where an operator opened an SFC faceplate. These coordinates are stored in the local client registry or user settings database.
Monitor Geometry Changes: If an operator desk previously had 3 or 4 monitors and was reconfigured to 2 monitors (or if Windows display scaling or GPU resolution was altered), the SFC faceplate opens at its previously saved coordinates—which now reside in virtual space outside the visible display boundaries.
The Hidden Faceplate: In Task Manager or the Windows taskbar, the faceplate window is active and running, but invisible to the operator. The operator clicks the icon repeatedly, assuming the system has crashed.

Root Cause 2: Server Data Package (`*.pck`) Desynchronization

If the underlying Automation Station program was recompiled with updated SFC Types or modified block contacts, but the OS Server packages were not updated on the MultiClient:

The OS Server generates an updated server data package (<OS_Project>.pck) containing updated SFC runtime descriptors.
If the OS MultiClient did not reload this package, its local tag browser references stale server prefixes.
When the operator attempts to open the SFC faceplate, the ActiveX control queries an invalid tag address, fails silently, and halts faceplate generation.

Root Cause 3: Automation License Manager (ALM) License Validation

SFC Visualization requires dedicated runtime licensing across all operational tiers:

Client License Key: Every OS MultiClient that opens or operates SFC faceplates requires the license key SIMATIC PCS 7 SFC-Visualization installed on local drive C: via Automation License Manager (ALM).
Trial License Expiration: During commissioning, systems often operate temporarily on 14-day trial licenses. If the trial period expires without installing permanent license keys, SFC faceplates will abruptly refuse to open, displaying a license missing warning dialog or failing to instantiate.

Diagnostic Matrix: SFC Visualization Failure Modes on OS MultiClients

Use the following matrix to diagnose and recover SFC Visualization failures:

Diagnostic SymptomUnderlying Root CauseCorrective Engineering ActionClick icon; nothing appearsFaceplate opened off-screen on virtual monitorReset multi-monitor layout in OS Project Editor; check registry'License missing' popupSFC-Visualization license expired or missingTransfer valid SFC-Visualization license to client drive C: in ALMFaceplate opens; shows 'Offline'Server package outdated or missing server prefixIn WinCC Explorer, reload Server Data package (*.pck)Faceplate crashes with OCX errorCorrupted @PG_SFC.pdl system pictureRe-run OS Project Editor on client with system pictures checkedSFC type steps display blankAS SFC Type and OS project time stamps differRe-compile CFC/SFC and execute full OS Compile with tags

Step-by-Step Restoration and Recovery Workflow

Follow this sequence to restore SFC Visualization functionality on affected MultiClients:

Check License Status: Open Automation License Manager (ALM) on the MultiClient. Verify that SIMATIC PCS 7 SFC-Visualization is present and displays status 'Valid'.
Reset Window Coordinates: In WinCC Explorer on the MultiClient, open the OS Project Editor. Navigate to the Layout tab. Verify that the number of monitors and screen resolution match the physical workstation hardware. Click OK to regenerate coordinate anchors.
Reload Server Data Packages:
- In WinCC Explorer, expand Server Data.
- Right-click the server package, select Delete, then select Load....
- Browse to the primary OS Server project folder and load the latest .pck file.
Re-Register System Pictures: Re-run the OS Project Editor with the option to update standard system pictures (@*.pdl) checked.
Restart WinCC Runtime: Deactivate and reactivate WinCC Runtime on the client. Click an SFC icon and verify immediate faceplate opening.

Verification

Confirm that SFC Visualization operates reliably in runtime:

In WinCC Runtime on the MultiClient, locate an SFC chart or SFC Type block icon.
Click the block icon; confirm that the standard SFC faceplate (@PG_SFC.pdl) renders in the center of the primary screen within 1.5 seconds.
Verify that the current active step is highlighted in green, transitions evaluate live conditions, and the time elapsed counter updates continuously.
Test operator control: Click 'Hold', 'Resume', and manual step advance; confirm that commands transmit cleanly across the Terminal Bus to the AS.

Limitations and Operational Precautions

Adhere to the following operational precautions:

Never Modify @PG_SFC.pdl Manually: System pictures prefixed with @ are automatically managed by the OS Project Editor; manual script edits will be overwritten during future compiles.
Client-Server Version Parity: Ensure that SFC Visualization software updates (e.g. V8.1 SP1 Upd1) are installed symmetrically across Engineering Stations, OS Servers, and all OS MultiClients.
Operator Authorization: Operating SFC sequencers (Hold, Abort, Manual Step) requires WinCC Authorization Level 6 (Higher process controlling); verify operator user privileges in User Administrator.

Engineer FAQ

Does SFC Visualization require a license on every OS MultiClient?

Yes. Every OS MultiClient that displays or controls SFC faceplates requires an active 'SIMATIC PCS 7 SFC-Visualization' license in Automation License Manager.

How can an operator retrieve an off-screen WinCC faceplate without restarting?

Click the faceplate icon on the Windows taskbar, press Alt + Space, select 'Move' (M), press an arrow key once, and move the mouse to snap the window back onto the active screen.

What happens if the OS Server is recompiled but server data is not loaded on the client?

The client attempts to query stale tag structures, leading to communication timeouts or blank step displays inside the SFC faceplate.

Technical References

Related Tags

SFC Visualization
OS MultiClient
Server Data Package
Multi-Monitor Layout
Off-Screen Coordinates
PCS 7 V8.1 SP1

Off-Screen Coordinates

PCS 7 V8.1 SP1

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Troubleshooting SIMATIC PCS 7 SFC Visualization Failures on MultiClients: Missing Faceplates and Window Coordinates