CEMAT V7 to V9 Migration Architecture and Preventing CFC Block Interface Disconnections

Directly copying CEMAT V9 function blocks into a CEMAT V7 project disconnects all CFC signal interconnections because Siemens completely overhauled the block architecture between generations, converting legacy discrete WORD/DWORD parameters into structured APL-compliant technological structures. Upgrading CEMAT from V7 to V9 cannot be performed in a single direct step. Instead, execute a phased multi-step migration: (1) Upgrade from CEMAT V7.0/V7.1 to CEMAT V8.2 SP1 on an intermediate engineering station; (2) Utilize the official CEMAT Migration Tool and Excel remapping scripts located under CEMAT_CS\ADDON\MIGRATION to convert parameter links; and (3) Upgrade the project from V8.2 SP1 to CEMAT V9.0/V9.1 with final OS faceplate regeneration.

Executive Summary

In cement, lime, and minerals processing plants operating under the SIMATIC PCS 7 CEMAT industry standard, upgrading legacy control systems from CEMAT V7.0 or V7.1 to modern CEMAT V9.0 or V9.1 is a critical lifecycle modernization. However, commissioning engineers who attempt to upgrade by simply pasting CEMAT V9 library blocks into their existing chart container encounter catastrophic engineering corruption: nearly all block inputs and outputs disconnect across hundreds of drive, valve, and damper charts. This disconnection occurs because CEMAT underwent a foundational architectural redesign between V7 and V9, adopting Advanced Process Library (APL) data structures. Successfully executing this modernization requires a phased multi-version upgrade path and specialized CEMAT signal remapping tools.

Architecture and Fundamental Mechanics

The structural evolution of CEMAT across product generations accounts for the incompatibility:

Architectural Paradigm Shift (V7 vs. V9):
- CEMAT V7 Architecture: Designed around classic SIMATIC S7 libraries. Drive blocks (C_DRV_1D, C_DRV_2D), valves (C_VALVE), and group controls (C_GROUP) utilized packed elemental data types (BYTE, WORD, DWORD) to exchange command and status words. Interlocking signals were mapped to discrete boolean and bitwise word offsets.
- CEMAT V9 Architecture: Fully re-engineered to align with PCS 7 APL standards. Parameters utilize structured data types (Struct: Value + ST signal status byte). In addition, numerous parameters were renamed, deprecated, or expanded to accommodate NAMUR NE107 diagnostics, 64-bit operating systems, and PROFINET field device communication.
Why Direct Block Type Overwriting Fails: When a block type is replaced in CFC, the CFC compiler matches pin connections based on identical parameter names and data types. Because V9 blocks introduce new structured types and renamed interfaces, CFC cannot map the old elementary types to the new structures. To protect data integrity, CFC severs all non-matching pins, leaving charts completely disconnected.
The Role of CEMAT Migration Add-ons: Siemens delivers dedicated migration macros and utilities within the CEMAT installation media under CEMAT_CS\ADDON\MIGRATION. These scripts parse existing CFC charts, export signal routing matrices to Excel/CSV, remap legacy bit offsets to the corresponding V8/V9 APL structures, and re-establish interconnections programmatically.

Step-by-Step Implementation Procedure

Execute the phased migration according to official Siemens CEMAT migration guidelines:

Phase 1: Preparation and Intermediate Migration to V8.2

Create a complete multi-project archive of the operational CEMAT V7.1 system.
Set up an intermediate Engineering Station running Windows 7 SP1 (64-bit) with PCS 7 V8.2 SP1 and CEMAT V8.2 installed.
Retrieve the V7.1 project on the intermediate ES. Run the PCS 7 Project Migrator to update database schemas.
In SIMATIC Manager, execute the CEMAT Check Tool to identify existing project discrepancies.

Phase 2: Parameter Remapping via Migration Tools

Open Windows Explorer on the CEMAT installation media and navigate to CEMAT_CS\ADDON\MIGRATION.
Launch the CEMAT Migration Tool (or Excel-based remapping macro).
Run the export routine to extract all existing block interconnections and parameter values from the V7 charts.
Copy the CEMAT V8.2 Master Data Library blocks into the project block folder.
Execute Options -> Block Types -> Update Block Types.
Execute the CEMAT Migration remapping script to re-wire all renamed and restructured pins automatically.
Open CFC charts and resolve any remaining manual interconnections flagged in the migration log.

Phase 3: Final Upgrade to PCS 7 V9.0 / V9.1

Archive the cleanly migrated V8.2 project.
Transfer the archive to the final Engineering Station running Windows 10 LTSC / Server 2016 with PCS 7 V9.0 SP2 (or V9.1) and CEMAT V9.
Retrieve the project. Update block types to CEMAT V9 from the V9 Master Data Library.
Perform a complete CFC compilation (Generate Module Drivers checked) and full OS compilation.
Run OS Project Editor to modernize CEMAT faceplates in WinCC Graphics Designer.

Verification

Validate system integrity post-migration:

CFC Interconnection Audit: Open sample CFC charts for single-direction drives (C_DRV_1D), valves, and groups. Verify that all interlocks (EBM, ESB, EVS), feedbacks, and command outputs are intact with valid structured signal statuses (ST = 16#80).
CEMAT Check Tool Execution: Run the CEMAT Check Tool across all AS programs. Confirm that the diagnostic log reports zero syntax faults, zero orphaned blocks, and confirms valid runtime sequence positioning between OB1_START and OB1_END.
S7-PLCSIM Testing: Download the AS program to S7-PLCSIM. Test sequential group start and interlock trip behaviors to ensure dynamic logic execution matches the original V7 facility baseline.

Limitations and Operational Precautions

Never attempt a direct single-step upgrade jumping from CEMAT V7 to CEMAT V9; skipping the intermediate V8 architecture will result in unrecoverable CFC pin deletions. Furthermore, note that migrating to V9 requires replacing physical 32-bit server hardware and procuring PCS 7 and CEMAT V9 upgrade licenses. Licensing packages and software entitlements must always be confirmed with an authorized Siemens distributor or the Siemens Industry Mall before commencing migration.

Engineer FAQ

Why did all my block connections disconnect when copying CEMAT V9 blocks?

CFC disconnects pins when block parameter names or data types change. CEMAT V9 converted legacy elementary types (WORD, DWORD) into APL technological structures (Struct Value + ST), making direct block replacement incompatible.

Is there an automated tool to reconnect severed CEMAT pins?

Yes. Siemens delivers migration scripts and Excel remapping macros in the CEMAT delivery media under CEMAT_CS\ADDON\MIGRATION to automate the re-wiring process.

Can CEMAT V9 run on Windows 7?

No. CEMAT V9.0 and V9.1 require modern 64-bit operating systems, specifically Windows 10 Enterprise LTSC or Windows Server 2016/2019.

Does CEMAT V9 require new runtime licenses?

Yes. CEMAT V7 license keys cannot operate CEMAT V9. Upgrade licenses for PCS 7 OS, AS RT POs, and CEMAT Engineering/Runtime are required.

Can I perform a CEMAT V7 to V9 migration in RUN mode?

No. Major generational upgrades involving operating system replacements, CPU stop-mode driver compilation, and block restructuring require planned plant downtime.