CEMAT Version Compatibility and Legacy Migration Guidelines for SIMATIC PCS 7 V9.1

Legacy CEMAT V7.0 cannot be installed or executed on SIMATIC PCS 7 V9.1. CEMAT V7.0 is a 32-bit legacy package designed for Windows XP and PCS 7 V7.0, making it completely incompatible with the 64-bit Windows 10/Server 2019 architecture, STEP 7 V5.6, and WinCC V7.5 SP2 used in PCS 7 V9.1. Operating a CEMAT plant on PCS 7 V9.1 requires upgrading to the commercially released SIMATIC PCS 7 CEMAT V9.1 (or V9.1 SP1/SP2) through structured multi-stage project migration.

Generational Evolution and Technical Incompatibilities

The Siemens CEMAT (Cement and Minerals Automation) library is heavily customized for high-volume process applications, incorporating specialized AS function blocks, OS faceplates, and system scripts.

Attempting to run legacy CEMAT V7.0 on PCS 7 V9.1 faces insurmountable technical barriers:
* Operating System Architecture: CEMAT V7.0 relies on 32-bit system DLLs and legacy OCX controls designed for Microsoft Windows XP Professional and Server 2003. PCS 7 V9.1 operates strictly on 64-bit Windows 10 Enterprise LTSC (2019/2021) and Windows Server 2019/2022.
* WinCC Graphics Engine Evolution: WinCC evolved from V6.2/V7.0 to V7.5 SP2. CEMAT V7.0 faceplates utilize obsolete Visual Basic scripts and proprietary 32-bit ActiveX controls that fail to register or render in modern 64-bit WinCC environments.
* AS Block Structures and Compilers: The S7-SCL and CFC compilers in PCS 7 V9.1 enforce strict data type checks and memory alignments that reject unmigrated V7.0 block interfaces.
* Current Supported Releases: The active CEMAT release family for modern PCS 7 installations is CEMAT V9.1 (with service packs V9.1 SP1 and V9.1 SP2).

Step-by-Step Multi-Stage CEMAT Migration Path

Migrating a legacy plant from CEMAT V7.0 to CEMAT V9.1 requires an intermediate stepping stone strategy.

+---------------------+       Upgrade Step 1        +---------------------+
| CEMAT V7.0          | ==========================> | CEMAT V8.0 / V8.2   |
| (PCS 7 V7.0 / WinXP)|   Project Conversion        | (Windows 7 32-bit)  |
+---------------------+                             +---------------------+
                                                               |
                                                               v Upgrade Step 2
+---------------------+                             +---------------------+
| CEMAT V9.1 SP2      | <========================== | CEMAT V9.0 / V9.1   |
| (PCS 7 V9.1 / Win10)|       Final Migration       | (Windows 10 64-bit) |
+---------------------+                             +---------------------+

Prerequisites

Complete project archive of the operational CEMAT V7.0 system.
Intermediate migration engineering PC with Windows 7 and PCS 7 V8.2 / CEMAT V8.2.
Target Engineering Station with Windows 10 LTSC, PCS 7 V9.1 SP2, and CEMAT V9.1 SP2.
Valid upgrade licenses for PCS 7 and CEMAT V9.1.

Step 1: Intermediate Project Conversion to CEMAT V8.2

Restore the V7.0 project onto an intermediate Windows 7 engineering station running PCS 7 V8.2 and CEMAT V8.2.
Open the project in SIMATIC Manager and execute the CEMAT Migration Tool.
Recompile all SCL sources and CFC charts to adapt block signatures to V8.2 specifications.
Open WinCC Explorer and run the WinCC Project Migrator to convert the SQL database from SQL Server 2005 to SQL Server 2008/2014.
Save and archive the healthy intermediate V8.2 project.

Step 2: Final Project Migration to CEMAT V9.1

Transfer the V8.2 archive to the modern Windows 10 PCS 7 V9.1 SP2 engineering station.
In SIMATIC Manager, retrieve the archive and acknowledge automated project database conversion.
Open WinCC Explorer: the WinCC Project Migrator converts database structures to Microsoft SQL Server 2017.

Step 3: Update Block Types from CEMAT V9.1 Master Library

In SIMATIC Manager, open File -> Open -> Libraries and select the CEMAT V9.1 Library.
Copy the updated technological blocks (C_DRV_1D, C_DRV_2D, C_DAMPER, C_ANNUNC, C_MEASUR) into the project Master Data Library.
Select Options -> Block Types and update all chart instances.
Execute full CFC compilation: Chart -> Compile -> Entire Program.

Step 4: Run CEMAT OS Project Editor and Generate Server Data

In WinCC Explorer, run the CEMAT Project Update Utility to copy modern 64-bit @PG_C_*.pdl faceplates and scripts into GraCS.
Run the OS Project Editor to align screen resolution and monitor layouts.
Recompile the OS and download to the target servers and clients.

Verification

In SIMATIC Manager, verify that Installed Software reports SIMATIC PCS 7 CEMAT V9.1.
In CFC, confirm that all CEMAT blocks compile without signature mismatch errors.
In WinCC Runtime, click a drive block icon (e.g., C_DRV_1D). Confirm that the modern CEMAT faceplate opens instantly, displaying live motor currents, operational modes (Automatic/Manual/Local), and alarm states.
Verify in Automation License Manager that CEMAT Engineering and Runtime licenses are recognized as valid.

Limitations and Operational Precautions

Direct Jump Impossible: Attempting to skip the intermediate V8.x stepping stone and open a V7.0 project directly in V9.1 causes catastrophic project database corruption in the WinCC migrator.
Field Hardware Compatibility: Ensure legacy S7-400 CPUs meet minimum firmware requirements for PCS 7 V9.1 (CPU 414/416/417 firmware V5.3+ or modern CPU 410-5H).
Faceplate Customizations: Any customized C-scripts or modified graphics created in V7.0 must be manually recreated in the V9.1 environment to adhere to modern security and 64-bit standards.

Engineer FAQ

What is the current latest version of CEMAT?
The latest released versions are CEMAT V9.1 SP1 and CEMAT V9.1 SP2, matching PCS 7 V9.1 service pack releases.
Can I run CEMAT V7.0 in a Windows XP virtual machine connected to PCS 7 V9.1?
No. Client-server architectures and automation bus communications require all nodes to operate on matching, compatible software baselines.
Are CEMAT licenses perpetual or version-specific?
CEMAT licenses are version-specific; upgrading from V7.0 to V9.1 requires purchasing official software upgrade licenses from Siemens.
Does CEMAT V9.1 support PROFINET field devices?
Yes. CEMAT V9.1 fully supports modern PROFINET motor management devices (such as SIMOCODE pro V PN) and ET 200SP / ET 200SP HA remote I/O.
Where can I check compatibility between CEMAT and third-party tools?
Use the online Siemens Compatibility Tool (SIOS Entry ID 64847781) to verify all software dependencies.

Technical References

Siemens Industry Online Support Entry ID 109801081: CEMAT V9.1 Product Release and Upgrade Guidelines.
Siemens System Manual: Migration Guide - Upgrading SIMATIC PCS 7 CEMAT Systems.
Siemens Compatibility Tool: Operating Systems and Software Dependencies for CEMAT V9.1.

CEMAT Version Compatibility and Legacy Migration Guidelines for SIMATIC PCS 7 V9.1