Licensing Structure and Upgrade Procedures for SIMATIC PCS 7 CEMAT from V7.0 to V8.2

Upgrading SIMATIC PCS 7 CEMAT (the cement and mining industry standard software) from legacy V7.0 to V8.2 requires upgrading both the foundational PCS 7 system licenses and the specialized CEMAT functional packages. Standard PCS 7 licenses (Engineering Station, OS Server Redundancy, and Process Objects) do not include CEMAT entitlements. To upgrade, acquire the 'CEMAT Upgrade Package V8.2'—which upgrades existing CEMAT installations from V6.1, V7.0, or V8.0 to V8.2—along with version-specific CEMAT Single Station, CEMAT Server, and CEMAT Engineering upgrades. Redundant OS servers require dedicated CEMAT Server licenses for each physical machine. Final license quantities and MLFBs must be validated through the official Siemens CEMAT catalog and an authorized Siemens distributor quotation.

Executive Summary

SIMATIC PCS 7 CEMAT is Siemens' dedicated technological library and operational philosophy engineered specifically for the harsh, high-throughput demands of cement plants, mining facilities, and mineral processing sites. When migrating a legacy plant running PCS 7 V7.0 CEMAT to a modern PCS 7 V8.2 infrastructure, engineering teams must navigate a multi-tiered licensing structure. CEMAT incorporates unique function blocks, faceplates, and route management systems that require distinct engineering, runtime, and server licenses. Upgrading cannot be accomplished merely by upgrading core PCS 7 software; it mandates acquiring the dedicated CEMAT V8.2 upgrade packages, verifying OS server redundancy licensing, and executing structured database migrations.

Architecture and Fundamental Mechanics

The licensing architecture of SIMATIC PCS 7 CEMAT is layered directly on top of the standard PCS 7 licensing model, requiring distinct software entitlements:

The Dual-Tier Licensing Model:
* Core PCS 7 Licensing: Governs standard SIMATIC Manager, CFC, SFC, WinCC Runtime, and standard AS/OS Process Objects (POs). An upgrade from V7.0 to V8.2 requires standard PCS 7 Upgrade Packages (6ES7658-...) to transition the ES, OS servers, and OS clients.
* CEMAT Technological Licensing: Licenses the specialized CEMAT block library (C_DRV_1D, C_VALVE, C_ROUTE, C_GROUP), automated route management, Annunciation Modules, and standardized cement industry faceplates. CEMAT licenses are enforced via the Automation License Manager (ALM).
CEMAT License Classifications:
* CEMAT Engineering License: Required on the Engineering Station to compile CEMAT blocks, generate module drivers, and utilize the CEMAT engineering tools.
* CEMAT Single Station / Client License: Required for standalone stations or specialized CEMAT client operations.
* CEMAT Server License: Required on every WinCC OS Server that hosts CEMAT runtime archives, alarm systems, and route status tracking. In a redundant server pair, both the master and standby OS servers require their own CEMAT Server license.
The Upgrade Path from V7.0 to V8.2:
* Siemens provides a consolidated CEMAT Upgrade Package V8.2 designed to migrate installations from legacy versions (V6.1, V7.0, V7.1, or V8.0) directly to V8.2.
* Upgrading the engineering software requires transferring the upgrade license keys via ALM and applying the license upgrade to convert old V7.0 license artifacts into valid V8.2 authorizations.
AS and OS Process Object Consumption:
* While standard PCS 7 AS RT POs and OS RT POs count block instances (e.g., motor blocks consume POs), CEMAT blocks also register as process objects. Upgrading to V8.2 preserves version-independent PO counting rules, but expanded plant units require additional PO capacity upgrades.

Step-by-Step Implementation Procedure

Follow these procedures to prepare, procure, and execute a CEMAT license upgrade from V7.0 to V8.2:

Audit Existing V7.0 Licenses via Automation License Manager (ALM):
* Open ALM on the V7.0 Engineering Station, OS Servers, and OS Clients.
* Generate a complete license inventory report (File > Export...).
* Record all installed licenses, including:
- SIMATIC PCS 7 Engineering
- SIMATIC PCS 7 OS Software Server / Redundancy
- AS RT PO and OS RT PO quantities
- CEMAT Engineering V7.0
- CEMAT Server V7.0 (verify count on redundant servers)
- CEMAT Single Station V7.0
Develop the License Package Schedule:
* Prepare a formal procurement list separating core PCS 7 and CEMAT requirements:
- Core PCS 7: Order PCS 7 ES Upgrade V7.0 -> V8.2, OS Server Upgrade V8.2, and redundant server option upgrades.
- CEMAT Upgrade: Specify the CEMAT Upgrade Package V8.2 for each installed CEMAT station.
- Ensure separate CEMAT Server upgrade licenses are specified for both primary and secondary OS servers.
Validate with Authorized Distributor:
* Submit the license package schedule to an authorized Siemens distributor or review against the official Siemens Industry Mall catalog.
* Verify that the selected order numbers (MLFBs) cover all required software components and that no optional packages (e.g., MIS, Minerals) are omitted.
Install PCS 7 V8.2 and Upgrade Licenses in ALM:
* On the new or upgraded engineering workstation running Windows 7 SP1 or Windows Server (compatible with V8.2), install PCS 7 V8.2 followed by the CEMAT V8.2 installation package.
* Insert the Siemens License USB drives containing the V8.2 Upgrade licenses.
* Open ALM, connect to the old license store, and select License Key > Upgrade....
* Confirm that the V7.0 license keys are upgraded into valid V8.2 keys.
Transfer Licenses to Target Stations:
* Transfer the upgraded CEMAT Engineering license to the ES.
* Transfer the CEMAT Server licenses to OS Server 1 and OS Server 2 over the network via ALM.
Migrate Project Data:
* Dearchive the V7.0 multiproject on the V8.2 ES.
* Update the CEMAT Master Data Library using the CEMAT V8.2 migration procedure.
* Perform block type updates and compile charts and OS runtime.

Verification

Open Automation License Manager on the upgraded ES and OS servers; confirm that all CEMAT V8.2 and PCS 7 V8.2 license keys display 'OK' status with zero missing license warnings. In SIMATIC Manager, open a CFC chart containing CEMAT blocks (e.g., C_DRV_1D); execute Chart > Compile > Entire program. Confirm that compilation completes successfully without CEMAT licensing error prompts. Activate WinCC Runtime on both redundant OS servers; confirm that CEMAT faceplates and route management screens operate without demo mode banners.

Limitations and Operational Precautions

Direct software project migration from V7.0 to V8.2 requires intermediate project migration steps (typically V7.0 -> V7.1 SP4 -> V8.0 -> V8.2) to ensure database and block consistency. Always validate that operating system compatibility (e.g., migrating from Windows XP / Server 2003 to Windows 7 / Server 2008 R2) is respected. Never attempt to run CEMAT V8.2 software with legacy V7.0 license keys.

Engineer FAQ

Does the standard PCS 7 V8.2 upgrade include CEMAT licenses?

No. CEMAT is an industry-specific technological option requiring dedicated CEMAT upgrade licenses separate from core PCS 7 upgrade packages.

Do redundant OS servers require two CEMAT Server licenses?

Yes. In a redundant pair, each physical OS server must have its own CEMAT Server license installed in ALM.

Can a single CEMAT Upgrade Package upgrade from V6.1 directly to V8.2?

Yes. The official CEMAT Upgrade Package V8.2 is designed to upgrade existing installations running CEMAT V6.1, V7.0, V7.1, or V8.0.

Are CEMAT AS Runtime blocks licensed per Process Object?

Yes. CEMAT blocks consume standard AS Process Objects (POs) within the controller, but require the CEMAT engineering and server licenses for configuration and visualization.