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Migrating CEMAT from V7.0 to V8.1 in SIMATIC PCS 7 - Upgrade Paths and Migration Procedures

Migrating CEMAT from V7.0 to V8.1 in SIMATIC PCS 7 - Upgrade Paths and Migration Procedures

Upgrading a SIMATIC PCS 7 project with CEMAT from V7.0 (on PCS 7 V7.1) to CEMAT V8.1 (on PCS 7 V8.1) does not require installing intermediate CEMAT releases like V7.1. Siemens provides the dedicated CEMAT Upgrade Package V8.1, which supports direct database and engineering upgrades from CEMAT V6.1, V7.0, V7.1, and V8.0. However, the host SIMATIC PCS 7 engineering station must be migrated systematically through the approved PCS 7 OS and software migration sequence. The CEMAT upgrade process entails converting the Step 7 project database, running the migration spreadsheet C_MIG_V81.XLS to rewire module links, updating the CEMAT block library in the CFC charts, and compiling the WinCC OS with updated CEMAT faceplate PDLs.

Table of Contents

Executive Summary

In cement and heavy minerals processing plants automated with Siemens CEMAT, system lifecycle upgrades require rigorous alignment between the base SIMATIC PCS 7 DCS platform and the CEMAT industry-specific software package. Plant engineers migrating legacy systems from PCS 7 V7.1 / CEMAT V7.0 to PCS 7 V8.1 / CEMAT V8.1 frequently query whether intermediate installations (such as CEMAT V7.1 or V8.0) must be commissioned sequentially. Siemens CEMAT product architecture is engineered with cumulative migration support: the CEMAT Upgrade Package V8.1 contains migration scripts and conversion drivers capable of processing legacy block instances directly from V6.1 or higher. This guide explains the complete migration roadmap, software licensing prerequisites, block update mechanics in CFC, and WinCC picture regeneration.

Architecture and Fundamental Mechanics

CEMAT Upgrade Architecture

CEMAT is built as an add-on functional layer on top of SIMATIC PCS 7. In CEMAT V7.0, drive control, signal conditioning, group control, and route selection rely on dedicated function blocks (e.g., C_DRV_1D, C_VALVE, C_GROUP, C_ROUTE, C_INTER5) and global data blocks (C_INTCON, C_SIM_G1). 

+-------------------------------------------------------------------------+
|                        SIMATIC PCS 7 V8.1                               |
|                                                                         |
|  +-------------------------------------------------------------------+  |
|  |                     CEMAT Upgrade Package V8.1                    |  |
|  |                                                                   |  |
|  |   [C_MIG_V81.XLS]           [C_DRV_1D / C_VALVE]   [@PG_C_*.pdl]  |  |
|  |   Migration Script               APL-Style Block    WinCC Faceplate|  |
|  |   DB Link Rewiring            CFC Update Types       OS Regeneration |  |
|  +-------------------------------------------------------------------+  |
+-------------------------------------------------------------------------+
                                    ^
                                    | Direct Upgrade Path
                                    |
+-------------------------------------------------------------------------+
|                   Legacy System: PCS 7 V7.1 / CEMAT V7.0                 |
+-------------------------------------------------------------------------+

Between CEMAT V7.0 and V8.1, fundamental enhancements occurred:
1. Block Interface Harmonization: Inputs and outputs were modernized to align closer with PCS 7 Advanced Process Library (APL) structures, altering block pin layouts and internal data structures.
2. Group and Route Coupling: Legacy CEMAT relied heavily on direct inter-block pointer assignments. In V8.x, group/route coupling and status reporting utilize modernized message and interlock structures.
3. WinCC Faceplate Technology: V7.0 faceplates utilized classical OCX and basic PDL scripts. V8.1 utilizes standardized WinCC picture technology with enhanced User Administration and dynamic screen window embedding.

Because the CEMAT Upgrade Package V8.1 provides backward-compatible translation tables in C_MIG_V81.XLS, engineers can transform V7.0 block calls directly into V8.1 structures without installing intermediate engineering software environments.

Step-by-Step Implementation Procedure

Step 1: Pre-Migration System Backup and Verification

  1. Perform an uncompressed multi-project archive of the entire PCS 7 V7.1 / CEMAT V7.0 system from SIMATIC Manager via File > Archive.
  2. Export the CEMAT route, group, and drive link assignments into an Excel reference file using the legacy CEMAT documentation tool.
  3. Note all customized CEMAT blocks, user-defined modifications in C_AddOn, and modified WinCC PDL screens.

Step 2: Establish the PCS 7 V8.1 Engineering Environment

  1. Set up a modern engineering station running a compatible operating system (e.g., Windows 7 SP1 64-bit Enterprise or Windows Server 2008 R2 SP1 64-bit).
  2. Install SIMATIC PCS 7 V8.1 followed by the CEMAT Upgrade Package V8.1.
  3. Transfer valid software runtime and engineering license keys via Automation License Manager (ALM). Note: Validate license requirements and part numbers with an authorized Siemens distributor or the Siemens Industry Mall.

Step 3: Retrieve and Convert the SIMATIC Multiproject

  1. In SIMATIC Manager on the PCS 7 V8.1 ES, retrieve the archived project via File > Retrieve.
  2. When prompted by SIMATIC Manager, confirm the project database reorganization and migration to Step 7 V5.5 SP4.
  3. Open HW Config for each AS station, perform a Save and Compile, and verify that all CPs and interface modules have valid catalog representations.

Step 4: Run CEMAT Migration Scripts

  1. Open the CEMAT migration spreadsheet located in the CEMAT installation folder: C:\CEMAT_CS\Tools\C_MIG_V81.XLS.
  2. Connect the Excel macro to the retrieved SIMATIC project.
  3. Execute the migration script to scan all CFC charts, identify legacy V7.0 CEMAT block instances, and convert internal group and route link pointers to V8.1 parameter formats.

Step 5: Update Block Types in CFC and Master Data Library

  1. In the Master Data Library, open the S7 Program block container and copy the updated CEMAT V8.1 blocks from the system CEMAT library.
  2. Open any CFC chart, select Options > Update Block Types, and check all CEMAT blocks (C_DRV_1D, C_DRV_2D, C_VALVE, C_GROUP, C_ROUTE, C_INTER5, C_MEASUR).
  3. Select all target S7 programs and click OK to execute the global block type update.
  4. Perform a complete chart compilation: Chart > Compile > Changes Only (or complete compile if structural modifications mandate it).

Step 6: Update WinCC OS and Faceplates

  1. Open WinCC Explorer on each OS project in the multiproject.
  2. Run the OS Project Editor (WinCC Explorer > OS Project Editor > OK) to deploy updated system faceplates and scripts.
  3. Copy the updated CEMAT V8.1 WinCC screens (@PG_C_*.pdl, @PL_C_*.pdl) and C-scripts from C:\CEMAT_CS\WinCC\GraCS and C:\CEMAT_CS\WinCC\Library to the OS project directory.
  4. Perform an OS Compile from SIMATIC Manager with Entire OS and With memory reset selected for the first compilation.

Verification

  1. Block Call Verification: Open CFC charts containing C_DRV_1D and C_GROUP. Verify that all block inputs (such as ESVG, EBVG, EBEW) show valid interconnected signals without red error frames.
  2. Consistency Check: In SIMATIC Manager, right-click the Chart folder and select Check Block Types. Confirm that no obsolete V7.0 timestamps remain in the program.
  3. OS Runtime Test: Start WinCC Runtime on the OS simulation or server. Open the faceplate for a motorized drive (C_DRV_1D), navigate to the Diagnostics page, and click on an interlock symbol (ESVG). Confirm that the subordinate C_INTER5 interlock faceplate opens instantly with active dynamic status.

Limitations and Operational Precautions

  1. Field Hardware Firmware: Upgrading to PCS 7 V8.1 and CEMAT V8.1 may require updating firmware on older S7-400 CPUs (e.g., CPU 416-3 or 417-4) to meet minimum memory and instruction set requirements.
  2. Custom Script Overwrites: Running the OS Project Editor and copying CEMAT GraCS files will overwrite standard system PDLs. Any site-specific graphical customizations made in V7.0 must be re-applied or merged into custom user screens.
  3. Licensing Prerequisite: CEMAT Upgrade Package V8.1 requires an active base CEMAT installation license. Upgrade licenses will not validate in ALM if the original base license (V6.x, V7.x, or V8.0) is missing.

Engineer FAQ

Do I need to install CEMAT V7.1 or V8.0 before installing CEMAT V8.1?

No. The CEMAT Upgrade Package V8.1 is designed to upgrade existing CEMAT installations directly from V6.1, V7.0, V7.1, or V8.0 without intermediate software installations.

Where is the CEMAT Upgrade Package obtained?

CEMAT upgrade media and licenses are not available via standard public download. They must be ordered through an authorized Siemens distributor or the Siemens Industry Mall.

What does the spreadsheet C_MIG_V81.XLS do?

It is an automated Excel-based migration macro that reads the Step 7 database, translates legacy group/route interconnections, and re-maps parameter assignments to match V8.1 block signatures.

Can I perform a Delta Download to the AS after updating CEMAT blocks?

No. Changing the internal structure and parameter interface of core CEMAT blocks causes interface timestamp differences that require a complete AS program download in CPU STOP.

What happens to existing CEMAT user archive tables during migration?

CEMAT user archives must be exported to CSV prior to migration. After WinCC OS migration, the archives are re-imported into the updated User Archive structure.

Are CEMAT V7.0 block icons compatible with WinCC V8.1?

Legacy block icons will display basic states, but advanced V8.1 faceplate features and diagnostic navigation require generating new block icons via the Plant Hierarchy Create/Update Block Icons function.

Why do some interlock buttons appear disabled after the upgrade?

CEMAT V8.1 introduces stricter User Administration rights. If the logged-in user lacks configured authorization levels (e.g., Level 5 or Level 6), diagnostic faceplate links remain inaccessible.

Can S7-300 controllers run CEMAT V8.1 blocks?

CEMAT is strictly engineered for S7-400 and S7-410 controllers within a PCS 7 architecture; S7-300 CPUs cannot execute CEMAT standard blocks.

Does CEMAT V8.1 support Windows 10?

No. PCS 7 V8.1 and CEMAT V8.1 support Windows 7 SP1 (64-bit) and Windows Server 2008 R2 SP1. Windows 10 support was introduced in PCS 7 V9.0 with CEMAT V9.0.

What is the primary role of the C_INTCON data block?

C_INTCON serves as the central data exchange and diagnostic coordination block across interconnected CEMAT drive and interlock modules in the S7 program.

Technical References

Related Articles

Related Tags

  • CEMAT V8.1
  • CEMAT V7.0
  • PCS 7 Migration
  • C_MIG_V81.XLS
  • C_DRV_1D
  • CFC Block Update
  • Cement Automation
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