Selecting and Implementing Mining Automation Libraries in SIMATIC PCS 7

While engineers migrating from STEP 7 or TIA Portal can program custom mining blocks in PCS 7 using SCL, CFC, and SFC, developing a proprietary library is unnecessary and uneconomical. Siemens provides CEMAT (Minerals Automation Standard), a dedicated, globally standardized process control library engineered specifically for mining, cement, and bulk materials handling. CEMAT delivers pre-engineered technological blocks, faceplates, route management, group control, and conveyor interlocks, complemented by an official demonstration project.

Engineering Paradigms: STEP 7 / TIA Portal vs. PCS 7

Engineers transitioning from discrete PLC programming environments (such as STEP 7 classic or TIA Portal) to SIMATIC PCS 7 often begin by planning custom function blocks (FBs) in Structured Control Language (SCL) or Ladder Logic (LAD). In traditional discrete automation, building proprietary libraries for motor control, conveyor sequencing, and alarm management is standard practice.

However, SIMATIC PCS 7 is a full Distributed Control System (DCS) built on unified architectural standards:
* Continuous Function Charts (CFC) and Sequential Function Charts (SFC) provide graphical, object-oriented engineering.
* Advanced Process Library (APL) establishes standardized operating philosophies, alarm escalation, and faceplate graphics.
* Creating a proprietary mining library from scratch requires developing not only PLC code, but also OS faceplates, block icons, diagnostic drivers, and multi-client messaging scripts—demanding hundreds of engineering hours.

Overview of the CEMAT Minerals Automation Standard

To eliminate proprietary library development in heavy industrial operations, Siemens developed CEMAT (Cement and Minerals Automation Standard), which represents over 40 years of continuous domain engineering:
* Industry Focus: Specifically designed for mining, crushing, grinding, flotation, material handling, cement production, and bulk logistics.
* Standardization: Complies with NAMUR recommendations, ISO ergonomics, and strict process safety requirements.
* Ready-to-Use Demo Applications: Siemens provides complete demo projects ("SIMATIC PCS 7 in the mining industry") containing pre-engineered crushing circuits, overland conveyor belts, and grinding mills to accelerate commissioning.

Core CEMAT Functional Blocks and Architecture

CEMAT extends the PCS 7 system with specialized technological modules designed for rugged field conditions:

Group and Route Management (C_GROUP, C_ROUTE):
* Coordinates large networks of interdependent machinery (e.g., a 2-kilometer conveyor belt sequence with feed hoppers, transfer chutes, and stackers).
* Provides automated start/stop cascading, pre-warning horn activation, and route selection directly from operator faceplates.
Drive and Actuator Modules (C_DRV_1D, C_DRV_2D, C_VALVE):
* Heavy-duty unidirectional and bidirectional motor blocks featuring built-in speed monitor evaluation, slip detection, belt drift switch interlocks, and local emergency pull-cord supervision.
Analog and Silo Monitoring (C_MEASUR, C_SILO):
* Dedicated analog processing incorporating process smoothing, calibration offset tracking, level radar integration, and high/low level limit switching.
Diagnostic and Maintenance Tracking:
* Integrated runtime hour counters, maintenance cycle alarms, and trip sequence diagnostic memories that record which exact safety switch initiated a plant trip.

Verification

In SIMATIC Manager, open the CEMAT demo project provided by Siemens Industry Online Support.
Inspect the Master Data Library to explore the C_ block family and associated Control Module Types.
Open WinCC Explorer, activate Runtime, and test the pre-engineered mining faceplates. Confirm that drive diagnostics, group sequencing, and route interlocks operate dynamically out of the box.

Limitations and Operational Precautions

CEMAT requires dedicated runtime and engineering software licenses beyond standard PCS 7 packages.
Integrating CEMAT blocks into an existing plant running standard APL requires aligning operational philosophies, as CEMAT uses distinct faceplate styles and operator authorization levels.
Never modify the compiled internal code of standard C_ system blocks; always utilize extension interfaces and user parameter words provided by the library.

Engineer FAQ

Can I combine standard APL blocks with CEMAT in the same CPU?
Yes. Standard APL blocks (e.g., PIDConL, Pcs7AnIn) can coexist in the same AS program alongside CEMAT modules (C_DRV_1D), though operator faceplates will reflect their respective library designs.
Is CEMAT compatible with S7-410 controllers?
Yes. CEMAT is fully optimized for SIMATIC S7-410 controllers and ET 200SP HA / ET 200M distributed I/O systems across PROFINET and PROFIBUS.
Where can I find the official mining demo project?
The demo project and documentation can be downloaded from Siemens Industry Online Support under the title "SIMATIC PCS 7 in the mining industry (demo project)".

Technical References

SIMATIC PCS 7 Minerals Automation Standard (CEMAT) Engineering Manual (A5E41356280-AA).
Siemens Industry Online Support Entry ID 109801081: PCS 7 Mining Industry Demo Project Application Example.
CEMAT Function Block Reference Guide: Group and Drive Architecture.