Troubleshooting CEMAT Faceplate Failures on OS Servers Following Migration from PCS 7 V7.0 to V9.0

Following a migration from SIMATIC PCS 7 V7.0 to V9.0 with the CEMAT minerals library, faceplates fail to open on OS Servers if WinCC retains obsolete startup executable paths and unregistered ActiveX/OCX components. In migrated OS Server projects, WinCC Explorer's Computer Startup properties frequently point to legacy paths such as D:\CEM_V6_CS\BIN\Scan_CS.exe instead of the modern installation directory (D:\CEMAT_CS\BIN\Scan_CS.exe). Creating dummy folders or renaming directories fails because internal DLL registrations (cemat.dll, Cemat_CS.ocx) and C-script header references remain broken. To resolve this: update the startup application path in WinCC Computer Properties, execute the CEMAT Project Update utility (Update_CS.bat) on the server to register OCX controls, verify CEMAT V9.0 compatibility, and perform a full OS compilation.

Executive Summary

The SIMATIC PCS 7 Minerals (CEMAT) library is Siemens' specialized technological control package tailored for cement, mining, glass, and bulk materials processing plants. When migrating legacy production facilities from SIMATIC PCS 7 V7.0 (with CEMAT V7.0 SP1) to modern PCS 7 V9.0, commissioning teams frequently encounter a perplexing defect: CEMAT drive and valve faceplates open perfectly on OS Client stations, but completely fail to pop up when clicked on OS Server stations. This article analyzes the directory path evolution between CEMAT versions, explains WinCC Computer Startup application dependencies (Scan_CS.exe), and details the step-by-step procedure for registering OCX controls and updating migrated server projects.

Architecture and Fundamental Mechanics

CEMAT Architectural Evolution, Startup Services, and OCX Component Registration:

Historical Directory Path Changes (CEM_V6 vs CEMAT_CS):
In legacy releases (CEMAT V5.x and V6.x), Siemens installed the CEMAT runtime and engineering software into D:\CEM_V6_CS\BIN (or C:\CEM_V6_CS\BIN).
Starting in CEMAT V7.0 and continued in V8.x and V9.x, Siemens modernized the directory structure, standardizing the installation path to D:\CEMAT_CS\BIN (or C:\CEMAT_CS\BIN).
The Role of Scan_CS.exe in WinCC Startup:
CEMAT relies on a dedicated background runtime scanner, Scan_CS.exe, to manage alarm scanning, message dispatching, and faceplate communication routines.
In WinCC Explorer, under Computer Properties -> Startup -> Additional Applications, Scan_CS.exe must be registered to launch concurrently with WinCC Runtime.
During project migration from PCS 7 V7.0, the WinCC configuration database (CC_Config) on the OS Server frequently preserves legacy path entries pointing to D:\CEM_V6_CS\BIN\Scan_CS.exe. Because the file does not exist at that legacy path, Scan_CS.exe never starts on the OS Server.
Why Renaming Directories or Creating Aliases Fails:
Commissioning engineers often attempt a quick fix by copying D:\CEMAT_CS to D:\CEM_V6_CS. While this may allow Scan_CS.exe to launch, faceplates still fail to pop up because CEMAT faceplates rely on Windows COM/ActiveX controls (Cemat_CS.ocx, cemat.dll, CematTree.ocx) and global C-script headers (Cemat.h).
These COM components must be explicitly registered with the 64-bit Windows operating system via regsvr32.exe, and project C-scripts must be recompiled through the CEMAT Project Update tool (Update_CS.bat).
Version Compatibility and Licensing Guardrails:
CEMAT V7.0 SP1 is fundamentally incompatible with the 64-bit Windows Server 2016 operating system and WinCC V7.4/V7.5 engines used in PCS 7 V9.0.
Proper migration requires procuring and installing the official CEMAT V9.0 upgrade software package and corresponding engineering/runtime licenses.

Step-by-Step Implementation Procedure

Verify CEMAT Software and License Installation:
* Verify that the official CEMAT V9.0 software package is installed on the ES, OS Servers, and OS Clients.
* Open Automation License Manager (ALM) and confirm that valid CEMAT V9.0 engineering and runtime licenses are present on all stations.
Correct WinCC Startup Application Paths on OS Server:
* Open WinCC Explorer on the OS Server (or on the ES for the server project).
* In the navigation tree, right-click Computer and select Properties.
* Select the target OS Server computer name and click Properties.
* Navigate to the Startup tab.
* Under Additional Applications, locate Scan_CS.exe.
* Update the Application Path to the valid installed directory: D:\CEMAT_CS\BIN\Scan_CS.exe (or C:\...).
* Update the Working Directory to: D:\CEMAT_CS\BIN.
* Click OK to save changes.
Execute CEMAT Project Update Utility (Update_CS.bat):
* Close WinCC Explorer on the OS Server.
* Open an administrative Command Prompt (Run as administrator).
* Navigate to the CEMAT bin directory: cd /d D:\CEMAT_CS\BIN.
* Run the script: Update_CS.bat.
* This utility registers all required COM/ActiveX controls (Cemat_CS.ocx), updates project C-script headers, and synchronizes faceplate template pictures into the local WinCC GraCS directory.
Perform Full OS Compilation from SIMATIC Manager:
* On the Engineering Station, open SIMATIC Manager.
* Right-click the OS Server object and select Compile.
* Select Entire OS with memory reset.
* Download the compiled OS project to the target OS Server.
Restart WinCC Runtime and Validate Faceplate Pop-Up:
* Activate WinCC Runtime on the OS Server.
* Open Windows Task Manager and confirm that Scan_CS.exe is actively running under processes.
* Click on a technological block icon (e.g. C_DRV_1D motor or C_VALVE) in a plant graphic.
* Verify that the CEMAT faceplate pops up immediately without errors.

Verification

Verify CEMAT Runtime and Faceplate Operation:
1. In Windows Task Manager on the OS Server, confirm that Scan_CS.exe is running with active CPU/memory allocation.
2. Click multiple technological block icons (drives, dampers, valves) on the OS Server; verify that standard CEMAT faceplates open and display live process data.
3. In WinCC diagnostic viewer (apdiag.exe), verify that 0 script compilation or missing DLL errors occur during faceplate calls.
4. Verify in ALM that the CEMAT runtime license is active without license warning dialogs.

Limitations and Operational Precautions

Operational Precautions and Compatibility Boundaries:
- Never attempt to run mismatched versions between AS blocks and OS faceplates (e.g. CEMAT V7 blocks in controller with CEMAT V9 faceplates in WinCC); AS blocks and OS components must belong to the same CEMAT library version.
- Upgrading from CEMAT V7 to CEMAT V9 requires purchasing the official CEMAT Upgrade Package (6DL5436-...); licenses cannot be inferred from standard PCS 7 packages.
- Always validate final license quantities and exact MLFBs against the applicable Siemens catalog and authorized distributor quotation.

Engineer FAQ

Why did CEMAT faceplates work on OS Clients but fail on OS Servers?

OS Client projects often receive fresh templates pointing to D:\CEMAT_CS\BIN\Scan_CS.exe, whereas migrated OS Server databases frequently preserve obsolete startup strings pointing to D:\CEM_V6_CS\BIN\Scan_CS.exe.

What is the function of Scan_CS.exe in CEMAT?

Scan_CS.exe is the central background runtime engine for CEMAT in WinCC, managing alarm processing, faceplate communication, and operator command dispatching.

Why didn't copying CEMAT_CS to CEM_V6 fix the issue?

Copying files does not register required COM/ActiveX controls (Cemat_CS.ocx) with the 64-bit Windows registry. Running Update_CS.bat is required to register the components.

Can CEMAT V7.0 SP1 run on PCS 7 V9.0?

No. CEMAT V7.0 SP1 is fundamentally incompatible with the 64-bit operating systems and WinCC V7.4/V7.5 engines in PCS 7 V9.0. Upgrading to CEMAT V9.0 is required.