Upgrading CEMAT from v8.1 to v8.2 in SIMATIC PCS 7 - New Features and Project Migration Workflow

Upgrading a SIMATIC PCS 7 project from CEMAT v8.1 to CEMAT v8.2 introduces native PROFINET field device diagnostics (including SIMOCODE pro V PN integration), modernized APL-compliant faceplate ergonomics, and enlarged engineering limits. The migration workflow requires: 1) Archiving the multiproject, 2) Updating the Master Data Library with CEMAT v8.2 blocks, 3) Executing 'Update Block Types' across all AS stations, 4) Running the CEMAT Message Generator, 5) Executing the OS Project Editor on all OS Servers and Clients, and 6) Performing an Entire AS-OS Compilation.

Key Functional Enhancements in CEMAT v8.2 vs v8.1

CEMAT is the specialized Siemens DCS software standard engineered for the cement, mining, and bulk solids extraction industries. The transition from CEMAT v8.1 to CEMAT v8.2 aligns the minerals library with SIMATIC PCS 7 v8.2:
* Native PROFINET Diagnostics: Direct support for PROFINET motor management devices (such as SIMOCODE pro V PN 3UF7011-1AB00-0) and SINAMICS drives without custom glue logic.
* Modernized APL Faceplates: Faceplates updated to match PCS 7 v8.2 design standards, including high-DPI font stability, scalable block icons, and enhanced operator authorization levels.
* Extended Interlock Analysis: First-fault tracking displays provide instant diagnostic isolation of the exact field interlock that tripped a conveyor or kiln drive train.
* Engineering Scalability: Increased tag capacity, faster AS-OS message compilation, and full qualification on Windows 10 Enterprise 64-bit and Windows Server 2012 R2.

Prerequisites and System Software Compatibility

Prior to migrating an active project from CEMAT v8.1 to v8.2:
1. PCS 7 Base Platform: The Engineering Station must be upgraded to SIMATIC PCS 7 v8.2 (with STEP 7 v5.5 SP4 and CFC v8.2).
2. License Keys: Ensure that the appropriate CEMAT Engineering and Runtime upgrade licenses are transferred to the local Automation License Manager (ALM).
3. Hardware Catalog: Confirm that all PROFINET and PROFIBUS slave profiles match the updated hardware support packages in HW Config.

Step-by-Step Multiproject Migration Workflow

To migrate an existing CEMAT v8.1 project to v8.2 cleanly:

[Phase 1: Project Backup & Master Data Library Preparation]
   │  • Execute: SIMATIC Manager -> File -> Archive -> Multiproject (.zip)
   │  • Open Master Data Library (MDL) -> Blocks folder
   │  • Open CEMAT v8.2 System Library -> Blocks folder
   │  • Copy updated CEMAT blocks (e.g. C_DRV_1D, C_VALVE) into Master Data Library
   ▼
[Phase 2: AS Block Type Update]
   │  • Select Master Data Library -> Options -> Charts -> Update Block Types...
   │  • Select all target AS stations in the multiproject
   │  • Review interface changes (Check for changes requiring full download)
   │  • Complete block type update across all CFC charts
   ▼
[Phase 3: CEMAT Message Generation & OS Project Editor]
   │  • Run CEMAT Message Generator utility to refresh message class formatting
   │  • Open each OS Project -> Run OS Project Editor (updates GraCS and scripts)
   ▼
[Phase 4: Compilation and Commissioning]
   │  • Compile CFC charts: Scope "Changes only" (or "Entire" if interfaces changed)
   │  • Perform Entire AS-OS Compilation
   │  • Download to target AS and OS stations

AS Block Type Update and OS Faceplate Synchronization

The following table details key technological blocks and their migration considerations:

CEMAT Block TypeFunction / DescriptionInterface Changes in v8.2Download ConsequenceC_DRV_1D (FB1001)Unidirectional Motor DriveAdded PROFINET diagnostic inputsDelta download supported if structural offsets retained.C_DRV_2D (FB1002)Reversing / Two-Speed DriveUpdated interlock status structuresDelta download supported in most configurations.C_VALVE (FB1003)Process Valve ActuatorExpanded monitoring time inputsCheck interface compatibility before updating.C_MEASUR (FB1004)Analog Measured ValueIntegrated gradient monitoringRequires checking analog alarm limits in WinCC.C_GROUP (FB1010)Group Control / Route SelectionModernized group display faceplatesUpdate @PG_C_GROUP... in GraCS via OS Project Editor.

Verification

To confirm that the CEMAT v8.2 migration has succeeded:
1. In SIMATIC Manager, select Help -> About -> Installed Software; verify that CEMAT displays Version 8.2.
2. Open any CFC chart containing a CEMAT motor block; confirm the block version in Object Properties shows 8.2.
3. Compile CFC charts and verify that the compiler logs 0 errors and 0 missing block warnings.
4. Launch WinCC Graphics Designer; open @PG_C_DRV_1D_Standard.pdl and verify that the updated v8.2 faceplate layout renders correctly.
5. In WinCC Runtime, test an operational drive; confirm that start/stop commands, interlock trips, and alarms function cleanly.

Limitations and Operational Precautions

If block interface updates introduce new internal parameters that alter instance DB layouts, delta downloads to running controllers will be blocked, requiring an AS STOP mode download. Always perform block type updates and delta compile tests on an engineering simulation station (S7-PLCSIM) prior to touching production controllers.

Engineer FAQ

Where can I find the official CEMAT v8.2 upgrade documentation?

Refer to the Siemens Industry Online Support (SIOS) Product Note Entry ID 109739305 and the CEMAT v8.2 Migration Manual included on the CEMAT installation media.

Can I run CEMAT v8.1 blocks in a PCS 7 v8.2 project?

While legacy blocks may compile, operating mixed library versions is strongly discouraged. It causes faceplate graphic mismatches, missing PROFINET diagnostics, and script errors in WinCC.

Does CEMAT v8.2 require updating SIMOCODE firmware?

SIMOCODE pro V PN units operate with existing firmware, but to utilize the new diagnostic features of CEMAT v8.2, SIMOCODE firmware V1.4 or higher is recommended.

Why did custom faceplate modifications disappear after running OS Project Editor?

OS Project Editor restores standard Siemens template files. Custom faceplate changes must be maintained in user-defined files or re-applied using project-specific overrides.