Upgrading SIMATIC PCS 7 Systems Containing the CEMAT Minerals Library

In SIMATIC PCS 7 installations utilizing the CEMAT minerals and cement library, upgrading the system requires strict version alignment because each CEMAT release is certified exclusively for a single base PCS 7 version. Engineers cannot upgrade PCS 7 independently of CEMAT; a successful migration requires acquiring the matching CEMAT upgrade package, updating the Master Data Library, running block type synchronization across all CFC charts, and executing the CEMAT Check Tool before AS-OS compilation.

Strict Version Coupling: CEMAT and SIMATIC PCS 7 Releases

CEMAT is Siemens' comprehensive industry suite for cement, mining, and bulk solids automation. Unlike general-purpose Windows utilities, CEMAT deeply modifies the STEP 7 engineering database, CFC block compilers, WinCC faceplate engines, and OS Project Editor:
* One-to-One Version Coupling: Each major CEMAT release is strictly coupled to a dedicated PCS 7 version:
* CEMAT V8.0 is released exclusively for PCS 7 V8.0.
* CEMAT V8.1 is released exclusively for PCS 7 V8.1.
* CEMAT V8.2 is released exclusively for PCS 7 V8.2.
* CEMAT V9.0 is released exclusively for PCS 7 V9.0.
* CEMAT V9.1 is released exclusively for PCS 7 V9.1.
* Attempting to upgrade the base PCS 7 software (e.g., from V8.2 to V9.1) while retaining an older CEMAT library causes compiler incompatibilities, broken faceplate scripts, and compilation crashes.

Pre-Upgrade Prerequisites: Multiproject Archiving and License Validation

Before initiating software updates:
1. Complete Multiproject Backup: In SIMATIC Manager, perform a complete archive via File -> Archive with all AS stations, OS projects, and libraries included.
2. License Entitlements: Verify that Automation License Manager (ALM) contains the appropriate upgrade licenses:
* Base PCS 7 Upgrade License: Engineering and runtime upgrades.
* CEMAT Upgrade License: CEMAT Engineering and Runtime upgrade license keys (e.g., CEMAT Engineering V9.1).
* Final license quantities and MLFBs must be verified against official Siemens Industry Mall listings and authorized distributor quotations.
3. Hardware Compatibility Check: Cross-check existing controller hardware against the SIMATIC PCS 7 - Released Modules manual for the target version.

Step-by-Step Installation and Library Migration Sequence

Execute the upgrade across Engineering Stations and OS Servers following Siemens verified protocol:
1. Uninstall / Upgrade Operating System: Upgrade the host operating system to the certified Windows version (e.g., Windows 10 Enterprise LTSC or Windows Server 2019 for PCS 7 V9.1).
2. Install Base PCS 7 Software: Execute the primary PCS 7 setup, selecting Engineering Station or OS Server roles. Reboot the workstation.
3. Install Matching CEMAT Package:
* Run Setup.exe from the certified CEMAT installation media corresponding to the target PCS 7 version.
* Select the appropriate industry standard (e.g., Standard 001 Minerals, Standard 027 Lafarge, Standard 028 Holcim).
* Complete the setup and reboot.
4. Project Retrieval: In SIMATIC Manager, retrieve the archived multiproject.

Master Data Library Alignment and CFC Block Type Updates

To migrate the plant logic to the new CEMAT algorithms:
1. Open the project Master Data Library (MDL).
2. Copy the updated CEMAT blocks from the newly installed CEMAT library folder (C:/Program Files (x86)/SIEMENS/STEP7/S7LIBS/CEMAT/) into the project's Master Data Library.
3. In SIMATIC Manager, select the Master Data Library block folder and execute:
Options -> Charts -> Update Block Types....
4. Select all target Automation Stations. The wizard compares block signatures and updates block instances across all CFC charts.
5. Run the CEMAT Check Tool: Launch CematCheckTool.exe to scan the multiproject for object numbering collisions or unassigned group references.
6. Compile and Download:
* Execute an AS compilation with Generate module drivers enabled.
* Run the WinCC OS Project Editor on all OS servers to update system pictures.
* Execute an OS Compilation (Entire OS) to compile all tags and message definitions.

Verification

Run the CEMAT Check Tool: confirm that the multiproject validation reports 0 Errors.
Download the compiled program to an Automation Station: confirm that controllers transition smoothly to RUN mode without diagnostic buffer faults.
In WinCC OS runtime, open drive (C_DRV_1D) and group (C_GROUP) faceplates: verify that status indications, interlock displays, and operating commands function properly.
Open Alarm Logging: verify that CEMAT technological alarms populate with correct timestamps and text strings.

Limitations and Operational Precautions

Updating block types in CFC charts can alter block interface signatures, which may require placing the Automation Station in STOP mode for a full download if delta download capability is lost.
Never install CEMAT hotfixes intended for a different service pack or standard without explicit certification from Siemens CEMAT Product Management.
When upgrading redundant OS servers, always upgrade the standby server first and synchronize archives before switching over active operator control.

Engineer FAQ

Can I run CEMAT V8.2 on SIMATIC PCS 7 V9.1?
No, each CEMAT release is certified exclusively for a single matching PCS 7 version.
What happens if I upgrade PCS 7 without upgrading CEMAT?
CFC chart compilation will fail due to block compiler version mismatches, and WinCC faceplates will fail to open.
Where are updated CEMAT block types installed on the hard drive?
Under C:/Program Files (x86)/SIEMENS/STEP7/S7LIBS/ within the specific CEMAT standard library folder.
What utility verifies CEMAT project consistency after updating block types?
The standalone CEMAT Check Tool (CematCheckTool.exe) validates object numbers and message configurations.
Does updating CEMAT block types require a full AS download in STOP?
If internal block structures change between major versions, a complete download in STOP mode is typically required.
How do I preserve custom Lafarge or Holcim standard graphics during the upgrade?
Re-deploy the customized graphic files from the updated CEMAT add-on directory into the project's WinCC GraCS folder.
What license is required to engineer CEMAT in PCS 7?
A valid SIMATIC PCS 7 CEMAT Engineering license key registered in Automation License Manager.
Does CEMAT require dedicated WinCC OS Server licenses?
Yes, each OS Server running CEMAT requires a CEMAT OS Server runtime license package.
Can I migrate a CEMAT project directly across multiple major versions (e.g., V7.1 to V9.1)?
Multi-version migrations typically require intermediate migration steps (e.g., V7.1 to V8.2, then V8.2 to V9.1); consult the CEMAT Migration Guide.
Why must the OS Project Editor be run after a CEMAT upgrade?
To deploy updated CEMAT faceplate templates, script libraries, and screen navigation toolbars into the WinCC project.

Technical References

SIMATIC PCS 7 CEMAT Engineering Manual (V8.2 / V9.0 / V9.1)
Siemens Industry Online Support Entry: Upgrading PCS 7 Systems with CEMAT (Entry ID 299434)
SIMATIC PCS 7 Software Update Manual (without utilization of new functions)
CEMAT System Description and Migration Guidelines