Migration SIMATIC S5 to S7

In lots of machines and installations there are working PLCs SIMATIC S5, which are not produced any more. S5 controllers are really good equipment, but availability of spare parts is not so good, and delivery time can be even over 30 days (specially for CPUs, specialized PID modules, communication modules...). And finally, Siemens increase price for SIMATIC S5 year by year. 

We have to remamber few details about SIMATIC S5:

• production of SIMATIC S5 was stopped in year 2003 (it is over 5 years),
• production of spare parts will be stopped in 2015,
• SIMATIC S5 modules nad CPUs are not compatible with SIMATIC S7,
• conversion by "automatic tools" in 90% of cases wil be no enought.

Because of experience of our engineers, one of our specialization is migration (modernization) of control systems based on out of services SIMATIC S5 to the newest systems based on SIMATIC S7 (also PCS 7 solutions). Our experience in this kind of modernizations and lots of successfully finished projects, contribute to undertake migrations of even very complicated control systems.

Migration procedure is not so easy as it seems. In many cases of automatic conversion, converting software lists lots of errors and warnings, which are not corrected automatically. Correcting of this kind of errors is very difficult and inconvenient, and often causes incorrect work of application. Sometimes, this kind of errors appears after few weeks of correct working machine. Correct way of migration ensure only full understanding of algorithm, which work in SIMATIC S5. After recognition of algorithm it have to be implemented in SIMATIC S7. This way of migration is possible only for engineers, who knows both systems (SIMATIC S5 and SIMATIC S7). In other cases, there is possibility, that migrated system will be not stable and it can cause even damage of machines / production lines.

Additional problem connected with migration of systems based on SIMTIC S5 is very often lack of actual copy (backup) of software which is responsible for controlling whole system. Next problem is lack of parameters for specialized modules. The worst case is when CPU is out of order and there was either EPROM or software backup. In this cases reproducing of control algorithm and sequences takes lots of time. To be secured from this kind of coincidence, we recommend to make backups of control software, which is working in your machines and production lines. We can do it for you. 

It happens, that during exploatation, controls cabinets are modyficated. Many times, there are new devices added into it - eg. frequency inverters, new contactors. There is not enought ventilation, isolation sometimes even wires are not tighted correctly. In this cases, possibility of system failure increase, and troubleshooting time becme longer. Many times maintenance service have problems with finding correct signals and devices.

In this cases we propose migration (replacemnt) of whole control cabinets which are connected with SIMATIC S5 PLC. We ensure complex realization - from identification of existing signals, software analysis, thru preparation of new electrical documentation, software, assembly to system commisioning and service.