usa.siemens.com/modernize Modernization made easy: A step … · 2015-12-15 · Modernization made easy: A step-by-step guide ... Support Global and local sales and support in 190

Unrestricted / © Siemens AG 2015. All Rights Reserved. Digital Factory

Modernization made easy: A step-by-step guideFuture-focused technologies for today‘s Digital Enterprise

usa.siemens.com/modernize

Unrestricted / © Siemens AG 2015. All Rights Reserved.

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Table of ContentsYour future-focused partner 3Modernizing with Siemens Digital Enterprise 4Why Siemens? 5Why not just stay with my current vendor? 6Automation solutions for today and tomorrow 7-10Best-in-class individual components 11Support and consulting services 12-13Migration steps 14-26Modernization tools 27-35Siemens EtherNet/IP solutions 36-41Rockwell conversion example 42-52Contact Us 53


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Your Future-Focused Partner

To meet your customers’ expectations, you have to find new and innovative ways to

reduce time-to-market

enhance flexibility

increase efficiency

How Siemens Helps:

We’re your future-focused automation partner that can help you adapt to— and capitalize on —the furious pace of change in today’s global economy.


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Modernizing With Siemens Digital Enterprise

How Siemens enables the Digital EnterpriseWe help you leverage the latest automation technologies to build what we call the “Digital Enterprise.”

What is the Digital Enterprise? A holistic approach that covers the entire product lifecycle, from product design to production planning, production engineering, production execution and, finally, services.

Our Digital Enterprise Software Suite enables customers to complete the steps of the production lifecycle simultaneously rather than sequentially (the traditional method).

The result: improved productivity and efficiency.


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Why Siemens?

Return on investment TIA Portal—may reduce your engineering time by up to 30%

Productivity Integrated “no programming” diagnostic capabilities

Transparency Remote monitoring: Connect to existing third-party controllers for data sharing and move information to today’s MRP systems.

Leading Technology State-of-the-art portfolio, including SIMATIC S7-1500 controller

Safety Safety Integrated: Comprehensive portfolio of control, drive and switching technology

Security A comprehensive, integrated approach for the protection of plant, network and system security.

Support Global and local sales and support in 190 countries


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Why not just stay with my current vendor?

Siemens makes modernization easy with:

conversion tools a step approach

trainingsupport

state-of-the-art technologies to sustain future

growth

Obsolete ProductsYou may still need to:• Convert code to their new

programming software• Train your engineers and

maintenance personnel • Risk downtime during the

changeover


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Automation solutions for today and tomorrow


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A future-focused, totally integrated approach

Totally Integrated Automation (TIA)• An open system architecture that covers the

entire production process• Maximum interoperability across all

automation components

Minimized engineering time Reduced costs More flexibilityKey Benefits

TIA offers:• Consistent data management• Global standards• Uniform hardware• Software interfaces


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A future-focused, totally integrated approach

TIA optimizes the entire manufacturing process, leading to increased ROI

Improved engineering efficiency RESULT Lower design costsBENEFIT

Integrated communication tools RESULT Production flexibility

Technologies that protect personnel, machinery and the environment RESULT Improved safety

Integrated diagnostic functions RESULT Minimized downtime

Integrated security functions RESULT Enhanced plant and network security

Single, streamlined database RESULT Optimized data quality

More access to data RESULT Better decision making

Global standards RESULT Simplified implementation of automation solutions

Interoperability of system-tested components RESULT Improved overall performance


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The TIA Portal

TIA Portal = up to 30% reduction in engineering time!

The key to unlocking the full potential of TIA is our TIA Portal — A single engineering framework that seamlessly integrates:1. Controllers2. Distributed I/O3. HMI panels4. Drives, motion control

and motor management

Features that enable reduction of engineering time transparency and diagnostics include:• Integrated “no programming” diagnostics• One common tag database• Ability to create custom libraries• An overall project management tool• Intuitive system functions• Time-saving functions (such as online/offline

comparisons, pictorial system view with online diagnostics, no-PC-required trace)


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Best-in-class individual components

Upgrade individual products with:• Ease of integration with existing assets• Easy-to-configure hardware and software• Resolution of maturity/obsolescence issues • Features to support flexibility and competitiveness• Flexibility to support various network protocols,

including PROFINET and EtherNet/IP


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Support and consulting services

Industry Online Support SiteResource for comprehensive info, FAQs, and application examples for all products, systems and services in the fields of automation and drives

Technical and Engineering Support24/7 support for all inquiries about functionality, handling and fault clearance ofSiemens industrial products

Global SupportAvailable in 190 countries; Standardized global part numbers and ease ofcommunication in your preferred language

Regional Application EngineersProvide local assistance

Experienced Global Network of Certified Solution Partners Extensive industry knowledge using Siemens components to implement tailored solutions for specific applications and timetables


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Training Services

A workforce improvement program that is customized to your exact learning needs.

Assess Define Implement

Courses include:

• Product

• Safety

• Certification learning programs

Course delivery methods:• In-person• Virtual instructor-led• Digital

Siemens Standard Support Services reduce your total cost of ownership:• No Charge single, toll-free

number with live operators• No Charge standard

technical support until product maturity during normal business hours

Our training services help you:

Manage


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Modernize your operations, start-to-finish


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Modernization made easy: A step-by-step guide

Migration Steps

1 2 3 4 6 7 9 1085Physically inspect application / machine for fit, networking and function

Obtain a copy of the current documentation for hardware and software

Develop the hardware solution

Migrate control code

Add advanced diagnostics

Test the application using simulation

Update documentation

Install on-site

Start up on-site

Train plant personnel

INSPECT OBTAIN DEVELOP MIGRATE ADD TEST UPDATE INSTALL START TRAIN


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Modernization made easy: A step-by-step guide

Flow chart: Start-to-finish steps to modernize your operations

Physically review the system to be migrated

START

END

Determine the panel space and locale space for mounting an additional panel if required

Get drawings of the physical application and a copy of the application program

Analyze the current I/O and determine if special hardware is being used

Cross reference the I/O to appropriate SIMATIC I/O

Modify and documentthe updates to theapplication hardwareand software

Modify and release thefinal drawings for theapplication

Archive the applicationcode

Get acceptance sign-offfrom customer

Deliver all documentationand drawings to thecustomer

Locate an appropriate Siemens solution for any special hardware being used such as that supplied by AB Encompass partners

If required to connect to a specific network, determine an appropriate gateway or SIMATIC solution

Migrate the existing AB programs using the TIA Migration Tool

In the event that a SIMATIC library function is not available for a specific AB function, create a SIMATIC library function and add it to the SIMATIC AB library

Create SIMATIC functions for any new hardwareor gateways that will be used

Create the Main calling routine(s)

Add PROGRAM_ALARM for diagnostic messages to the S7-1500 display and HMI

Configure the HMI(s) in TIA Portal

Verify the HMIConnection(s)

Configure the HMI Tags

Configure the HMIGraphics

Configure the HMIAlarms

Configure the HMITrending

Configure the PLC/HMI security

Test the new configuration using simulation

Correct any issuesfound during simulation

Develop preliminarydrawings for theapplication using thenew SIMATIC hardware

Develop an operator/maintenance manualfor the plant

Take the new system to site and install it

Wire the IO using thefastest method possible

Adapt the networkconfiguration to the plantnetwork infrastructure

Startup and test thenew application

Choose and configure an appropriate SIMATIC PLC and configure it in TIA Portal

*AB refers to Allen-Bradley® owned by Rockwell Automation®


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Migration Steps

Physically inspect application / machine for fit, networking and function

1INSPECT

Fit• Examine existing panel spaces• Does new hardware fit into

existing spaces?• Space for new panel(s)?

Networking• Distributed I/O?• Drive(s) connectivity?• Connectivity to MES?

FunctionExisting control capabilities• Memory sizes• Execution time• I/O type• Specialized components

being used?• HMI(s)?

Physically review the system to be migrated

START

Determine the panel space and locale space for mounting an additional panel if required


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Migration Steps

Obtain a copy of the current documentation for hardware and software

2OBTAIN

HardwareWiring• Connectivity• Number of spares• Sensors used

Controller hardware• Controller• I/O• HMI

Networking details

Software• Symbols (tag names)• Comments• Structure• LogicGet drawings of the

physical application and a copy of the application program


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Migration Steps

Develop the hardware solution

3DEVELOP

Special Hardware NeedsUpgrade/change• Encompass partner productsGatewaysSensors

Cross Reference Control HardwareController• Memory size• Execution time• Networking support• Certifications

Choose and configure an appropriate SIMATIC PLC and configure it in TIA Portal

If required to connect to a specific network, determine an appropriate gateway or SIMATIC solution

Analyze the current I/O and determine if special hardware is being used

Cross reference the I/O to appropriate SIMATIC I/O

Locate an appropriate Siemens solution for any special hardware being used such as that supplied by AB Encompass partners

I/O• Module types• Quantity• Wiring• Panel fitDrivesHMI


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Migration Steps

Migrate control code

4MIGRATE

Create Equivalent Data Files or StructuresRetain current structure• Create equivalent data files

with tag names / commentsSymbolic • Create equivalent symbolic

arrays and commentsCreate New Logic• Required for new

hardware / gateways / sensors

Convert LogicRetain current structure• Create equivalent instructions

and calling structureSymbolic • Create new instructions and

calling structureIn the event that a SIMATIC library function is not available for a specific AB function, create a SIMATIC library function and add it to the SIMATIC AB library

Create SIMATIC functions for any new hardwareor gateways that will be used

Create the Main calling routine(s)

Migrate the existing AB programs using the TIA Migration Tool


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Migration Steps

Add advanced diagnostics

5ADD

Application-Specific Messages • For the integrated Controller

display• For the HMI display

Fast Machine DiagnosticsMaintenance without Development ToolsReduced Downtime and Production Loss

Add PROGRAM_ALARM for diagnostic messages to the S7-1500 display and HMI

Configure the HMI(s) in TIA Portal

Verify the HMIConnection(s)

Configure the HMI Tags

Configure the HMIGraphics

Configure the HMIAlarms

Configure the HMITrending

Configure the PLC/HMI security


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Migration Steps

Test the application using simulation

6TEST

Test without Hardware

Test Incrementally

Reduce Startup Time

Test the new configuration using simulation

Correct any issuesfound during simulation


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Migration Steps

Update documentation

7UPDATE

Ensure Proper Documentation for Plant Maintenance

Develop preliminarydrawings for theapplication using thenew SIMATIC hardware

Develop an operator/maintenance manualfor the plant


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Migration Steps

Install on-site

8INSTALL

Install New Control Hardware• Controller• I/O• Network components

(Distributed I/O)• HMI(s)• Sensors• Drive(s)

Install New Control Hardware• Disconnect/Connect

Take the new system to site and install it

Wire the IO using thefastest method possible

Adapt the networkconfiguration to the plantnetwork infrastructure


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Migration Steps

Start up on-site

9START

Startup and test thenew application

Verify I/O

Test Machine Operation

Make Changes as Necessary

Finalize Application

Finalize Documentation


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Migration Steps

Train plant personnel

10TRAIN

Hardware Training

Development Tools Training

Operator Training

Maintenance Training

Documentation OverviewEND

Modify and documentthe updates to theapplication hardwareand software

Modify and release thefinal drawings for theapplication

Archive the applicationcode

Get acceptance sign-offfrom customer

Deliver all documentationand drawings to thecustomer


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Modernization Tools

To access our complete offering, please visit: usa.siemens.com/modernization-tools.


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Modernization tools

Rockwell Automation® PLC-5® to SIMATIC S7 Application Conversion Guide

Provides guidance for users who have used legacy control systems based on Rockwell Automation Controller-5 or SLC-500.• Explains the major differences between

the Rockwell Automation control system and the SIMATIC S7 control system

• Describes and illustrates migration approaches

• Demonstrates a number of use cases


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Modernization tools

WinCC Tag Converter

Provides a fast and easy way to convert tags exported from the Rockwell Controller to a format that can be imported into WinCC (TIA Portal).Produces output for:• HMI systems • SIMATIC Panels• WinCC Runtime Advanced• WinCC ProfessionalProvides the ability to synchronize Rockwell tag data with WinCC (TIA-Portal). This allows WinCC panels to easily communicate with Rockwell controllers.


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Modernization tools

Open communication between Logix and S7-1200 / S7-1500

Provides a library for Rockwell ControlLogix/GuardLogix and SIMATIC S7-1200 / 1500 that allows communication via a standard protocol (TCP/IP) without using a gateway.

Libraries contain communication function blocks for the S7-1200 / 1500 to communicate with Rockwell Logix controllers.

Send

Receive

Send

Receive

CompactLogix

ControlLogix

S7-1500


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Modernization tools

EtherNet/IP™ connectivity

S7-1500 EtherNet/IP Function Block (GET/PUT)

Function Blocks for SIMATIC S7-1200 / S7-1500 to read/write data in a Rockwell controller via EtherNet protocols with no code changes in the Rockwell controller. Put

Get

Put

Get

CompactLogix

ControlLogix

S7-1500 •No Code Modifications Required

In developmentIn development


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Modernization tools

ProSoft gateways

PROFINET to EtherNet/IP™ Gateway • Provides simple connectivity

between controllers and periphery using a ProSoft* Gateway (PROFINET to EtherNet/IP).

• Using gateways from other vendors is possible.


Function Blocks• Function Blocks for

SIMATIC S7-1200 / S7-1500 to communicate EtherNet/IP to ProSoft Gateways for connectivity to Rockwell Automation legacy networks (AB RIO and DCSNet)

ProSoft third-party gateway

PeripherySystems Controllers

EtherNet/IP

PROFINET

Drives

SiemensProSoft gatewayDriver

FB in S7-1500

PeripherySystems Drives

ProSoft third-party gateway

ROK legacy fieldbus (RIO)

*ProSoft is owned by ProSoft Technology®:


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Modernization tools

FAQs (Frequently Answered Questions)

Sample FAQQ: How do I communicate with a Rockwell PLC from a Siemens HMI?

A: The answer demonstrates:• How to communicate with the maximum

data throughput between a Rockwell Controller and a Comfort Panel / Advanced Runtime using the included communication networking driver “Allen-Bradley EtherNet/IP.”

Rockwell Controller

SIMATIC HMI


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Modernization tools

Siemens Migration Studio

Migration Studio reads Rockwell software from…

RSLogix5 (Controller-5)RSLogix5 (Controller-5)

RSLogix500 (SLC 500)RSLogix500 (SLC 500)

Studio 5000 *(Compact-, ControlLogix)Studio 5000 *(Compact-, ControlLogix)

RSView32 (PanelView32)RSView32 (PanelView32)

Migration Studio converts…

data files (tags) code files (logic) program files tasks routines

Migration Studio exports to…

TIA Portal V13 SP1 Upd 1(Openness required)TIA Portal V13 SP1 Upd 1(Openness required)

WinCC Comfort AdvancedWinCC Comfort Advanced

Hardware ConversionHardware Conversion



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Modernization tools

ET200 converter

Quickly converts third-party order numbers (Rockwell –1734 Point I/O, 1756 ControlLogix, Beckhoff, etc.) into SIMATIC ET200 order numbers.• Optimizes conversion result automatically with regard

to the number of channels and type of connection

Via IntranetVia Intranet


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The EtherNet/IP™ Solutions family offers the flexibility to support both PROFINET and EtherNet/IP, and compatibility within any PLC. Solutions offer best-in-class features, and configuration to your existing network is fast and easy.

Siemens EtherNet/IP Solutions


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Siemens EtherNet/IP™ Solutions

Connecting ET200S I/O through EIP-200S adapter interface

EIP-200S adapter interface facilitates the connection of ET200S modules with EtherNet/IP networks.An application example demonstrates the setup, installation and use of the EIP-200S module with CompactLogix.


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SINAMICS Drives

Choose correct control module plus CBE20 board• SINAMICS G130 High-Horsepower

Modular Drive Components• SINAMICS G150 Enclosed Drives• SINAMCIS S120 High Performance /

Servo Drive System (In chassis, bookshelf, blocksize and enclosed cabinets) EtherNet/IP Connectivity

• SINAMICS S150 Enclosed Regenerative Drive• SINAMICS DCM DC Drives

CBE20 Communication Board

Choose correct Ethernet control module • SINAMICS G120 General Performance

Vector Drives (In compact, modular, distributed and enclosed versions)


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SIMATIC Ident – RFID and code reading solutions

Rockwell does not currently have a complete RFID solution.The RFID181EIP module acts as theinterface to anEtherNet/IP network.

RF 181EIP

Logix Platform

SIMATIC RF300SIMATIC RF200

SIMATIC RF600


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Networking Infrastructure / cabling

Wired / Wireless CommunicationsEtherNet/IP requires IGMP snooping, supported in the following products:• X-500• X-400• X-300• XB200EtherNet/IP is standard TCP/IP; the networking components just transport the information

FastConnectThe most superior cabling solution in the market components just transport the information


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Minimize Risk

Allows easier distribution, installation, license management and maintenance of Siemens Engineering Software at key, multi-site accounts with large numbers of users. Customers who have a long, trusting relationship with Siemens qualify for this program and are able to host Siemens Engineering Software without any copy protection on a centrally located server. This offers an economical solution for customers to maintain a large number of engineering software installations across multiple sites.

Enterprise License Program (ELP)One central software and license management location• Lean and efficient processes• Complete transparency of software use ensures compliance• Easy software inventory provides ad hoc reporting

Master Software DVD and reusable Master License Key• Time-saving and standardized installation• Immediate reinstallation in case of hardware crash or change• Existing current licenses can be applied to EPL

Easy software maintenance• Supports Engineering Software related to Automation and Drive

families• Provides more price stability and simplifies budgeting for the customer


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Rockwell Conversion Example


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Rockwell conversion example

Packaging machine

Rockwell• Allen Bradley SLC 500• Panelview• AMCI Resolver

Siemens• SIMATIC S7-1500• SIMATIC Basic Panel• SIMOTICS Encoder


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Controller program structure

Similar program structure for maintenance personnel


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Controller program file structure

Similar file-naming structure, but more intuitive

Siemens can still work with absolute data files • No need to convert to arrays


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Controller program logic structure

Ladder logic is ladder logic

Similar symbols

Comments are the same


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Controller tags

Tag names nearly identical

Similar addressing

Comments are the same


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HMI structure

Same screen names


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HMI tags

Tag names nearly identical


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HMI screens

Similar look and feel


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New diagnostic features

Integrated Controller display• Hardware diagnostics• Machine diagnostics• Command functions• System Maintenance• No PC required• Password protected


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Benefits

No surprises for maintenance• Controller program structure• Controller logic• Controller tags• HMI structure• HMI tags• HMI screens

Enhanced Diagnostics• Controller Display• Self configuring Ethernet devices• Web pages

ROI until mid-century

For a comprehensive set of tools to ease your transition, visit

usa.siemens.com/modernization-tools


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Contact Us

Contact Siemens today for a free consultation! 1-888-454-4704

Siemens Sales Representative

SiemensDistributor

Siemens Solution Partner

Or visit the web:

www.usa.siemens.com/saleslocator

www.usa.siemens.com/distributorlocator

www.usa.siemens.com/solutionpartnerlocator

usa.siemens.com/modernize Modernization made easy: A step … · 2015-12-15 · Modernization made easy: A step-by-step guide ... Support Global and local sales and support in 190

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