s57 optimacs processor - s5 to s7 plc upgrades

OptimaoIn control since 1995

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Optima S5 to S7 ConversionsThe risk-free upgrade option


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Optima S5 to S7 conversionsYour risks

What is this processor?

The new* S57 processor has been developed to run Step5 and Step7 programs simultaneously

How does this help the upgrade?

Program conversion can be taken in stages according to shutdown timescales

Are these the only benefits?

NO. Our upgrade route is unique and allows complete flexibility of hardware upgrades as well, be that SCADA systems or servo drives

* The processor, having successfully undergone beta-trials for over 3 years at key customer sites is now available for full release


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Optima S5 to S7 conversionsYour risks

Your problems:

CPU’s are now unsupported by Siemens

Specialist S5 modules can contain unsupportable code

Data held on EEPROM / Battery Backup – possibility of total data

loss on battery/EEPROM failure

Other systems connected to S5 are obsolete as well

PC’s running machine SCADA or other applications

Serial communication to Third party systems

Spares cost and availability:

*Prices obtained from Siemens A&D Mall 27th April 2009 for a 928 processor. Cheaper prices may be available for refurbished items


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Optima S5 to S7 conversionsWhat do I do first???

Up until now, the only option has been to take the machine down

completely and re-fit the entire PLC system including all ancillary items:

SCADA systems, operator HMI’s, Factory-wide automation monitoring

Do you know every function on every screen?

Recipes, trending, logging of data.

Are there even backup configurations for all these?

Serial/Ethernet communications with custom protocols

How do you know what protocol is used (this data held on EEPROM in processor

and only accessible with Siemens COM525 package and programmer – also now a

rarity)

After conversion, how do you know the protocol will still work with equipment


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Optima S5 to S7 conversionsWhat do I do first???

Function of dedicated option modules to be replicated

IP246 (Positioning)

IP244 (13-channel PID controller)

CP523 …544 (Communications)

All the above need to be rewritten and commissioned

Are you sure all functionality has been covered?

What if each module function could be converted step-by-step to S7 and even tested alongside the original?

Well, now it can!


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Optima S5 to S7 conversionsIs there another way???

What this solution offers:

Large machines carry large risks, so minimise the risk by reducing

the engineering at each stage

Take project stages one step at a time

Identify key functional areas – target these for upgrade

Fit key equipment in stages – even test side-by-side

Fully test new kit, then decommission old equipment

Number of shutdowns required can vary according to complexity and the time available


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Optima S5 to S7 conversionsCommon S5 Systems

Main S5 Hardware Systems are:

115U Rack

CPU 941, 942, 943, 944, 945

135/155U Rack

CPU 922, 928, 928B, 948

150U Rack

CPU 921, 922


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Optima S5 to S7 conversionsS5 Systems Supported

Rack types:

115, 135, 150, 155 U

U denotes a standard rack

115, 135, 150, 155 F

F denotes ‘Fault-tolerant’

115, 135, 150, 155 H

H denotes ‘High-availability’

This system only supports the U rack (most common)

Only single-processor racks are supported


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Optima S5 to S7 conversions115U series

The 115U Rack processor:

Replaces CPU’s

941

942

943

944

945

Designed to meet specification of the high-end processor 945

S7 operation equivalent: S7-416 high-performance processor


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Optima S5 to S7 conversions135U series

The 135U Rack processor:

Replaces CPU’s

922

928

928B

948

Designed to meet specification of the high-end processor 948



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Optima S5 to S7 conversions150 series

The 150 Rack processor:

Replaces CPU’s

921

922

Designed to meet specification of 922



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Optima S5 to S7 conversionsHow does it work?

The advanced S57 processor runs the S5 program and is programmed using Siemens SIMATIC STEP5 software *

The S57 processor also runs an S7 program and is programmed using Siemens SIMATIC STEP7 software

Machine operates exactly as with the original processor

New S7 code is written stage-by-stage and runs alongside the S5 program

New code activated in stages

All diagnostic features of STEP5 and STEP7 retained

Compatibility with all STEP5 and STEP7 FC’s, FB’s, OB’s, etc.* some re-work of S5 code may be required depending on program complexity and original processor type. For example, a 941 program is not directly compatible with a 945 processor

so this must be converted prior to install in S57 processor. Optima will advise and complete this all as part of the upgrade.


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Optima S5 to S7 conversionsOther shutdown options

In addition to converting the program from Step 5 to Step 7, other upgrade

options are:

Replace ageing SCADA or HMI systems with Ethernet based systems

Create new WinCC application to run alongside your existing SCADA system. Fully

test the new SCADA before de-commissioning you old system

Upgrade to new Siemens TP’s, MP’s with Ethernet capability

Create new PROFIBUS network and replace old networked devices with new

Remote Input/Outputs

New AC, DC or servo drive systems


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Optima S5 to S7 conversionsYour choice

Step 5 program ‘resides’ in FC 10001 and is called by UC command each S7 cycleStep 5 memory words accessible in Step 7 by offset of 40,000

Step 5 memory words accessible in Step 7 by offset of 40,000

Step 5 data blocks accessible in Step 7 by offset of 10,000Step 5 data blocks accessible in Step 7 by offset of 10,000


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Our S5 to S7 upgrades allow a degree of flexibility that no other provider can offer

Shutdown times to suit you

Pinpoint critical items

Software written by our Siemens Solution Partner qualified engineers


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The new S57-II Processor is now available!

On-board networks available using additional plug-in module

Super-fast program execution: <10ns operation time

4 x Ethernet ports each with a dedicated communication processor

Integrated e-mail client and Web-server onboard

Even more flexible upgrade opportunities

s57 optimacs processor - s5 to s7 plc upgrades

Technology

s5 program

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s7 conversions s5 systems

s7 program

supportedoptima s5

releaseoptima s5

u rack processor