upgrading siemens simatic s5 to s7 siemens ag decided to discontinue it (2003) and then cease its...

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  • Copyright 2018www.ashellas.com


    For businesses to remain competitive in the

    long term, their equipment should adapt to

    the ever-increasing demands. In recent

    years, the upgrading needs of obsolete

    systems are unusually high, following several

    years of economic crisis with very little

    capital investment in upgrading. As a

    consequence, maintenance teams struggle

    to implement plant improvement projects and

    support the plant’s outdated hardware and

    software. The inability to gather and analyze

    meaningful data prohibit the engineers to

    make the right decisions while production

    costs are mounting.

    The need to upgrade the system is becoming


    One of the most common upgrades we

    encounter is of SIEMENS SIMATIC S5, one of

    the most popular automation systems in the

    world. SIMATIC S5 is not supported by

    SIEMENS anymore, and the company advises

    the migration to SIMATIC S7.

    Tassos Sifniadis Industrial Automation & Electrical Engineering Director Automation System Hellas


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    After nearly 30 years of production of the successful SIMATIC S5 series,

    SIEMENS AG decided to discontinue it (2003) and then cease its support

    (2013). During these years, the next series S7-200, S7-300, S7-400 and S7-

    1200 appeared, and finally, a few years ago, SIEMENS introduced the latest

    generation SIMATIC S7-1500 series.

    In recent years SIEMENS has developed the TIA PORTAL software, which has special features and built-in

    PLC and HMI / SCADA programming functions. TIA PORTAL supports the programming of the S7-1200 and

    S7-1500, S7-300 and S7-400 series PLCs. It also supports the programming of SIMATIC HMI Panels (Basic,

    Advanced) as well as the SCADA WinCC Advanced, Professional software.

    Upgrading automation system to SIMATIC S7

    Note that from the SIMATIC S7 family, the S7-200 is already in the process of withdrawing, with the S7-1200

    series being the preferred option. Also, the monitors (HMIs) of the old series OP, TP, MP are in the process of

    withdrawal and their replacements are the new series Basic and Comfort HMI Panels.


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    Disadvantages of maintaining the SIMATIC S5 systems

    Operational Production disruption due to material malfunction is more frequent and repair takes much longer, compared to modern systems

    Qualitative There is a gradual reduction in the quantity and quality of production

    Financial  High hardware maintenance costs:

    SIMATIC S5 family spare parts inventories are now scarce, hard to find, and at a particularly high cost.

     High Software Maintenance Costs: Technical support for SIMATIC S5 automation systems is done by very few engineers and at considerably higher costs compared to the latest systems.


  • Copyright 2018www.ashellas.com

    Why upgrading is necessary

    • Improving the monitoring of energy consumption

    • Savings from avoiding a new installation

    Cost Reduction

    •Flexibility in interfacing with MES, ERP systems

    •Easier communication with other PLCs


    •Easier compliance with environmental, health & safety regulations


    • Easier and safer (eg via VPN) remote support

    • Improve monitoring of installation equipment and production process

    Monitor & Control

    • Improve standardization of production products

    • Improving the security of automation systems against malware

    Quality & Safety

    • Increase the reliability of automation materials

    • Increase processing speed and PLC capabilities

    • Increasing the efficiency of the existing equipment and its lifetime

    • Increased production due to reduced downtime

    • Reducing production breaks due to greater flexibility in faulty repair

    • Improve production planning •Full technical support from a

    large number of companies • Greater capabilities to expand

    with lower costs


    The main benefit of the upgrade is to reduce production costs and increase productivity, ultimately increasing the company's competitiveness.


  • Copyright 2018www.ashellas.com

    The upgrading procedure of SIMATIC S5 to S7

    Upgrading each system is a complex process and many

    different parameters have to be taken into account as the

    requirements of each installation differ. SIEMENS has taken

    care of both hardware and software, to support the necessary

    migration interventions of S5 systems in the most efficient way.

    This is done having developed specific tools that help smooth

    transition from the old system to the new one.

    AS Hellas, as a SIEMENS Solution Partner, is well aware of

    their use and has standardized the upgrade process to require

    minimal interference in an industry's production schedule. Thus,

    a seemingly complex intervention is transformed by AS Hellas

    into an organized transition to the new system.

    Before the upgrade After the upgrade

    Some of our installed systems SIEMENS SIMATIC S7


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    Automation System Hellas

    AS Hellas discusses with the client the complexity

    of the system and the requirements of its

    installation, and plans the transition by minimizing

    the risks of this process. It takes into account the

    production schedule and the maximum allowable

    interruptions of production and performs the

    transition process in a flexible manner to the

    shortest possible duration.

    Contact us to inform you about the upgrade

    capabilities of your plant's automation system.

    http://www.ashellas.com/ mailto:info@ashellas.com?subject=Automation%20Upgrade

    Slide Number 1 Slide Number 2 Slide Number 3 Disadvantages of maintaining the SIMATIC S5 systems Why upgrading is necessary The upgrading procedure of SIMATIC S5 to S7 Automation System Hellas

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