upgrading siemens simatic s5 to s7 siemens ag decided to discontinue it (2003) and then cease its...
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UPGRADING SIEMENS SIMATIC S5 TO SIMATIC S7
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support the plant’s outdated hardware and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
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.
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.
Why upgrading is necessary
• Improving the monitoring of energy consumption
• Savings from avoiding a new installation
•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.
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
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.
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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