STRATEGY FOR SIMATIC® PCS7/505 MIGRATION TO zenon® SCADA

© 2013 - NAPA INTERNATIONAL FRANCE

What is Simatic®PCS7/505 ?SimaticSimatic®® PCS7/505 was a migration solution proposed by Siemens PCS7/505 was a migration solution proposed by Siemens®® to replace to replace SimaticSimatic®® PCS OSx SCADA systems. This solution used a Database PCS OSx SCADA systems. This solution used a Database Automation tool (DBA) to import the APT objects in the SCADA database.Automation tool (DBA) to import the APT objects in the SCADA database.•SimaticSimatic®® PCS Osx was marketed by SiemensPCS Osx was marketed by Siemens®® from 1994 until 2004. from 1994 until 2004.•SimaticSimatic®® PCS7/505 was marketed by SiemensPCS7/505 was marketed by Siemens®® from 2005 until 2013. from 2005 until 2013.

Today’s situationToday’s situation

SimaticSimatic®® PCS7/505 is phased out by SIEMENS®

It is thus getting hard to obtain spare parts and not possible to order new licenses

Users are looking for replacement solutions:

• On the Control Level (SimaticSimatic®® 505 CPU’s are obsolete)

• On the Programming Level (Tisoft ® and APT® are obsolete)

• On the network Level (Sinec® H1 is obsolete)

• On the SCADA Level (Simatic® PCS7/505 is discontinued)

What are your options?What are your options?

An obvious choice on the Control Level is to use CTI 2500 Series® PLC’s & CPU’s.

CTI products are compatible mechanically, electrically, and software wise: the existing Tisoft®/ WorkShop® or APT® programs run

without requiring any modification.

The Control LevelThe Control Level

The APT replacement product is the only software on the market to directly replace the discontinued APT software. The APT replacement product, together with the CTI 2500 Series™ PLCs, extends the APT programming languages for years to come and eliminates the need to migrate to another hardware or software platform. The APT replacement product supports all APT languages, and may be used to maintain existing APT-based PLC programs, as well as write new programs. The APT replacement product offers the same functionality APT users are accustomed to within a modern, Windows® environment: •APT program import: load any existing APT program•Solution Explorer: directly access multiple PLC programs and program components•Configurable User Interface: customize windows•Advanced Editors: increase programming efficiency for CFC, SFC, MATH•Module Editor: configure 505 I/O•Profibus Editor: configure Probifus I/O•Compiler: convert program into PLC logic•Download program: load compiled logic to PLC•On line Debug and Data Charts•The APT replacement product is currently available as a beta software and will be released in 2014

The Programming LevelThe Programming Level

100% compatibility

100% compatibility

The APT Library works together with a zenon® wizard which reads the INSTALL.TAG file from APT and generates all required variables, alarms, trends and functions automatically.

The Programming Level: The Programming Level: APT APT WizardWizard

APT Library objects505 Tag Name Description PCS 7 Tag Structure

AI Analog Input 505_AI – 16 external tagsAO Analog Output 505_AO – 5 external tagsDI Digital Input (including 1 bit and multiple bit) 505_DI – 4 external tagsDI10 10 bit Discrete Input 505_DI10 – 5 external tagsDO Discrete Output 505_DO – 5 external tagsDO10 10 Bit Discrete Output 505_DO10 – 15 external tagsVLV1 Single Feedback Valve 505_VLV1 – 10 external tagsVLV2 Dual Feedback Valve 505_VLV2 – 10 external tagsRMTR Reversible Motor 505_RMTR – 10 external tagsMTR1 Non-reversible Motor 505_MTR1 – 10 external tagsMTR2 Two Speed Motor 505_MTR2 – 10 external tagsCALC Calc Variable 505_CALC – 4 external tagsIVAR Integer Variable 505_IVAR – 4 external tagsTMR Timer 505_TMR – 5 external tagsCTR Counter 505_CTR – 4 external tagsLOOP Loop 505_LOOP – 21 external tagsTEXT Three text strings 505_TEXT – 4 external tagsN/A 505 PLC 505_PLC – 10 external tags

The CTI 2500P-ECC1 Ethernet Communication Coprocessor :•optimizes the communication between CTI CPU’s and the zenon® SCADA system•provides an easy solution to replace obsolete peer-to-peer communications by means of a user friendly configuration tool

The Network LevelThe Network Level

3 protocols are currently supported:•CAMP (CTI ASCII Messaging Protocol)

– Server and Client (includes multicast)– Allows communication with 2572, 2572-A, and 2500 Series®

Processors, HMI which support CAMP (or OPC)

•Open Modbus (Ethernet) – Modbus Server– Modbus Client

•Network Data Exchange – Shares with other 2500P-ECC1 and CTI HMI panels– Publish/ Subscribe Model– Publish based on change in value

The CTI 2500P-ECC1 Ethernet Communication Coprocessor both :•optimizes the communication between CTI CPU’s and SCADA systems •provides an easy solution to replace obsolete peer-to-peer communications by means of a user friendly configuration tool

The Network LevelThe Network Level

• Separate Ethernet Network to connect CTI PLC’s to zenon® server PC’s• Separate Ethernet Network to connect zenon ® client PC’s to zenon ® server PC’s• Possibility to merge both networks on a single Ethernet media• Possibility to use optical ring network• NAPA can propose the solution that suits your topology requirements, with a wide

range of managed and unmanaged Ethernet switches

Our solution replaces Simatic® PCS7/505 with zenon® Supervisor.

Hardware architecture will depend on your needs and can include:

• Single or redundant zenon® servers

• Standard zenon® clients

• Optional Historian connection to external SQL® or Oracle® database

• Optional Web servers (possibly redundant)

PLC communication to CTI CPU’s uses a dedicated CTI driver over Ethernet TCP/IP

The SCADA LevelThe SCADA Level

The SCADA LevelThe SCADA Level

Copa-Data is an Austrian company specialized in HMI and SCADA software. Its product, zenon®, is powerful, hardware independent, Windows®-based, stable over 3 decades and continuously improved with new exciting features, such as multi-touch.

The SCADA LevelThe SCADA Level

EngineeringYou can develop projects in your own exact style, use available templates and intelligent wizards. Once created, you are able to reuse objects in other projects and keep an overview with the multi-project administration, also when working with a team.MaintenanceWell documented and offering version administration, you can quickly find your way around any project and also easily access projects and equipment remotely.Hot reloadThe Hot Reload enables changes to be made during a running operation, while your production keeps on running.ReportingReal time process views, historical trends, alarms and events, you will be informed of whatever is happening in as detailed a way as you wish. Starting with history of changes in engineering, up to effective reports in the runtime.

The SCADA LevelThe SCADA Level

RecipesComplex recipes can be easily and securely modified even during the Runtime. A dedicated screen enables the user, to call up only the part that needs to be changed and adjust the necessary parameters directly in the screen.NetworkFull data security, maximum availability without downtimes and no loss of data is guaranteed. zenon® network technology with seamless redundancy and circular redundancy makes it possible. zenon® is impressive not just technically, but also economically.Securityzenon® is continually being adapted to modern safety standards. This provides stable and safe equipment running.Powerzenon® Logic is an integrated IEC-61131 soft-PLC which can run in your zenon® servers to process some piece of logic in interaction with zenon® SCADA. This would allow possible automation of your recipes to PLC in a logical sequence.

The SCADA LevelThe SCADA Level

… AND MORE AND MORE OPTIONS:

Remote Maintenancezenon® Message Control allows to send SMS or e-mails to your maintenance people using a simple modem.Dual Screen and Multi-ScreenIt is easy to configure several screen on your zenon® interface in any arrangement.Extended Trend and ArchivingStore the data you need for how long you need.Web ServerUp to 10 (or more) simultaneous connections of your company network PC’s as zenon® Web Client using a web browser (Internet Explorer 8, Firefox, Safari or Chrome). Historian SQL ServerThis allows transparent evacuation of archive data into any SQL data base after a definable time. The connection to the original archives remains active. So all zenon® modules (Extended Trend Module, Report Generator...) can transparently access data evacuated in this way, e.g. display archive data as if they still were stored in the internal zenon® archive files.

• Support for the APT library objects• Consistent look & feel of the faceplate library• Easy customization of faceplates with standard editor

The SCADA Level The SCADA Level APT Library with familiar Look & Feel

Operator quickly becomes familiar using zenon® interface: minimum training of personnel required

The SCADA Level The SCADA Level APT Library with familiar Look & Feel

Color conventions are centralized in palette for easy tuning to customer requirements

Large standard library of devices to integrate and customize your APT library

The SCADA Level The SCADA Level APT Library : Object Oriented

NAPA servicesNAPA International France and its partner network is able to provide you with complete turn-key migration services.

With their combined experience of PCS7/505® and zenon®, our engineers provide the best migration approach: Using zenon® modern features while keeping a similar look and feel interface to minimize training of your operator and maintenance staff.

NAPA International France also offer secure remote support contracts.

CONCLUSIONNAPA International France and its partner network is able to provide you with the most cost effective migration solution of your complete process control system while drastically reducing risk compared to any other solution on the market :

• No replacement of your existing PLC hardware

• No reprogramming of your existing PLC programs

• Optimal migration from legacy proprietary technology to standard Ethernet TCP/IP network

• Modern, powerful, state-of-the-art SCADA system

CONCLUSION• Further extend the total life cycle of your initial investment• Minimized investment for several more decades

NAPA INTERNATIONAL France 1545 Route Nationale 7 - Marina 7

06270 VILLENEUVE – LOUBETFRANCE

Support :

Carlo Maris : +33 4 92 02 44 07Mario Riccardi : +33 4 93 20 93 93

Technical questions : support@napa.fr

Commercial issues : sales@napa.fr

and visit our web site at: http://www.napa.fr/en/