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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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Automation solutions for today and tomorrow
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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Automation solutions for today and tomorrow
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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Automation solutions for today and tomorrow
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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Automation solutions for today and tomorrow
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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Automation solutions for today and tomorrow
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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Automation solutions for today and tomorrow
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.
In developmentIn development
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
In developmentIn development
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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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Siemens EtherNet/IP™ Solutions
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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Siemens EtherNet/IP™ Solutions
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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Siemens EtherNet/IP™ Solutions
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
Packaging machine
Rockwell• Allen Bradley SLC 500• Panelview• AMCI Resolver
Siemens• SIMATIC S7-1500• SIMATIC Basic Panel• SIMOTICS Encoder
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Rockwell conversion example
Controller program structure
Similar program structure for maintenance personnel
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Rockwell conversion example
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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Rockwell conversion example
Controller program logic structure
Ladder logic is ladder logic
Similar symbols
Comments are the same
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Rockwell conversion example
Controller tags
Tag names nearly identical
Similar addressing
Comments are the same
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Rockwell conversion example
HMI structure
Same screen names
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Rockwell conversion example
HMI tags
Tag names nearly identical
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Rockwell conversion example
HMI screens
Similar look and feel
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Rockwell conversion example
New diagnostic features
Integrated Controller display• Hardware diagnostics• Machine diagnostics• Command functions• System Maintenance• No PC required• Password protected
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Rockwell conversion example
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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Page 53
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