Migrating SIMATIC S5 to S7-1500: The Strategic Upgrade for High Availability

Risks of Staying with SIMATIC S5

Legacy SIMATIC S5 systems, discontinued in 2006, with discontinued manufacturer technical support in October of 2015, pose significant risks to production processes. The limited availability of spare parts, outdated technology, and shortage technical support increase the risk of unexpected failures and costly downtime. These systems cannot integrate easily with modern technologies, such as advanced diagnostics, cybersecurity features, and digitalization initiatives—essential elements for staying competitive in today’s market.

Implementing the current restrictive safety standards, becomes nearly impossible using the S5 controllers. Futheremore, a sudden hardware failure could mean a long downtime in production, as finding replecement parts becomes more and more like looking for a needle in a haystack. For manufacturing businesses, the rising maintenance costs and operational risks mean that sticking with SIMATIC S5 is no longer viable.

Benefits of Migrating to SIMATIC S7-1500

1. Increased Performance: The S7-1500 offers dramatically faster processing times, up to 30 times faster than S5 systems. This translates to better throughput, more accurate control, and smoother operations.
2. Enhanced Security: Built-in cybersecurity features help protect critical production systems from external and internal threats.
3. Scalability and Flexibility: The modular architecture of the S7-1500 allows for easy expansion, adaptation to new technologies, and integration with modern communication standards like PROFINET.
4. Advanced Diagnostics: The S7-1500 includes integrated diagnostics for faster fault detection and resolution, reducing downtime and enabling predictive maintenance.
5. Compatibility with Modern Technologies: S7-1500 supports integration with Industry 4.0 technologies, data collection, and analysis tools that enable smarter, more efficient manufacturing.

Important Steps in the Migration Process

Migrating a control system isn’t just about swapping the hardware - it’s a complex process that demands careful planning and execution. Here are the key steps involved:

1. Initial Assessment: Conduct a detailed audit of your current S5 system to understand the scope of the migration. This includes inventorying existing PLCs, I/O modules, HMI panels and communication networks. Identify critical production areas that require minimal downtime and plan accordingly.
2. Detailed FAT (Factory Acceptance Testing): Software Testing: Ensure all control logic is properly translated from S5 to S7. Migration tools can automate parts of this process, but manual adjustment of complex logic will often be necessary. Hardware Testing: Conduct FAT to validate the hardware functionality of the new S7-1500 CPU, I/O panels, and Motor Control Cabinets (MCC). This ensures that the new system communicates flawlessly with all components.
3. SAT, Testing Phases: Dry Runs and Simulations: Perform extensive simulations and dry runs of the new system to detect any inconsistencies before the actual switch. Stress Testing: Ensure the new system can handle full production loads under various conditions to eliminate potential performance bottlenecks.
4. Seamless Switch-Over: Downtime Minimization: Carefully plan the migration to align with scheduled maintenance windows or other periods of low production. This helps minimize the disruption to normal operations. Fallback Strategy: Develop a rollback plan in case the new system encounters issues during commissioning. Retaining the ability to switch back to the S5 system ensures production can continue while troubleshooting the new setup.

Whenever it is possible try to conduct on site testing in two stages:

1. At first, connect the new S7-1500 PLC to the existing infrastructure and run the production to test all possible cycles and scenarios. When you make sure that the migrated logic works as expected, then plan the stage two.
2. Stage two – plan and execute the hardware switch-over. Since you know that the logic works fine, if any error occurs, you know where to look for potential mistakes – the wiring.

The Importance of Choosing the Right Partner

Not every system integrator is equipped to handle the complexities of an S5 to S7-1500 migration. While Siemens provides a list of certified solution partners, the partner you choose must have deep expertise in upgrading legacy systems and expertise in a specific industry. Experience matters, especially since many aspects of the S5 logic will need manual conversion.

Future-Proof Your Operations

The transition to SIMATIC S7-1500 is more than an upgrade; it’s a strategic decision that positions your manufacturing process for the future. With improved performance, enhanced security, and the ability to integrate with modern technologies, S7-1500 brings your operations up to speed with the demands of the modern industrial landscape.

Do you feel like you need a support?

We’ve built our reputation by delivering seamless, efficient migrations with minimal disruption to production. Our experience spans a variety of control systems across diverse industries, such as automotive, food & beverage, chemicals, etc. By choosing us as your partner, you’ll benefit from:

• Expertise in both automated and manual code migration from S5 to S7.
• Deep understanding of Siemens hardware and software, ensuring quick problem-solving when unexpected challenges arise.
• A strategic approach to testing and validation, ensuring that your new system runs flawlessly from day one.
• A commitment to limit downtime and maintaining production schedules.

And more to make your migration a success, ensuring that your production processes are as efficient and secure as possible.