Download Digitalization with Totally Integrated Automation

usa.siemens.com/modernize
Modernization made easy: A step-by-step guide
Future-focused technologies for today‘s Digital Enterprise
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Digital Factory
Table of Contents
Your future-focused partner
3
Modernizing with Siemens Digital Enterprise
4
Why Siemens?
5
Why not just stay with my current vendor?
6
Automation solutions for today and tomorrow
7-10
Best-in-class individual components
11
Support and consulting services
12-13
Migration steps
14-26
Modernization tools
27-35
Siemens EtherNet/IP solutions
36-41
Rockwell conversion example
42-52
Contact Us
53
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 2
Your Future-Focused Partner
To meet your customers’ expectations, you have to
find new and innovative ways to
reduce
time-to-market
enhance
flexibility
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 3
increase
efficiency
How Siemens Helps:
We’re your futurefocused automation
partner that can help
you adapt to
— and capitalize on —
the furious pace of
change in today’s
global economy.
Modernizing With Siemens Digital Enterprise
How Siemens enables the Digital Enterprise
We 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.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 4
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 5
Why not just stay with my current vendor?
Obsolete Products
Siemens makes modernization easy with:
You may still need to:
•
Convert code to their new
programming software
•
Train your engineers and
maintenance personnel
•
conversion tools
a step approach
Risk downtime during the
changeover
support
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 6
training
state-of-the-art
technologies to
sustain future
growth
Automation solutions for today and tomorrow
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 7
Automation solutions for today and tomorrow
A future-focused, totally integrated approach
Totally Integrated Automation (TIA)
TIA offers:
•
•
•
•
•
•
An open system architecture that covers the
entire production process
Maximum interoperability across all
automation components
Key Benefits
Minimized
engineering time
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 8
Consistent data management
Global standards
Uniform hardware
Software interfaces
Reduced costs
More flexibility
Automation solutions for today and tomorrow
A future-focused, totally integrated approach
BENEFIT
TIA optimizes the
entire
manufacturing
process, leading to
increased ROI
Improved engineering efficiency
RESULT
Lower design costs
Integrated diagnostic functions
RESULT
Minimized downtime
Integrated communication tools
RESULT
Production flexibility
Integrated security functions
RESULT
Enhanced plant and network security
Technologies that protect personnel,
machinery and the environment
RESULT
Improved safety
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 9
Automation solutions for today and tomorrow
The TIA Portal
The key to unlocking the
full potential of TIA is our
TIA Portal — A single
Features that enable reduction of
engineering time transparency and
diagnostics include:
engineering framework that
seamlessly integrates:
1. Controllers
2. Distributed I/O
3. HMI panels
4. Drives, motion control
and motor management
•
•
•
•
•
•
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 10
TIA Portal = up to
30% reduction in
engineering time!
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)
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 11
Automation solutions for today and tomorrow
Support and consulting services
Industry Online Support Site
Resource for comprehensive info, FAQs, and application examples for all products,
systems and services in the fields of automation and drives
Technical and Engineering Support
24/7 support for all inquiries about functionality, handling and fault clearance of
Siemens industrial products
Global Support
Available in 190 countries; Standardized global part numbers and ease of
communication in your preferred language
Regional Application Engineers
Provide local assistance
Experienced Global Network of Certified Solution Partners
Extensive industry knowledge using Siemens components to implement tailored
solutions for specific applications and timetables
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 12
Automation solutions for today and tomorrow
Training Services
Our training services help you:
Assess
Define
Implement
Manage
A workforce improvement program that is customized to your exact learning needs.
Courses include:
•
Product
•
Safety
•
Certification learning
programs
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 13
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
Modernize your operations, start-to-finish
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 14
Modernization made easy: A step-by-step guide
Migration Steps
1
2
INSPECT
OBTAIN
Physically
inspect
application /
machine for fit,
networking
and function
Obtain a copy
of the current
documentation
for hardware
and software
3
DEVELOP
Develop the
hardware
solution
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 15
4
MIGRATE
Migrate
control
code
5
6
ADD
TEST
Add
advanced
diagnostics
Test the
application
using
simulation
7
8
UPDATE
INSTALL
Update
documentation
Install
on-site
9 10
START
Start up
on-site
TRAIN
Train plant
personnel
Modernization made easy: A step-by-step guide
Flow chart: Start-to-finish steps to modernize your operations
START
Physically review the
system to be migrated
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
Locate an appropriate
Siemens solution for any
special hardware being
used such as that supplied
by AB Encompass partners
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
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 hardware
or 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 HMI
Connection(s)
Configure the HMI Tags
Configure the HMI
Graphics
Configure the HMI
Alarms
Configure the HMI
Trending
Configure the PLC/HMI
security
Test the new configuration
using simulation
Correct any issues
found during simulation
Develop preliminary
drawings for the
application using the
new SIMATIC hardware
Modify and document
the updates to the
application hardware
and software
Develop an operator/
maintenance manual
for the plant
Modify and release the
final drawings for the
application
Take the new system to
site and install it
Archive the application
code
Wire the IO using the
fastest method possible
Get acceptance sign-off
from customer
Adapt the network
configuration to the plant
network infrastructure
Deliver all documentation
and drawings to the
customer
Startup and test the
new application
END
*AB refers to Allen-Bradley® owned by Rockwell Automation®
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 16
Migration Steps
Physically inspect application / machine for fit, networking and function
1
Fit
INSPECT
•
•
START
•
Physically review the
system to be migrated
Determine the panel space
and locale space for
mounting an additional
panel if required
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 17
Function
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?
Existing control
capabilities
• Memory sizes
• Execution time
• I/O type
• Specialized components
being used?
• HMI(s)?
Migration Steps
Obtain a copy of the current documentation for hardware and software
2
OBTAIN
Get drawings of the
physical application and a
copy of the application
program
Hardware
Software
Wiring
• Connectivity
• Number of spares
• Sensors used
•
•
•
•
Controller hardware
• Controller
• I/O
• HMI
Networking details
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 18
Symbols (tag names)
Comments
Structure
Logic
Migration Steps
Develop the hardware solution
3
DEVELOP
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
Special Hardware Needs
Cross Reference Control Hardware
Upgrade/change
• Encompass partner products
Gateways
Sensors
Controller
• 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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 19
I/O
• Module types
• Quantity
• Wiring
• Panel fit
Drives
HMI
Migration Steps
Migrate control code
4
Create Equivalent Data
Files or Structures
MIGRATE
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 hardware
or gateways that will be
used
Create the Main calling
routine(s)
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 20
Retain current structure
• Create equivalent data files
with tag names / comments
Symbolic
• Create equivalent symbolic
arrays and comments
Create New Logic
• Required for new
hardware / gateways / sensors
Convert Logic
Retain current structure
• Create equivalent instructions
and calling structure
Symbolic
• Create new instructions and
calling structure
Migration Steps
Add advanced diagnostics
5
Application-Specific
Messages
ADD
•
Add PROGRAM_ALARM
for diagnostic messages to
the S7-1500 display and
HMI
•
Configure the HMI(s) in TIA
Portal
Verify the HMI
Connection(s)
Configure the HMI Tags
Configure the HMI
Graphics
Configure the HMI
Alarms
Configure the HMI
Trending
Configure the PLC/HMI
security
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 21
For the integrated Controller
display
For the HMI display
Fast Machine Diagnostics
Maintenance without
Development Tools
Reduced Downtime and
Production Loss
Migration Steps
Test the application using simulation
6
Test without
Hardware
TEST
Test the new configuration
using simulation
Correct any issues
found during simulation
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 22
Test
Incrementally
Reduce
Startup Time
Migration Steps
Update documentation
7
UPDATE
Ensure Proper
Documentation
for Plant Maintenance
Develop preliminary
drawings for the
application using the
new SIMATIC hardware
Develop an operator/
maintenance manual
for the plant
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 23
Migration Steps
Install on-site
8
INSTALL
Install New Control Hardware
•
•
•
Take the new system to
site and install it
Wire the IO using the
fastest method possible
Adapt the network
configuration to the plant
network infrastructure
•
•
•
Controller
I/O
Network components
(Distributed I/O)
HMI(s)
Sensors
Drive(s)
Install New Control Hardware
• Disconnect/Connect
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 24
Migration Steps
Start up on-site
9
START
Startup and test the
new application
Verify I/O
Test Machine Operation
Make Changes
as Necessary
Finalize Application
Finalize Documentation
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 25
Migration Steps
Train plant personnel
10
Hardware Training
TRAIN
Development Tools
Training
Modify and document
the updates to the
application hardware
and software
Modify and release the
final drawings for the
application
Archive the application
code
Get acceptance sign-off
from customer
Deliver all documentation
and drawings to the
customer
Operator Training
Maintenance Training
END
Documentation Overview
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 26
Modernization Tools
To access our complete offering, please
visit: usa.siemens.com/modernization-tools.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 27
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 28
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 Professional
Provides the ability to synchronize
Rockwell tag data with WinCC (TIA-Portal).
This allows WinCC panels to easily
communicate with Rockwell controllers.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 29
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.
S7-1500
CompactLogix
Receive
Send
Libraries contain communication function
blocks for the S7-1200 / 1500 to
communicate with Rockwell Logix
controllers.
Receive
Send
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 30
ControlLogix
Modernization tools
EtherNet/IP™ connectivity
S7-1500 EtherNet/IP Function
Block (GET/PUT)
In development
S7-1500
No Code Modifications
Required
•
CompactLogix
Function Blocks for SIMATIC S7-1200 / S71500 to read/write data in a Rockwell
controller via EtherNet protocols with no
code changes in the Rockwell controller.
Get
Put
Get
Put
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 31
ControlLogix
Modernization tools
ProSoft gateways
In development
PROFINET to
EtherNet/IP™ Gateway
•
•
Function Blocks
•
Provides simple connectivity
between controllers and
periphery using a ProSoft*
Gateway (PROFINET to
EtherNet/IP).
PROFINET
Using gateways
ProSoft third-party gateway
from other vendors
EtherNet/IP
is possible.
Periphery
Systems
Controllers
Drives
Siemens
ProSoft gateway
Driver
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)
FB in S7-1500
ProSoft third-party
gateway
ROK legacy fieldbus (RIO)
Periphery
Systems
Drives
*ProSoft is owned by ProSoft Technology®:
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 32
Modernization tools
FAQs (Frequently Answered Questions)
Sample FAQ
Q: 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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 33
Modernization tools
Siemens Migration Studio
Migration Studio reads
Rockwell software from…
RSLogix5
(Controller-5)
RSLogix500
(SLC 500)
Studio 5000 *
(Compact-, ControlLogix)
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)
Hardware Conversion
WinCC Comfort
Advanced
RSView32
(PanelView32)
In development
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 34
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 35
Via Intranet
Siemens EtherNet/IP Solutions
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.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 36
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.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 37
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


•
•
CBE20
Communication
Board
(In chassis, bookshelf, blocksize and enclosed cabinets)
EtherNet/IP Connectivity
SINAMICS S150 Enclosed Regenerative Drive
SINAMICS DCM DC Drives
Choose correct Ethernet control module
• SINAMICS G120 General Performance
Vector Drives

Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 38
(In compact, modular, distributed and enclosed versions)
Siemens EtherNet/IP™ Solutions
SIMATIC Ident – RFID and code reading solutions
Rockwell does not currently have a
complete RFID solution.
Logix Platform
The RFID181EIP
module acts as the
interface to an
EtherNet/IP network.
RF 181EIP
SIMATIC RF300
SIMATIC RF200
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 39
SIMATIC RF600
Siemens EtherNet/IP™ Solutions
Networking Infrastructure / cabling
Wired / Wireless Communications
FastConnect
EtherNet/IP requires IGMP snooping,
supported in the following products:
• X-500
• X-400
• X-300
• XB200
EtherNet/IP is standard TCP/IP; the
networking components just transport the
information
The most superior cabling solution in
the market components just transport
the information
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 40
Minimize Risk
Enterprise License Program (ELP)
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.
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 41
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
Rockwell Conversion Example
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 42
Rockwell conversion example
Packaging machine
Rockwell
• Allen Bradley SLC 500
• Panelview
• AMCI Resolver
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 43
Siemens
• SIMATIC S7-1500
• SIMATIC Basic Panel
• SIMOTICS Encoder
Rockwell conversion example
Controller program structure
Similar program
structure for
maintenance personnel
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 44
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
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 45
Rockwell conversion example
Controller program logic structure
Ladder logic is ladder logic
Similar symbols
Comments are the same
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 46
Rockwell conversion example
Controller tags
Tag names nearly identical
Similar addressing
Comments are the same
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 47
Rockwell conversion example
HMI structure
Same screen names
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 48
Rockwell conversion example
HMI tags
Tag names nearly identical
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 49
Rockwell conversion example
HMI screens
Similar look and feel
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 50
Rockwell conversion example
New diagnostic features
Integrated Controller display
• Hardware diagnostics
• Machine diagnostics
• Command functions
• System Maintenance
• No PC required
• Password protected
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 51
Rockwell conversion example
Benefits
No surprises for maintenance
Enhanced Diagnostics
•
•
•
•
•
•
•
•
•
Controller program structure
Controller logic
Controller tags
HMI structure
HMI tags
HMI screens
Unrestricted / © Siemens AG 2015. All Rights Reserved.
Page 52
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/modernizationtools