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Sector: Metal Fabrication
SIMATIC S5 to S7-1500 Retrofit (Sample Case)
Migration of a production line running on an unsupported SIMATIC S5 controller to the S7-1500 platform and current-series drives during a single planned stop.
Challenge
Spare parts for the line’s S5 controller had become practically unobtainable; a single failure carried the risk of days of unplanned downtime, and no line data reached any higher-level system.
Our Approach
The existing program was documented through reverse engineering, and a migration plan was prepared for the S7-1500 architecture and latest-series drives. The conversion was executed in one maintenance stop scheduled around the production calendar; line data was exposed to the SCADA layer.
Results
- Unplanned downtime risk eliminated
- Energy and cycle data made traceable
- A standards-compliant platform with guaranteed spare-part availability
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