SIEMENS S5 TO S7 UP GRADE TO INCLUDE

DRIVE REPLACEMENT
Project Description
The W H Good Systems Division were awarded the contract to design & manufacture an existing Trancel Wrapper Control system from a
Siemens S5 PLC based system to a Siemens S7 PLC complete with Siemens MP270 Operator Interface and replace the existing ABB drives
with Siemens Drives on Profibus
Details of Work
The existing S5 135 PLC and I/O were removed and replaced with the following S7 PLC equipment and the software will be re-written for
the S7 400 system, providing the same functionality as previously using existing cable wiring.
Manufacture and install a new operator control desk to
Include SiemensMP270 touch screen operator panel with 10” graphical display
Complete with new Pushbuttons and Lamps, as required to provide the functionality.
A new multi-core cable was installed between the new operator panel and the existing control panel, to include MPI comms. Cable installed
between the HMI and the main control panel.
Removal of existing, obsolete ABB drives and associated brake resistors and replace them with Siemens equivalent drives and brake
resistors, complete with Profibus communication to the PLC. Allowing additional drive diagnostic data to be displayed on the HMI
Commissioning and providing on site support
Plant Details Control of the Plant
• Wrappers • Reel Diameter Laser Measurement
• Chain Conveyor • Positional Control with Encoder Feed Back
• Pneumatic Pickers • Light Curtain with Safety Relays
• Hydraulic Pumps • Touch Screen HMI for operator control
• Roller Table • Inverter Drives with Profibus DP Comms
• Glue Guns
Special Project Requirements
In conjunction with SIEMENS, WH GOOD Systems were able to offer S7 Migration Siemens would normally supply a free S7-300 PLC processor
equivalent to the current S5 processor, based on a survey by their engineers, which in theory would have the functionality and memory capable to carry
out the same function as the S5 processor. In this case it was not practical to fit an S7-300 system into the same space occupied by the existing S5-135
system. Siemens agreed to provide the S7-400 processor free of charge. In addition to the above cost savings Siemens provided a Free S7
Familiarisation Programme.
It was necessary to have the machine completely out of production during installation and initial commissioning, for approximately 7 days. Following this
period limited production was available for approximately 3 days. The machine would be available for full production runs. A W H Good engineer was
made available on-site during normal working hours (8:30am – 5:00pm) for the first 2 days of full production, to rectify any issues and provide operator
assistance.
Summary
All the panels were tested at our works with the customer before shipping. All the PLC and Simulated HMI communications were tested as
testing specification.