1. Optima o
In control since 1995
Optima S5 to S7 Conversions
The risk-free upgrade option 1

2. Optima In control since 1995
o
What is this processor?
The new* S57 processor has been developed to run Step5 and
Step7 programs simultaneously
How does this help the upgrade?
Program conversion can be taken in stages according to shutdown
timescales
Are these the only benefits?
NO. Our upgrade route is unique and allows complete flexibility of
hardware upgrades as well, be that SCADA systems or servo
drives
* The processor, having successfully undergone beta-trials for over 3 years at key customer sites is now available for full release
Optima S5 to S7 conversions
Your risks 2

3. Optima In control since 1995
o
Your problems:
CPU’s are now unsupported by Siemens
Specialist S5 modules can contain unsupportable code
Data held on EEPROM / Battery Backup – possibility of total data
loss on battery/EEPROM failure
Other systems connected to S5 are obsolete as well
PC’s running machine SCADA or other applications
Serial communication to Third party systems
Spares cost and availability:
*Prices obtained from Siemens A&D Mall 27th April 2009 for a 928 processor. Cheaper prices may be available for refurbished items
Optima S5 to S7 conversions
Your risks 3

4. Optima o
In control since 1995
Up until now, the only option has been to take the machine down
completely and re-fit the entire PLC system including all ancillary items:
SCADA systems, operator HMI’s, Factory-wide automation monitoring
Do you know every function on every screen?
Recipes, trending, logging of data.
Are there even backup configurations for all these?
Serial/Ethernet communications with custom protocols
How do you know what protocol is used (this data held on EEPROM in processor
and only accessible with Siemens COM525 package and programmer – also now a
rarity)
After conversion, how do you know the protocol will still work with equipment
Optima S5 to S7 conversions
What do I do first??? 4

5. Optima o
In control since 1995
Function of dedicated option modules to be replicated
IP246 (Positioning)
IP244 (13-channel PID controller)
CP523 …544 (Communications)
All the above need to be rewritten and commissioned
Are you sure all functionality has been covered?
What if each module function could be converted step-by-step to
S7 and even tested alongside the original?
Well, now it can!
Optima S5 to S7 conversions
What do I do first??? 5

6. Optima o
In control since 1995
What this solution offers:
Large machines carry large risks, so minimise the risk by reducing
the engineering at each stage
Take project stages one step at a time
Identify key functional areas – target these for upgrade
Fit key equipment in stages – even test side-by-side
Fully test new kit, then decommission old equipment
Number of shutdowns required can vary according to complexity
and the time available
Optima S5 to S7 conversions
Is there another way??? 6

7. Optima o
In control since 1995
Main S5 Hardware Systems are:
115U Rack
CPU 941, 942, 943, 944, 945
135/155U Rack
CPU 922, 928, 928B, 948
150U Rack
CPU 921, 922
Optima S5 to S7 conversions
Common S5 Systems 7

8. Optima o
In control since 1995
Rack types:
115, 135, 150, 155 U
U denotes a standard rack
115, 135, 150, 155 F
F denotes ‘Fault-tolerant’
115, 135, 150, 155 H
H denotes ‘High-availability’
This system only supports the U rack (most common)
Only single-processor racks are supported
Optima S5 to S7 conversions
S5 Systems Supported 8

9. Optima o
In control since 1995
The 115U Rack processor:
Replaces CPU’s
941
942
943
944
945
Designed to meet specification of the
high-end processor 945
S7 operation equivalent: S7-416 high-
performance processor
Optima S5 to S7 conversions
115U series 9

10. Optima o
In control since 1995
The 135U Rack processor:
Replaces CPU’s
922
928
928B
948
Designed to meet specification of the
high-end processor 948
S7 operation equivalent: S7-416 high-
performance processor
Optima S5 to S7 conversions
135U series 10

11. Optima o
In control since 1995
The 150 Rack processor:
Replaces CPU’s
921
922
Designed to meet specification of 922
S7 operation equivalent: S7-416 high-
performance processor
Optima S5 to S7 conversions
150 series 11

12. Optima In control since 1995
o
The advanced S57 processor runs the S5 program and is
programmed using Siemens SIMATIC STEP5 software *
The S57 processor also runs an S7 program and is programmed
using Siemens SIMATIC STEP7 software
Machine operates exactly as with the original processor
New S7 code is written stage-by-stage and runs alongside the S5
program
New code activated in stages
All diagnostic features of STEP5 and STEP7 retained
Compatibility with all STEP5 and STEP7 FC’s, FB’s, OB’s, etc.
* some re-work of S5 code may be required depending on program complexity and original processor type. For example, a 941 program is not directly compatible with a 945 processor
so this must be converted prior to install in S57 processor. Optima will advise and complete this all as part of the upgrade.
Optima S5 to S7 conversions
How does it work? 12

13. Optima o
In control since 1995
In addition to converting the program from Step 5 to Step 7, other upgrade
options are:
Replace ageing SCADA or HMI systems with Ethernet based systems
Create new WinCC application to run alongside your existing SCADA system. Fully
test the new SCADA before de-commissioning you old system
Upgrade to new Siemens TP’s, MP’s with Ethernet capability
Create new PROFIBUS network and replace old networked devices with
new
Remote Input/Outputs
New AC, DC or servo drive systems
Optima S5 to S7 conversions
Other shutdown options 13

14. 14 Your choice
Optima S5 to S7 conversions
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In control since 1995
o Optima

15. Optima o
In control since 1995
Our S5 to S7 upgrades allow a degree of flexibility that no other
provider can offer
Shutdown times to suit you
Pinpoint critical items
Software written by our Siemens Solution Partner qualified
engineers
Optima S5 to S7 conversions
15
Your choice

16. Optima o
In control since 1995
The new S57-II Processor is now available!
On-board networks available using additional plug-in module
Super-fast program execution: <10ns operation time
4 x Ethernet ports each with a dedicated communication processor
Integrated e-mail client and Web-server onboard
Even more flexible upgrade opportunities
Optima S5 to S7 conversions
16
Your choice