A Comprehensive Guide to Migrating from Siemens S7-200 to S7-1200 PLCs

Key Takeaways

Why Migrate? Upgrading from the S7-200 to the S7-1200 PLC offers enhanced performance, advanced features, and future-proofing for your automation systems.
Hardware Differences: The S7-1200 provides faster processing speeds, more memory, and improved networking capabilities compared to the S7-200.
Software Transition: You’ll move from Micro/WIN to the more advanced TIA Portal, which offers a modern programming environment with better diagnostics.
Migration Tools: Siemens offers official tools to assist in the migration process, making the transition smoother and more efficient.
Preparation is Key: Properly assessing your current system and understanding compatibility will save time and prevent issues during migration.

Introduction

Migrating from the Siemens S7-200 to the S7-1200 PLC is a significant step toward modernizing your automation systems. Established in 2013, ControlNexus is a leading provider of Siemens PLCs, HMIs, and Inverters. We’re here to guide you through this transition with clear, practical advice.

1. Understanding the Differences Between S7-200 and S7-1200

Hardware Differences

CPU Modules Comparison: The S7-1200 CPUs offer higher processing speeds and larger memory capacities.
I/O Capabilities: Enhanced input/output options allow for more complex automation tasks.
Networking Capabilities: Improved Ethernet and PROFINET support for better connectivity.

Software Differences

Programming Environment: Transition from Micro/WIN to the advanced TIA Portal.
Programming Languages: Support for more programming languages, including Structured Text and Function Block Diagram.
Enhanced Diagnostics: Better tools for troubleshooting and system diagnostics.

Feature Enhancements

Integrated Technologies: Built-in functions for PID control, motion control, and more.
Security Features: Improved security measures to protect your system.
Scalability: Easier to expand and integrate with other Siemens products.

2. Benefits of Migrating to S7-1200

Enhanced Performance

Faster Processing: Quicker execution of programs improves system efficiency.
Increased Memory: Handle more complex programs with larger memory capacity.

Advanced Programming Environment

User-Friendly Interface: TIA Portal offers a modern and intuitive interface.
Improved Debugging Tools: Easier to find and fix issues in your programs.

Future-Proofing

Long-Term Support: Siemens will continue to support and update the S7-1200 series.
Compatibility: Better integration with new technologies and devices.

3. Preparing for Migration

Assessing Your Current System

Hardware Inventory: List all your existing S7-200 hardware components.
Software Audit: Document your current programs and any special functions.
Compatibility Check: Identify any peripherals that may not be compatible with the S7-1200.

Hardware Compatibility Checks

Peripheral Devices: Ensure sensors, actuators, and other devices are compatible.
Obsolete Components: Plan to replace any outdated hardware that won’t work with the new system.

Software Requirements

Obtain TIA Portal: Acquire the latest version of the TIA Portal software.
Licensing: Ensure you have the proper licenses for all software components.

4. Using Siemens Migration Tools

Overview of Official Migration Tools

Siemens provides official tools to assist in migrating your programs from the S7-200 to the S7-1200.

Downloading and Installing Tools

Access Tools: Download the migration tools from the Siemens Support website.
Installation: Follow the on-screen instructions to install the tools on your PC.

Understanding Tool Limitations

Conversion Capabilities: The tool automates much of the conversion but may not handle custom code.
Manual Adjustments: Be prepared to make manual tweaks after the automated conversion.

5. Step-by-Step Migration Process

Backing Up Your S7-200 Program

Secure Your Data: Use Micro/WIN to back up your existing program.
Multiple Copies: Keep backups in different locations for safety.

Converting the Program

Use the Migration Tool: Follow the tool’s instructions to convert your program.
Handle Unsupported Instructions: Manually rewrite any code that didn’t convert properly.

Updating Hardware Configuration

Set Up S7-1200 PLC: Configure your new PLC using the TIA Portal.
Network Settings: Reconfigure IP addresses and network parameters as needed.

6. Programming in TIA Portal

Navigating the TIA Portal Interface

The TIA Portal offers a user-friendly interface that integrates all your automation tasks. Here’s how to get started:

Project View: Central hub for managing your projects.
Device Configuration: Set up your hardware components within the software.
Program Blocks: Where you write and edit your PLC code.
Watch Tables: Monitor and force variables during runtime.

Adapting Ladder Logic and Other Languages

When transitioning from Micro/WIN to TIA Portal, you’ll notice some differences in programming languages:

Ladder Logic (LAD): Still widely used and supported.
Structured Control Language (SCL): Similar to high-level languages like Pascal.
Function Block Diagram (FBD): Graphical representation ideal for complex logic.

Optimizing Code

Use Libraries: Leverage pre-built functions to save time.
Modular Programming: Break down your code into Function Blocks (FB) and Function Calls (FC) for better organization.
Comments and Documentation: Always comment on your code for future reference.

7. Hardware Setup and Configuration

Installing the S7-1200 PLC

Proper installation is crucial for optimal performance:

Mounting: Secure the PLC on a DIN rail in your control panel.
Wiring: Connect the power supply, inputs, and outputs as per the wiring diagram.
Grounding: Ensure the system is properly grounded to prevent electrical noise.

Configuring Modules and Extensions

Add I/O Modules: Expand your system by adding compatible modules.
Update Configuration: Reflect these changes in your TIA Portal project.
Firmware Updates: Keep your PLC’s firmware up to date for the latest features.

Communication Setup

Ethernet Settings: Configure IP addresses for network communication.
PROFINET Configuration: Set up real-time data exchange between devices.
Integrate HMIs: Connect Human-Machine Interfaces like Siemens HMIs for better control.

8. Common Challenges and Troubleshooting

Migration Pitfalls

Unsupported Instructions: Some S7-200 instructions may not have direct equivalents.
- Solution: Manually rewrite these sections using TIA Portal’s supported functions.
Hardware Differences: Not all peripherals are directly compatible.
- Solution: Consult the compatibility guide for alternatives.

Hardware Compatibility Issues

Incompatible Devices: Older devices might not work with the S7-1200.
- Solution: Consider upgrading to compatible Siemens devices.
Network Conflicts: IP address conflicts can disrupt communication.
- Solution: Assign unique IP addresses to each device.

FAQs

Can I use my old programming cables?
- The S7-1200 uses standard Ethernet cables, making it more convenient.
What if my program is password-protected?
- Refer to our guide on removing write protection.

9. Practical Examples

Real-World Migration Case Study

Let’s consider a manufacturing plant that upgraded from the S7-200 to the S7-1200:

Challenges Faced:
- Incompatible I/O modules.
- Need to rewrite custom communication protocols.
Solutions Implemented:
- Replaced obsolete modules with S7-1200 compatible ones.
- Utilized TIA Portal’s advanced functions for communication.

Code Snippets

Before Migration (S7-200):

LD   I0.0
AND  I0.1
=    Q0.0

After Migration (S7-1200 in TIA Portal):

A “Input1”
A “Input2”
= “Output1”

Visual Aids

Figure: S7-1200 Hardware Setup

10. Expert Tips and Best Practices

Advice from Industry Professionals

Plan Thoroughly: “A well-planned migration saves time and resources,” says our senior engineer at ControlNexus.
Test Incrementally: Validate each part of your system before moving to the next.

Optimizing System Performance

Leverage New Features: Utilize the S7-1200’s advanced functions like PID control for better efficiency.
Regular Updates: Keep your TIA Portal and PLC firmware updated.

Maintenance and Support

Documentation: Keep detailed records of your new system configuration.
Training: Invest time in learning the TIA Portal for long-term benefits.

11. Additional Resources

Conclusion

Migrating from the S7-200 to the S7-1200 PLC is a worthwhile investment for modernizing your automation systems. With enhanced performance, advanced features, and robust support, the S7-1200 positions your operations for future success.

At ControlNexus, we’re dedicated to assisting you through every step of this journey. Feel free to contact us for personalized support or visit our product page to explore our range of Siemens automation solutions.

Don Tang

Hi, I’m Don Tang, the CEO of Plcvfd.com, we are a seasoned Siemens dealer in China with over 10 years, and the purpose of this article is to share with you valuable information about Siemens items, grounded in a decade of hands-on experience.