Key Takeaways

Introduction

In the world of industrial automation, efficiency and reliability are crucial. For years, the Siemens S7-200 PLC has been a popular choice in controlling automated systems, thanks to its robust features and reliability. However, as technology advances, the S7-200 PLC has reached obsolescence, prompting industries to explore more advanced alternatives like the Siemens S7-1200 and S7-1500. At ControlNexus, established in 2013 and a leading provider of Siemens PLCs, HMIs, and Inverters, we understand the challenges of migrating from trusted, familiar technology to newer systems. This guide will help you navigate these changes smoothly.

1. Understanding the Obsolescence of the S7-200 PLC

Overview of the Siemens S7-200 PLC

The Siemens S7-200 PLC was renowned for its compact design and reliable performance, making it a staple in smaller, less complex applications across industries. Its ease of use and durability allowed countless businesses to automate processes efficiently.

Why the S7-200 Became Obsolete

While the S7-200 provided solid functionality, advancements in technology quickly highlighted its limitations:

• Limited Processing Power: Compared to modern PLCs, the S7-200’s processing speed and memory are minimal.
• Connectivity Constraints: As industries increasingly rely on interconnected systems, the S7-200 lacks the necessary communication protocols.
• Phased-out Support: Siemens has shifted its support focus toward newer models, with limited spare parts and software updates for the S7-200.

The evolution of Siemens’ more advanced PLC models like the S7-1200 and S7-1500 ensures that industries can harness greater processing power, connectivity, and future-ready capabilities.

2. The Impact of Using an Obsolete PLC

Risks Associated with the S7-200

Continuing to rely on the S7-200 PLC can expose businesses to multiple risks:

• Increased Maintenance and Downtime: An obsolete PLC requires more frequent repairs, and spare parts are increasingly scarce, leading to longer downtimes.
• Limited Integration Capabilities: Modern automated systems rely on robust connectivity. The S7-200 struggles to integrate with current systems, potentially causing compatibility issues.
• Security Vulnerabilities: Obsolete devices lack the latest security updates, making them more vulnerable to cybersecurity threats.

Real-world Scenario:

Imagine a production facility relying on the S7-200 to control critical processes. When a malfunction occurs, finding replacement parts may take days, if not weeks, resulting in costly downtime. By upgrading, this facility could reduce repair frequency, improve system connectivity, and maintain high security standards.

3. Benefits of Upgrading to a Modern PLC (e.g., S7-1200, S7-1500)

Enhanced Performance and Connectivity

One of the most compelling reasons to upgrade from the S7-200 is the drastic improvement in performance and connectivity that newer PLC models offer. The Siemens S7-1200 and S7-1500 bring powerful processing capabilities, allowing for more complex operations and quicker execution times. Additionally, these models support various modern communication protocols, including Profinet, Modbus, and OPC UA, enabling seamless integration with other industrial devices.

Advanced Features and Capabilities

Beyond just performance, the new Siemens PLCs introduce features that make industrial automation more efficient and user-friendly:

• Data Logging and Monitoring: Real-time monitoring and data logging capabilities help track system performance, predict failures, and ensure smoother operation.
• Built-in Security Features: The S7-1200 and S7-1500 PLCs offer advanced security configurations to safeguard against unauthorized access.
• Expanded Memory and I/O: These models accommodate more complex processes and larger I/O requirements, making them ideal for scaling operations.

Long-term Cost-Effectiveness

Though upgrading involves an initial investment, modern PLCs ultimately offer better cost-efficiency by reducing downtime, minimizing maintenance, and future-proofing operations. With continuous support from Siemens, businesses can rely on software updates, availability of parts, and technical support.

4. Step-by-Step Guide to Upgrading from S7-200 to S7-1200/S7-1500

Transitioning from the S7-200 to a newer PLC like the S7-1200 or S7-1500 is a multi-step process that requires planning and precision to ensure minimal disruption.

Step 1: Assessing Your Current System

Before making the switch, assess your current setup:

• Identify Compatibility Needs: Take note of your current I/O requirements, connected devices, and processes to ensure a smooth migration to a modern PLC.
• Evaluate Software and Hardware Needs: Modern PLCs may require updates to your programming software, such as TIA Portal.

Step 2: Choosing the Right Replacement PLC

Choosing between the S7-1200 and S7-1500 depends on your specific application:

• S7-1200: Ideal for smaller applications requiring a compact yet powerful PLC.
• S7-1500: A high-performance PLC suited for complex, large-scale applications needing faster processing and more extensive connectivity options.

Step 3: Planning the Transition

A successful transition from the S7-200 to a modern PLC like the S7-1200 or S7-1500 requires careful planning to minimize disruption:

• Scheduling Downtime: Plan the upgrade during low-production periods or scheduled maintenance windows to reduce any impact on operations.
• Training for Technicians and Operators: Provide training sessions for your team on the new PLC’s interface, features, and functions to ensure smooth operation post-upgrade.
• Developing a Migration Plan: Outline each step of the upgrade, including installation, programming, and testing, to keep the process on track and ensure all tasks are completed efficiently.

Step 4: Implementing the Upgrade

The upgrade process from the S7-200 to a more advanced PLC can vary depending on your system requirements, but the following general steps are recommended:

1. Disconnect the S7-200 PLC: Safely remove the old PLC from your system, ensuring all power sources are disconnected.
2. Install the New PLC: Physically install the S7-1200 or S7-1500 PLC, connecting all necessary input/output devices and communication modules.
3. Configure Settings in TIA Portal: Use TIA Portal to configure the new PLC and adjust network settings for seamless integration with your existing system.
4. Transfer Program and Test: Import the existing program if compatible, or reprogram specific processes as needed. Run tests to confirm that all functions operate correctly in the new system.

Step 5: Testing and Validation

After installation, it’s crucial to thoroughly test and validate your upgraded system:

• Initial Tests: Run all connected equipment and processes to verify that signals, I/O devices, and communication links are functioning as expected.
• Calibration and Adjustment: Fine-tune any parameters and calibrate sensors to ensure precise operation and accurate data collection.
• Trial Run and Monitoring: Perform a trial run with full operational parameters, monitoring for any issues or adjustments required. Logging initial performance data can be useful for future comparisons and ongoing maintenance.

Testing and validation ensure that your upgraded PLC is fully operational, integrated correctly, and ready for regular production use.

5. Expert Advice on Future-Proofing Your Automation System

Long-Term Support and Maintenance

Investing in a PLC with a long support lifecycle is essential to avoid future obsolescence issues. The S7-1200 and S7-1500 PLCs are both supported by Siemens with regular updates, parts availability, and ongoing technical support, making them a reliable choice for the long term.

Regular System Updates

To maintain optimal performance and security, schedule regular updates for your PLC’s software and firmware. Using Siemens’ TIA Portal allows you to stay current with the latest features and security patches, which can protect against evolving cybersecurity threats and enhance overall system performance.

Staying Informed on Industry Trends

Industrial automation is evolving rapidly, with new technologies and standards continually emerging. Staying informed about trends such as the integration of IoT, machine learning, and artificial intelligence into industrial systems will help your business remain competitive and well-prepared for future automation advancements.

Conclusion

Upgrading from the Siemens S7-200 PLC to a more advanced model, such as the S7-1200 or S7-1500, is a wise investment for any industry looking to enhance its automation capabilities, reduce downtime, and future-proof its operations. While the S7-200 served as a foundational tool in industrial automation, advancing to modern PLCs brings improved performance, connectivity, and flexibility.

With the guidance provided in this article, businesses can confidently navigate the transition process, optimize their automation systems, and set the stage for a more efficient, reliable, and scalable future. Explore ControlNexus’ extensive selection of Siemens products to find the right fit for your unique operational needs and unlock the full potential of your industrial automation system.

FAQs

• Is the S7-200 PLC still supported by Siemens?
  Siemens has largely phased out support for the S7-200 PLC, though some replacement parts and limited technical support may still be available.
• Can I replace my S7-200 PLC with an S7-1200 without changing my entire system?
  Yes, the S7-1200 can often be integrated into an existing setup with minor adjustments, though reprogramming and testing will likely be required.
• What are the major differences between S7-1200 and S7-1500 PLCs?
  The S7-1200 is compact and suitable for smaller applications, while the S7-1500 offers more advanced processing power and extensive connectivity options for larger, more complex operations.

This guide empowers industries to make informed decisions and smoothly transition from the Siemens S7-200 PLC to newer models, reinforcing ControlNexus’ commitment to supporting efficient, cutting-edge automation solutions.