A major paper processing plant experienced problems with an old/outdated S5 PLC system. The system was an S5-95U CPU with a large amount of I/O. The existing system was difficult to troubleshoot and not easy to maintain. Fast Automation was contracted to upgrade the system to a new and serviceable system but at a minimum cost.

Existing System:-

Existing Rack Components:-

Part No.	Description	Qty
6ES5103-8MA12	SIMATIC S5 CPU 103	1
6ES5470-8MA11	Analog Output Module – 2AO	1
6ES5385-8MA11	Down counter with 2 Channels up to 500Hz	1
6ES5421-8MA12	Digital Input 8x 24V DC	11
6ES5441-8MA11	Digital Output 8x 24V DC 1A	8

 

At first glance not an obvious choice but the Siemens ET200s was selected as the platform solution. Fast Automation believes the Siemens ET200S IM151-7 CPU is a hard option to look past, for smaller Siemens S5 upgrades.

Summary of ET200s suitability factors:-

• Processing power is not a real requirement when upgrading the S5-95U, most modern small PLC’s will outperform it. IF using the ET200s CPU’s
• The memory requirement is minimal
• The I/O can be selected to match card for card upgrading which minimizes drawing changes.
• The footprint is exceptionally small and therefore can usually be mounted alongside the old PLC without the need for existing cabinets.
• Spares are readily available, and the system is hot-swappable and low power.

New Rack Components:

Order number	Designation	Quantity
6ES7131-4BF00-0AA0	Electronics module, 8DI, 24 V DC, standard (1 unit)	14
6ES7132-4BF00-0AA0	Electronics module, 8DO, 24 V DC/0.5A, standard (1 unit)	9
6ES7135-4FB01-0AB0	Electronic module, 2AO, U	2
6ES7138-4DE02-0AB0	1 Count 5V/500kHz, connection for RS422 incremental encoders
6ES7138-4CA01-0AA0	PM-E DC 24V power module for electronic modules, with diagn.	1
6ES7151-7AA20-0AB0	IM 151 – 7 CPU	1
6ES7193-4CA40-0AA0	Universal terminal module; screw connection (5 pcs.)	5
6ES7193-4CD20-0AA0	Terminal module for AUX1 supply; screw connection	3