usa.siemens.com/modernize Modernization made easy: A step-by-step guide Future-focused technologies for today‘s Digital Enterprise

Table of Contents Your future-focused partner 3 Modernizing with Siemens Digital Enterprise 4 Why Siemens? 5 Why not just stay with my current vendor? 6 Automation solutions for today and tomorrow 7-10 Best-in-class individual components 11 Support and consulting services 12-13 Migration steps 14-26 Modernization tools 27-35 Siemens EtherNet/IP solutions 36-41 Rockwell conversion example 42-52 Contact Us 53

Your Future-Focused Partner How Siemens Helps: We’re your future- focused automation partner that can help you adapt to — and capitalize on — the furious pace of change in today’s global economy. To meet your customers’ expectations, you have to find new and innovative ways to reduce time-to-market enhance flexibility increase efficiency

Modernizing With Siemens Digital Enterprise We help you leverage the latest automation technologies to build what we call the “Digital Enterprise.” What is the Digital Enterprise? A holistic approach that covers the entire product lifecycle, from product design to production planning, production engineering, production execution and, finally, services. How Siemens enables the Digital Enterprise Our Digital Enterprise Software Suite enables customers to complete the steps of the production lifecycle simultaneously rather than sequentially (the traditional method). The result: improved productivity and efficiency.

Why Siemens? Return on investment Productivity Transparency TIA Portal—may reduce your engineering time by up to 30% Productivity Integrated “no programming” diagnostic capabilities Transparency Remote monitoring: Connect to existing third-party controllers for data sharing and move information to today’s MRP systems. Leading Technology State-of-the-art portfolio, including SIMATIC S7-1500 controller Safety Safety Integrated: Comprehensive portfolio of control, drive and switching technology Security A comprehensive, integrated approach for the protection of plant, network and system security. Support Global and local sales and support in 190 countries

Why not just stay with my current vendor? Obsolete Products You may still need to: Convert code to their new programming software Train your engineers and maintenance personnel Risk downtime during the changeover Siemens makes modernization easy with: conversion tools a step approach state-of-the-art technologies to sustain future growth support training

Automation solutions for today and tomorrow

Automation solutions for today and tomorrow A future-focused, totally integrated approach Totally Integrated Automation (TIA) An open system architecture that covers the entire production process Maximum interoperability across all automation components TIA offers: Consistent data management Global standards Uniform hardware Software interfaces Minimized engineering time Reduced costs More flexibility Key Benefits

Automation solutions for today and tomorrow A future-focused, totally integrated approach BENEFIT Improved engineering efficiency RESULT Lower design costs Integrated diagnostic functions RESULT Minimized downtime Integrated communication tools RESULT Production flexibility Integrated security functions RESULT Enhanced plant and network security Technologies that protect personnel, machinery and the environment RESULT Improved safety TIA optimizes the entire manufacturing process, leading to increased ROI Single, streamlined database RESULT Optimized data quality More access to data RESULT Better decision making Global standards RESULT Simplified implementation of automation solutions Interoperability of system-tested components RESULT Improved overall performance

Automation solutions for today and tomorrow The TIA Portal The key to unlocking the full potential of TIA is our TIA Portal — A single engineering framework that seamlessly integrates: Controllers Distributed I/O HMI panels Drives, motion control and motor management Features that enable reduction of engineering time transparency and diagnostics include: Integrated “no programming” diagnostics One common tag database Ability to create custom libraries An overall project management tool Intuitive system functions Time-saving functions (such as online/offline comparisons, pictorial system view with online diagnostics, no-PC-required trace) TIA Portal = up to 30% reduction in engineering time!

Automation solutions for today and tomorrow Best-in-class individual components Upgrade individual products with: Ease of integration with existing assets Easy-to-configure hardware and software Resolution of maturity/obsolescence issues Features to support flexibility and competitiveness Flexibility to support various network protocols, including PROFINET and EtherNet/IP

Automation solutions for today and tomorrow Support and consulting services Industry Online Support Site Resource for comprehensive info, FAQs, and application examples for all products, systems and services in the fields of automation and drives Technical and Engineering Support 24/7 support for all inquiries about functionality, handling and fault clearance of Siemens industrial products Global Support Available in 190 countries; Standardized global part numbers and ease of communication in your preferred language Regional Application Engineers Provide local assistance Experienced Global Network of Certified Solution Partners Extensive industry knowledge using Siemens components to implement tailored solutions for specific applications and timetables

Automation solutions for today and tomorrow Training Services Siemens Standard Support Services reduce your total cost of ownership: No Charge single, toll-free number with live operators No Charge standard technical support until product maturity during normal business hours Our training services help you: Assess Define Implement Manage A workforce improvement program that is customized to your exact learning needs. Courses include: Product Safety Certification learning programs Course delivery methods: In-person Virtual instructor-led Digital

Modernize your operations, start-to-finish

Modernization made easy: A step-by-step guide Migration Steps 1 2 3 4 5 6 7 8 9 10 INSPECT OBTAIN DEVELOP MIGRATE ADD TEST UPDATE INSTALL START TRAIN Physically inspect application / machine for fit, networking and function Obtain a copy of the current documentation for hardware and software Develop the hardware solution Migrate control code Add advanced diagnostics Test the application using simulation Update documentation Install on-site Start up on-site Train plant personnel

Modernization made easy: A step-by-step guide Flow chart: Start-to-finish steps to modernize your operations START Physically review the system to be migrated Locate an appropriate Siemens solution for any special hardware being used such as that supplied by AB Encompass partners In the event that a SIMATIC library function is not available for a specific AB function, create a SIMATIC library function and add it to the SIMATIC AB library Verify the HMI Connection(s) Develop preliminary drawings for the application using the new SIMATIC hardware Modify and document the updates to the application hardware and software Determine the panel space and locale space for mounting an additional panel if required Configure the HMI Tags Develop an operator/ maintenance manual for the plant Configure the HMI Graphics Modify and release the final drawings for the application Choose and configure an appropriate SIMATIC PLC and configure it in TIA Portal Create SIMATIC functions for any new hardware or gateways that will be used Get drawings of the physical application and a copy of the application program Configure the HMI Alarms Take the new system to site and install it Archive the application code If required to connect to a specific network, determine an appropriate gateway or SIMATIC solution Configure the HMI Trending Create the Main calling routine(s) Wire the IO using the fastest method possible Get acceptance sign-off from customer Analyze the current I/O and determine if special hardware is being used Configure the PLC/HMI security Add PROGRAM_ALARM for diagnostic messages to the S7-1500 display and HMI Adapt the network configuration to the plant network infrastructure Deliver all documentation and drawings to the customer Migrate the existing AB programs using the TIA Migration Tool Cross reference the I/O to appropriate SIMATIC I/O Test the new configuration using simulation Startup and test the new application Configure the HMI(s) in TIA Portal Correct any issues found during simulation END *AB refers to Allen-Bradley® owned by Rockwell Automation®

Migration Steps Physically inspect application / machine for fit, networking and function 1 Fit Examine existing panel spaces Does new hardware fit into existing spaces? Space for new panel(s)? Networking Distributed I/O? Drive(s) connectivity? Connectivity to MES? Function Existing control capabilities Memory sizes Execution time I/O type Specialized components being used? HMI(s)? INSPECT START Physically review the system to be migrated Determine the panel space and locale space for mounting an additional panel if required

2 Obtain a copy of the current documentation for hardware and software Migration Steps Obtain a copy of the current documentation for hardware and software 2 Hardware Wiring Connectivity Number of spares Sensors used Controller hardware Controller I/O HMI Networking details Software Symbols (tag names) Comments Structure Logic OBTAIN Get drawings of the physical application and a copy of the application program

3 Develop the hardware solution Migration Steps Special Hardware Needs Upgrade/change Encompass partner products Gateways Sensors Cross Reference Control Hardware Controller Memory size Execution time Networking support Certifications I/O Module types Quantity Wiring Panel fit Drives HMI DEVELOP Analyze the current I/O and determine if special hardware is being used Cross reference the I/O to appropriate SIMATIC I/O Choose and configure an appropriate SIMATIC PLC and configure it in TIA Portal Locate an appropriate Siemens solution for any special hardware being used such as that supplied by AB Encompass partners If required to connect to a specific network, determine an appropriate gateway or SIMATIC solution

4 Migrate control code Migration Steps Create Equivalent Data Files or Structures Retain current structure Create equivalent data files with tag names / comments Symbolic Create equivalent symbolic arrays and comments Create New Logic Required for new hardware / gateways / sensors Convert Logic Retain current structure Create equivalent instructions and calling structure Symbolic Create new instructions and calling structure MIGRATE Migrate the existing AB programs using the TIA Migration Tool In the event that a SIMATIC library function is not available for a specific AB function, create a SIMATIC library function and add it to the SIMATIC AB library Create SIMATIC functions for any new hardware or gateways that will be used Create the Main calling routine(s)

5 Add advanced diagnostics Migration Steps Application-Specific Messages For the integrated Controller display For the HMI display Fast Machine Diagnostics Maintenance without Development Tools Reduced Downtime and Production Loss ADD Add PROGRAM_ALARM for diagnostic messages to the S7-1500 display and HMI Configure the HMI Graphics Configure the HMI(s) in TIA Portal Configure the HMI Alarms Verify the HMI Connection(s) Configure the HMI Trending Configure the HMI Tags Configure the PLC/HMI security

6 Test the application using simulation Migration Steps Test without Hardware Test Incrementally Reduce Startup Time TEST Test the new configuration using simulation Correct any issues found during simulation

7 Update documentation Migration Steps Ensure Proper Documentation for Plant Maintenance UPDATE Develop preliminary drawings for the application using the new SIMATIC hardware Develop an operator/ maintenance manual for the plant

8 Install on-site Migration Steps Install New Control Hardware Controller I/O Network components (Distributed I/O) HMI(s) Sensors Drive(s) Disconnect/Connect INSTALL Take the new system to site and install it Wire the IO using the fastest method possible Adapt the network configuration to the plant network infrastructure

9 Start up on-site Migration Steps Verify I/O Test Machine Operation Make Changes as Necessary Finalize Application Finalize Documentation START Startup and test the new application

10 Train plant personnel Migration Steps Hardware Training Development Tools Training Operator Training Maintenance Training Documentation Overview TRAIN Modify and document the updates to the application hardware and software Get acceptance sign-off from customer Modify and release the final drawings for the application Deliver all documentation and drawings to the customer Archive the application code END

Modernization Tools To access our complete offering, please visit: usa.siemens.com/modernization-tools.

Rockwell Automation® PLC-5® to SIMATIC S7 Application Conversion Guide Modernization tools Rockwell Automation® PLC-5® to SIMATIC S7 Application Conversion Guide Provides guidance for users who have used legacy control systems based on Rockwell Automation Controller-5 or SLC-500. Explains the major differences between the Rockwell Automation control system and the SIMATIC S7 control system Describes and illustrates migration approaches Demonstrates a number of use cases

WinCC Tag Converter Modernization tools Provides a fast and easy way to convert tags exported from the Rockwell Controller to a format that can be imported into WinCC (TIA Portal). Produces output for: HMI systems SIMATIC Panels WinCC Runtime Advanced WinCC Professional Provides the ability to synchronize Rockwell tag data with WinCC (TIA-Portal). This allows WinCC panels to easily communicate with Rockwell controllers.

Open communication between Logix and S7-1200 / S7-1500 Modernization tools Open communication between Logix and S7-1200 / S7-1500 Provides a library for Rockwell ControlLogix/GuardLogix and SIMATIC S7-1200 / 1500 that allows communication via a standard protocol (TCP/IP) without using a gateway. Libraries contain communication function blocks for the S7-1200 / 1500 to communicate with Rockwell Logix controllers. Send Receive CompactLogix ControlLogix S7-1500

EtherNet/IP™ connectivity Modernization tools EtherNet/IP™ connectivity In development S7-1500 EtherNet/IP Function Block (GET/PUT) Function Blocks for SIMATIC S7-1200 / S7-1500 to read/write data in a Rockwell controller via EtherNet protocols with no code changes in the Rockwell controller. No Code Modifications Required Put Get CompactLogix ControlLogix S7-1500

ProSoft gateways Modernization tools Function Blocks In development PROFINET to EtherNet/IP™ Gateway Provides simple connectivity between controllers and periphery using a ProSoft* Gateway (PROFINET to EtherNet/IP). Using gateways from other vendors is possible. Function Blocks Function Blocks for SIMATIC S7-1200 / S7-1500 to communicate EtherNet/IP to ProSoft Gateways for connectivity to Rockwell Automation legacy networks (AB RIO and DCSNet) Siemens ProSoft gateway Driver FB in S7-1500 Periphery Systems Drives ProSoft third-party gateway ROK legacy fieldbus (RIO) ProSoft third-party gateway Periphery Systems Controllers EtherNet/IP PROFINET Drives *ProSoft is owned by ProSoft Technology®:

FAQs (Frequently Answered Questions) Modernization tools FAQs (Frequently Answered Questions) Sample FAQ Q: How do I communicate with a Rockwell PLC from a Siemens HMI? A: The answer demonstrates: How to communicate with the maximum data throughput between a Rockwell Controller and a Comfort Panel / Advanced Runtime using the included communication networking driver “Allen-Bradley EtherNet/IP.” SIMATIC HMI Rockwell Controller

Siemens Migration Studio Modernization tools Siemens Migration Studio Migration Studio converts… data files (tags) code files (logic) program files tasks routines Migration Studio reads Rockwell software from… RSLogix5 (Controller-5) RSLogix500 (SLC 500) Studio 5000 * (Compact-, ControlLogix) RSView32 (PanelView32) Migration Studio exports to… TIA Portal V13 SP1 Upd 1 (Openness required) WinCC Comfort Advanced Hardware Conversion In development

ET200 converter Modernization tools Via Intranet Quickly converts third-party order numbers (Rockwell – 1734 Point I/O, 1756 ControlLogix, Beckhoff, etc.) into SIMATIC ET200 order numbers. Optimizes conversion result automatically with regard to the number of channels and type of connection

Siemens EtherNet/IP Solutions The EtherNet/IP™ Solutions family offers the flexibility to support both PROFINET and EtherNet/IP, and compatibility within any PLC. Solutions offer best-in-class features, and configuration to your existing network is fast and easy.

Siemens EtherNet/IP™ Solutions Connecting ET200S I/O through EIP-200S adapter interface EIP-200S adapter interface facilitates the connection of ET200S modules with EtherNet/IP networks. An application example demonstrates the setup, installation and use of the EIP-200S module with CompactLogix.

Siemens EtherNet/IP™ Solutions SINAMICS Drives CBE20 Communication Board Choose correct control module plus CBE20 board SINAMICS G130 High-Horsepower Modular Drive Components SINAMICS G150 Enclosed Drives SINAMCIS S120 High Performance / Servo Drive System (In chassis, bookshelf, blocksize and enclosed cabinets) EtherNet/IP Connectivity SINAMICS S150 Enclosed Regenerative Drive SINAMICS DCM DC Drives Choose correct Ethernet control module SINAMICS G120 General Performance Vector Drives (In compact, modular, distributed and enclosed versions)

Siemens EtherNet/IP™ Solutions SIMATIC Ident – RFID and code reading solutions RF 181EIP Logix Platform SIMATIC RF300 SIMATIC RF200 SIMATIC RF600 Rockwell does not currently have a complete RFID solution. The RFID181EIP module acts as the interface to an EtherNet/IP network.

Siemens EtherNet/IP™ Solutions Networking Infrastructure / cabling Wired / Wireless Communications EtherNet/IP requires IGMP snooping, supported in the following products: X-500 X-400 X-300 XB200 EtherNet/IP is standard TCP/IP; the networking components just transport the information FastConnect The most superior cabling solution in the market components just transport the information

Enterprise License Program (ELP) Minimize Risk Enterprise License Program (ELP) Allows easier distribution, installation, license management and maintenance of Siemens Engineering Software at key, multi-site accounts with large numbers of users. Customers who have a long, trusting relationship with Siemens qualify for this program and are able to host Siemens Engineering Software without any copy protection on a centrally located server. This offers an economical solution for customers to maintain a large number of engineering software installations across multiple sites. One central software and license management location Lean and efficient processes Complete transparency of software use ensures compliance Easy software inventory provides ad hoc reporting Master Software DVD and reusable Master License Key Time-saving and standardized installation Immediate reinstallation in case of hardware crash or change Existing current licenses can be applied to EPL Easy software maintenance Supports Engineering Software related to Automation and Drive families Provides more price stability and simplifies budgeting for the customer

Rockwell Conversion Example

Rockwell conversion example Packaging machine Rockwell Allen Bradley SLC 500 Panelview AMCI Resolver Siemens SIMATIC S7-1500 SIMATIC Basic Panel SIMOTICS Encoder

Rockwell conversion example Controller program structure Similar program structure for maintenance personnel

Rockwell conversion example Controller program file structure Similar file-naming structure, but more intuitive Siemens can still work with absolute data files No need to convert to arrays

Rockwell conversion example Controller program logic structure Ladder logic is ladder logic Similar symbols Comments are the same

Rockwell conversion example Controller tags Tag names nearly identical Similar addressing Comments are the same

Rockwell conversion example HMI structure Same screen names

Rockwell conversion example HMI tags Tag names nearly identical

Rockwell conversion example HMI screens Similar look and feel

Rockwell conversion example New diagnostic features Integrated Controller display Hardware diagnostics Machine diagnostics Command functions System Maintenance No PC required Password protected

Rockwell conversion example Benefits For a comprehensive set of tools to ease your transition, visit usa.siemens.com/modernization-tools No surprises for maintenance Controller program structure Controller logic Controller tags HMI structure HMI tags HMI screens Enhanced Diagnostics Controller Display Self configuring Ethernet devices Web pages ROI until mid-century