A customer asked to look at an old obsolete S7-300 with an old siemens MP Touch Panel where the touch screen had died with respect to a siemens upgrade.
After looking at costs of new verses old it was decided to upgrade from the old processor and HMI to a new current S7-1500 PLC and TP1900 Comfort HMI.
The software was upgraded from STEP7 v5.5 in TIA portal V15.1 and all blocks that didn’t transfer over correctly in STL were debugged and re-written. There were quite a few old STL blocks that didn’t come over correctly in TIA Portal which is quite normal with old STL code. The old MP HMI software in WinCC had to go through various conversion process’s before being able to be converted to a TIA Portal TP1900 touch panel
All of this was checked in Siemens PLC Simulator (S7-PLCSIM) and then the upgrade was done over a weekend. The old S7-300 processor was removed and the newer modern S7-1500 processor was added, this had both profit and profibus on-board as some of the old weighing equipment was all on profibus. The old IM151 processor was also upgraded and after all the hardware had been fitted the control panel was powered up and testing was performed of ll functionality fo the system. Then after this final commissioning was performed under customer supervision on the Monday with production.