After a factory audit was performed for obsolete control panel equipment, it was highlighted that two convey systems which were critical to a machines operation were still in operation.
After discussions we uploaded the old PLC software from the EX40’s and checked this with the on-site version in the manuals (this was different and the EX40 had been modified over the years and the manuals not updated).
We re-wrote the software for both the EX40’s to a new S7-1200 and an S7-1200F safety PLC. The old equipment was removed during a shutdown and the new Siemens PLCs were fitted and commissioned. A backup of the software in ZAP format was given to the customer.