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Converting OMAG Concrete Block Making Machine PLC from S5 to S7

Question:

Hello everyone, I am currently tasked with converting an S5 PLC to an S7 PLC system for an OMAG Concrete Block making machine project. I am seeking guidance and support from experienced experts familiar with the OMAG PLC system. Your expertise in this area would be greatly appreciated.

Top Replies

I highly recommend steering clear of the S5 program when transitioning to S7-1500. While it may offer some insight into previous functionalities, attempting to migrate it can result in a convoluted mess that is difficult to understand and maintain. Instead, opt to develop a brand new S7-1500 program following current programming best practices. This process will require thorough research to ensure a well-documented program. I recently completed the conversion of a PLC program to my updated standard, originally designed for the S7-300. The complexity of the program led me to believe it may have originated as an S5 program, ultimately taking me three weeks of intensive programming to complete.

JesperMP recommends abandoning the outdated S5 program and creating a new, modern S7-1500 program using current programming standards. Migrating the S5 program to S7-1500 can lead to confusion and difficulties in maintenance. It is essential to conduct thorough research and analysis to develop a comprehensive program description. Recently, JesperMP successfully converted a PLC program to their latest standard after three weeks of intensive programming. The process of converting a PLC5 program to CLX is likened to the challenges faced when upgrading from S5 to S7-1500.Working on programs that were haphazardly upgraded can be frustrating and inefficient.

JesperMP suggested avoiding the S5 program and instead focusing on understanding its functionality for reference purposes. Attempting to migrate the S5 program to S7-1500 may result in confusion and difficulties in maintenance. It is advisable to develop a new S7-1500 program using updated programming standards to ensure efficiency. Creating a new program will require thorough investigation and proper program description. JesperMP recently converted a PLC program to their latest standard, which took intensive programming over three weeks. While the original program was for S7-300, it seemed to have originated as an S5 program due to its structure. For assistance in converting all logic to ladder format, considering using IBHsoftware to read the PLC5 program. Some parts of the program may only open in STL, making it challenging for understanding. Seek guidance on finding ways to convert the logic to ladder for better comprehension.

When familiarizing yourself with a new machine, prioritize speaking with experienced operators who have practical knowledge. Refer to any available user manual and thoroughly examine all electrical and mechanical documentation. Develop a detailed functional description outlining how the machine should operate. Create a new program based on this description. If unsure of the machine's intended functions, review the old code as a last resort. By following these steps, you can gain a comprehensive understanding of the machine and optimize its performance.

In response to JesperMP's advice, it is recommended to consult with experienced machine operators, review any available user manuals and technical documentation, and create a functional description outlining the machine's intended operation. By developing a new program based on this information, the complexity of the logic involved in operating a block making machine can be better understood. While converting the STL code to ladder logic may be necessary to improve comprehension, studying the previous code should only be done if there is uncertainty about the machine's intended functions.

More Replies

Converting all STL code to ladder may not always be possible. It is recommended to analyze each STL instruction individually to grasp their functionality. Add comments to the code explaining the purpose of each instruction and reverse engineer it accordingly. If you encounter difficulties understanding a specific part, seek assistance from the community for clarification. Nick

When using the S5 > S7 conversion tool, it is possible that certain Siemens blocks may not convert properly. These blocks may show up in the S7 program without any code, such as the step flag sequence FB. Understanding the functionality of these blocks can be challenging, especially since the code is often locked. It is important to be aware of this potential issue and be prepared to troubleshoot and manually adjust these blocks in the converted program.

In response to a query from Manglemender, it is crucial to acknowledge that not all STL code can easily transition into ladder logic. A practical strategy would involve analyzing each STL instruction meticulously to comprehend its functions. By annotating the code with comments that outline the purpose of each instruction, one can effectively reverse engineer the process. Should you encounter difficulty in grasping a particular aspect, the community can undoubtedly offer valuable insights. Thank you, Nick, for this insightful advice.

Parky mentioned that when using the S5 > S7 conversion tool, there may be Siemens blocks that do not convert properly. These blocks may appear in the S7 program without any code, such as the step flag sequence FB. Understanding the functionality of these blocks can be challenging, especially since the code is often locked. Thank you for your input, it's definitely a risky task.

Before proceeding, it is advisable to see if there are any Siemens standard blocks available. While some issues, such as analog blocks, can be easily resolved, others may pose more challenges.

Parky advised checking for Siemens standard blocks as some, like analog blocks, can be easily bypassed while others may pose a greater challenge. It is important to be aware of these factors when working with Siemens PLCs.

Frequently Asked Questions (FAQ)

FAQ: 1. What is involved in converting an S5 PLC to an S7 PLC system for an OMAG Concrete Block making machine?

Answer: Converting an S5 PLC to an S7 system typically involves rewriting the existing program, mapping hardware configurations, and ensuring compatibility between the old and new systems.

FAQ: 2. Are there specific challenges or considerations when working with the OMAG Concrete Block making machine PLC system?

Answer: Yes, the OMAG PLC system may have unique features or specifications that require special attention during the conversion process. It's important to have expertise in this area.

FAQ: 3. How can I find experienced experts familiar with the OMAG PLC system to provide guidance and support for this project?

Answer: You can reach out to professional forums, online communities, or contact the manufacturer directly to connect with experts who have experience with the OMAG PLC system.

FAQ: 4. What are some best practices or tips for a successful conversion of the PLC system from S5 to S7 for the OMAG Concrete Block making machine?

Answer: It's advisable to thoroughly document the existing system, create a detailed plan for the conversion process, test the new system extensively before deployment, and seek assistance from experienced professionals when needed.

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