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Max Zeller Söhne AG - Retrofit of a loading device for pharmaceutical production

The existing SIMATIC S5-100U controller with 2 drives with frequency converters for a loading device has been in operation since 1997. The safety technology was no longer up to date. Likewise, more frequent breakdowns have affected availability. The controller was to be replaced by a modern SIMATIC S7 solution with touch panel and integrated safety.

The aim was to increase equipment availability and safety. The availability of spare parts should also be given.

A particular challenge was the shortest possible conversion and recommissioning time. For this purpose, a solution was worked out with replacement of the mounting plate with the complete control system while retaining the motors, encoder and cabling.

The control concept is based on SIMATIC ET 200SP with CPU 1512SP F-1PN. Two SINAMICS frequency converters with ProfiNet/ProfiSafe were selected for the drives. They are connected via a SCALANCE switch. A SIMATIC HMI KTP700 with 7″ Touch was used as HMI.

The concept allows a fully integrated software solution of PLC, Safety, HMI and Motion Control functionality. Programming takes place completely in the TIA Portal.

TBM Automation AG was able to contribute its more than 25 years of experience in control and drive technology to the solution. Siemens was favored by the customer due to the complete integration under the TIA Portal.

The customer benefits from simple operation and high availability of the system. The integrated solution allows extensive diagnostic options, reducing downtime and maintenance costs in the case of a malfunction.

Through the integration of safety and motion functionality, the safety of the system could be brought up to date (PLd). For example, manual operation takes place at safe, reduced speed (SLS).

Please click on the images to enlarge them!


SIMATIC ET 200SP with CPU 1512SP F-1PN

Retrofit of a Loading Device

SINAMICS frequency converter with ProfiSafe