SIMATIC is a series of programmable logic controller and automation systems, developed by Siemens. Introduced in 1958, the series has gone through four major generations, the latest being the SIMATIC S7 generation. The series is intended for industrial automation and production.
The name SIMATIC is a registered trademark of Siemens. It is a portmanteau of "Siemens" and "Automatic".
Function
As with other programmable logic controllers, SIMATIC devices are intended to separate the control of a machine from the machine's direct operation, in a more lightweight and versatile manner than controls hard-wired for a specific machine. Early SIMATIC devices were transistor-based, intended to replace relays attached and customized to a specific machine. Microprocessors were introduced in 1973, allowing programs similar to those on general-purpose digital computers to be stored and used for machine control. SIMATIC devices have input and output modules to connect with controlled machines. The programs on the SIMATIC devices respond in real time to inputs from sensors on the controlled machines, and send output signals to actuators on the machines that direct their subsequent operation.
Depending on the device and its connection modules, signals may be a simple binary value ("high" or "low") or more complex. More complex inputs, outputs, and calculations were also supported as the SIMATIC line developed. For example, the SIMATIC 505 could handle floating point quantities and trigonometric functions.
History
On April 2, 1958 the name Simatic (composed of "Siemens" and "Automatic") was registered with the German Patent and Trademark Office (DIN) as a registered trademark of the company Siemens.
A year later, in 1959, the Simatic G was launched on the market, a system that could replace relay logic with a hard-wired programmed logic controller (based on the use of germanium transistors). The system was launched under the name "Building-Block System for Solid-State Controls".
In 1964, the Simatic N (1964) was launched (hard-wired programmed logic controller) - based on Silicon transistors.
In 1973, the Simatic S3 was launched, the first microprocessor-based Simatic system that implemented programmable logic.
In 1979, the Simatic S5 series was launched, a series that was maintained until 2000. Automation systems based on Simatic S5 are still functional worldwide. S5 systems were programmed using the STEP 5 software system. In 1984 the Simatic S5 U (universal) programmable controller series is introduced.
In 1994, the Simatic S7 series was launched, a series based mainly on the S7-200 controllers (dedicated to simple automation systems), S7-300 (suitable for almost any automation system) and S7-400 (dedicated to large and very large automation projects). All controllers in these series allow networking, especially in Profibus or Industrial Ethernet networks.
In 1996 Siemens presented the concept of "Totally Integrated Automation", initially a concept referring to the interconnectivity of automation equipment.
In 2009, the S7-1200 series of PLCs was launched, a series that replaced the S7-200 series.
In 2011, the TIA Portal (Totally Integrated Automation Portal) software package was also launched, a software platform dedicated to the complex programming of automation systems.
In 2013, the S7-1500 series appeared on the market, a new generation of programmable logic controllers intended to replace the S7-300 and S7-400 series over time.
S7-1200 G2, a second generation of the S7-1200, was launched in December 2024.
Controllers
SIMATIC control systems (PLC) are designed to automate as much of the control of industrial plants as possible. Through the system inputs and outputs, it can monitor and control process elements (operation flow, mechanical element status, temperature, pressure) reducing the need for continuous supervision by a human operator.
The operating logic is stored in the form of a software program in the memory of a Central Processing Unit-type control system. The automation system is modular and, in addition to the CPU, can be equipped with various digital and/or analog peripheral modules, as well as intelligent control modules. The modules can be configured centrally (mounted in close proximity to the CPU unit) or decentralized, close to the controlled plant. The range of controllers extends from small, compact controllers to high-performance PLC systems. What all Simatic controllers have in common is their robustness against electromagnetic interference (e.g. Simatic-S7 complies with the requirements of Directive 2014/30/EU on electromagnetic compatibility and climatic stress - e.g. 0 to + 60 °C ambient temperature during operation). Simatic is programmed using STEP 7 (formerly STEP 5) programming software or software from third-party manufacturers.
Siemens has developed more product lines to date. First versions were hard-wired, the first processor based series being SIMATIC S3
SIMATIC S3 (starting from 1973)
S3 was based on hard-wired logic SIMATIC C3. Example: Simatic S3-111
Simatic S5
(1979 - 2000)
The S5 line was sold in various chassis configurations. Within each chassis style, several CPUs were available, with varying speed, memory, and capabilities. Some systems provided "fail-safe" control, used for safety applications or redundant CPU operation for ultra-high-reliability control, as used in pharmaceutical manufacturing, for example.
Each configuration was built starting from the central unit to which the various input and output modules, communication or modules for special functions were attached. The compact variants were configured by directly coupling the modules onto the support rail, the complex variants were configured by mounting modular boards in a dedicated drawer.
Simatic S5-010 – Modular PLC system Simatic S5-010K – Variant for injection molding machines (Kunststoffspritz). Simatic S5-010W – Variant for machine tools (Werkzeugmaschinen) or positioning systems. Simatic S5-90U – Compact control units Example: 6ES5090-8MA0x / S5-90 / 4 kByte RAM / Integrated 230 V AC power supply, 10 binary inputs, 6 relay outputs directly on the CPU Simatic S5-95 – Compact control units Simatic S5-95F – Failsafe version - integrated safety functions Simatic S5-95U – universal version
Simatic S5-100U – Modular unit Simatic S5-101 – Compact unit Simatic S5-101R – Programming in LAD language only Simatic S5-101U – Programming in AWL/STL, LAD and CSF/FBD; Expansion possible with expansion module Simatic S5-105R – Modular system in 19-inch drawer. Programming only in LAD ("R" stands for Relay - programming in LAD = relay diagram) Simatic S5-110 – Modular system Simatic S5-110A – Modular Simatic S5-110F – Failsafe version - integrated safety functions Simatic S5-110S – Modular, drawer mounting with external I/O bus Simatic S5-115 – Modular system, fanless central unit, (fans for certain drawer types), different memory capacities depending on version, expandable memory with plug-in modules Simatic S5-115F – Failsafe version - integrated safety functions Simatic S5-115H – Redundant version (High Availability) Simatic S5-115U – Universal version Simatic S5-130 – Mid-range modular system (performance-wise) Simatic S5-130A – Robust version (encapsulated modules) Simatic S5-130K – Compact version (cardboard in drawer) Simatic S5-130W – Cardboard in drawer version for industrial process automation Simatic S5-135U – Mid-range modular system (performance-wise). The first Simatic system that allows multiprocessor configurations (up to 4 central units in parallel). Each central unit has its own PLC program, its own memory areas, counters and timers. Communication between the processors can be achieved via a common memory area (Dual-Port-RAM) or via data blocks (DB blocks). Ex.: 6ES5 920-3UA1x, 6ES5 921-3UA1x, 6ES5 922-3UA1x, 6ES5 928-3UA1x, 6ES5 928-3UA2x, 6ES5 928-3UB1x, 6ES5 928-3UB2x, ... Simatic S5-150 – Modular system with ventilated drawer for complex automation or central coordination systems, introduced on the market in 1980. Simatic S5-150A – Robust design variant (encapsulated modules) Simatic S5-150K – Compact design variant (card boards in drawer) Simatic S5-150S – Drawer design variant (card boards in drawer) Simatic S5-150U – Drawer design variant (card-type boards in the drawer) Ex.: 6ES5 924..., 6ES5 925..., 6ES5 926..., 6ES5 927... Simatic S5-155 – Modular system, with ventilated drawer, for complex automation, allows single- or multi-processor configurations. Simatic S5-155H – Redundant version ("High Availability") Simatic S5-155U - Universal version Ex.: 6ES5 946..., 6ES5 947..., 6ES5 948...
Simatic S7 (S7-200, S7-300, S7-400) (since 1994)
The first entries in the S7 line were released in 1994, available under three performance classes: S7-200, S7-300 and S7-400. The introduction of SIMATIC S7 saw also the release of a new fieldbus standard Profibus, and the pioneer use of industrial Ethernet to facilitate communication between automation devices. The great success of the S7-300 CPU family in particular helped to cement the role of Siemens as one of the global leaders in automation technology. These series are expected to be phased out in 2033.
Simatic S7-200
(phased-out - )
A series of small (80 mm x 62 mm), fast (0.22 μs binary execution time) PLC modules with an integrated RS 485 interface (PPI Interface = Point to Point Interface). for low-complexity automation applications Programmable using the Step 7 MicroWin software (originally Step 7 MicroDos). Although no longer marketed as such, S7-200 units are still used for the PLC units integrated in the Sinumerik 828D CNC Numerical Controls series.
Simatic S7-300
Modular PLC system (but there are also some compact CPU units, with integrated Inputs/Outputs). Communication with other devices is possible via the integrated RS 485 (MPI = Multi Point Interface), Profibus, Profinet and Ethernet interfaces. modular system, expansion of the number of inputs/outputs by adding modules for automation applications of low or medium complexity system programming is done using the STEP 7 software package. PLC program storage is done on an MMC card inserted in the CPU unit. The system consists of: A CPU unit that also includes communication functions (MPI, Profibus or Profinet, depending on the chosen variant) SM modules for connecting inputs and outputs (digital or analog) Optional: IM interface modules or SP communication processors for various types of communication buses Optional: FM function modules such as high-speed counters, positioning (closed/open loop), PID control, etc. Simatic S7-300: Control units (extract) CPU 312 32 KB working memory, MPI interface; storage medium: MMC card CPU 314 128 KB working memory, MPI interface; storage medium: MMC card CPU 315-2DP 256 KB working memory, MPI interface, ProfiBus DP main/subordinate interface; storage medium: MMC card CPU 315-2 PN/DP 384 KB working memory, dual interface MPI/PROFIBUS DP main/subordinate, Ethernet/PROFINET interface with 2-port switch; MMC card CPU 317-2 DP 1 MB working memory, MPI interface, PROFIBUS DP main/subordinate interface; MMC card CPU 317-2 PN/DP 1 MB working memory, dual interface MPI/PROFIBUS DP main/subordinate, Ethernet/PROFINET interface with 2-port switch; MMC card CPU 319-3 PN/DP 2 MB working memory, dual interface MPI/PROFIBUS DP main/subordinate, PROFIBUS DP main/subordinate, Ethernet/PROFINET interface with 2-port switch; MMC card
Simatic S7-300F
Modular PLC system, based on S7-300, with extended functions for process control in which functional safety ("safety functionality") plays an important role. the system allows the achievement of functional safety requirements SIL 1 to SIL 3 according to IEC 61508, PL a to PL e according to EN ISO 13849-1, Cat 1, 2, 3 and 4 according to EN 954-1.