SIGMATEK ETT Series HMI Replacement and Selection Guide

SIGMATEK ETT Series HMI Replacement and Selection Guide

SIGMATEK ETT/HGT series HMI replacement upgrade and Industry 4.0 integration guide

In today's rapidly iterating industrial automation field, engineers often face issues such as the discontinuation of old equipment spare parts, processor performance bottlenecks, or the inability of existing single touch panels to meet the complex visualization requirements of modern smart factories. When the existing single touch human-machine interface (HMI) lifecycle reaches its end or cannot support the networked and modular architecture required for Industry 4.0, how to choose an alternative solution that can seamlessly upgrade and replace, and has a forward-looking technological architecture, has become the core challenge faced by automation engineers. SIGMATEK, as an automation solution provider originating from Austria, provides highly valuable solutions for this problem with its new series of operation panels, control panels, and mobile terminals.

This article will analyze SIGMATEK's core advantages in multi touch technology, dual/multi CPU separated architecture, HMI Link remote communication, and configuration software from the perspective of system upgrade and replacement engineering, providing detailed professional guidance for engineers facing equipment upgrade and selection challenges.

Core pain points and architecture reconstruction for replacing outdated HMI

When considering replacing outdated human-machine interfaces that have been discontinued, engineers first need to evaluate the limitations of the existing control architecture. The traditional single CPU solution has inherent risks throughout the project lifecycle: as program code continues to expand and visual interfaces become increasingly complex, a single processor will soon reach its performance limit. Once the CPU is overwhelmed, the response speed and stability of the entire production line will face severe challenges.

SIGMATEK's flexible dual CPU or multi CPU solution provides a perfect breakthrough solution for this pain point. The core concept of this architecture is to separate the "visual interface" from the "logical control and motion control". Through this separated design, the computational workload can be modularly adjusted according to actual needs. When replacing the original single control terminal, users only need to add a programmable separated display terminal (such as SIGMATEK's HMI Link unit), which can greatly reduce the burden on the main control CPU. This modular future trend allows the system to adapt to new needs by flexibly expanding modules, and although multi CPU solutions have more flexible configurations, their costs are comparable to single CPU solutions, making them highly economical.

At the software level, replacement and upgrade is not only a hardware replacement, but also a reconstruction of data flow management. SIGMATEK's object-oriented programming software LASAL combines modern and efficient programming techniques to simplify modularity while improving software utilization. For communication between distributed machines and system components, the "Machine Manager" in LASAL environment can perfectly manage the data flow in the network system vertically and horizontally. It can clearly and systematically display individual software projects in machines or systems, and intelligently adjust distributed communication to achieve arbitrary data exchange. In addition, all SIGMATEK control panels support OPC UA communication protocol, which can be used as a server or client to connect to third-party software for cross platform data exchange, completely breaking the information island problem in traditional HMI replacement.

Core replacement device selection: in-depth analysis of ETT multi touch operation panel

After determining the top-level architecture of the separated control, selecting a suitable front-end display operation panel is the top priority of the replacement project. SIGMATEK's ETT series panels offer a wide range of options from 4:3 format to modern widescreen format, fully utilizing advanced projected capacitive touch technology (PCT).

1. Modern widescreen series (10.1 inches to 21.5 inches)

For high demand modern visualization projects, modular series human-machine interfaces are an ideal choice to replace old equipment. This series of widescreen HMI provides great clarity and freedom. The ultra-thin design covers five display sizes, with resolutions ranging from 1280 x 800 pixels (10.1 inches and 12.1 inches) to 1366 x 768 pixels (15.6 inches and 18.5 inches), and the largest 21.5-inch model reaches the full HD level of 1920 x 1080 pixels. Whether installed vertically or horizontally, the widescreen panel can perfectly adapt to any complex control cabinet or workstation space.

In terms of hardware configuration, this series of modular widescreen HMIs provides extremely high flexibility. Users can customize the required performance and display size according to their personal preferences. It can choose to add CPU units (ET series) or HMI Link units (TAE series). The CPU unit can use EDGE2 technology processors or x86 processors for higher performance requirements (such as Intel Celeron J4005 dual core 2.0 GHz). Integrate 2 Ethernet ports, 1 USB 2.0, 1 USB-OTG, and support external OPC UA. Whether it is EDGE2 technology, x86 processor, or HMI Link unit, HMI can be easily upgraded after installation.

2. Classic 4:3 format multi touch panel (8.4 inches to 19 inches)

For replacement projects that wish to maintain the original console opening size or prefer traditional proportions, the 4:3 format multi touch panel of the ETT series is an excellent choice. This series of panels supports intuitive gestures and multi finger operations, enabling complex click functions and even multi finger input with thin gloves, which is particularly practical in scenarios with special environmental requirements such as food processing and pharmaceutical industries.

This series of panels is equipped with ARM based EDGE2 technology dual core processors (2x 800 MHz), which have low power consumption and high performance. They do not require a cooling fan during use, completely eliminating the potential for malfunctions caused by fan wear and dust accumulation. The installation depth is only 48mm, and the panel can be directly embedded into the console and integrated controls for machine operation. In terms of configuration, it has 512MB of RAM for storing programs and data parameters, and 512MB of SD card for storing formulas, alarms, and log files.

3. Intelligent adjustable backlight logo

When replacing old equipment, the SIGMATEK ETT series offers an innovative additional feature - an adjustable backlight logo. Due to the borderless design, the logo on the screen can be customized into the customer's company logo according to their needs, with backlight function. Backlight can be activated through a program and changed to any color. What is more practical is that the program has a dedicated functional module built-in, which can actively control the backlight of the logo, change the color of the logo backlight or make the logo backlight flash when receiving an error alarm signal. This means that engineers can sense the alarm immediately through the flashing status of the logo without approaching the screen when equipment malfunctions, greatly improving the efficiency of on-site fault diagnosis.

In addition, all interfaces of the ETT series are located at the bottom of the panel, and the back is equipped with an easy to disassemble safety input module SIB 061. This module is equipped with 6 independent read secure input points and can be connected to 3 external devices containing two signals and commands. The panel motherboard is equipped with 2 Ethernet ports, 2 USB 2.0 ports, 1 USB-OTG port, and 1 CAN port, as well as 8 digital input and output points, which can be used for external signal towers, independent operation switches, and other signal command devices.

Replacement plan for special scenarios: control panel and mobile terminal

Not all replacement projects require a separate architecture, and for moderately complex applications, an integrated control panel can provide a more cost-effective solution. At the same time, for scenarios that require on-site mobile operations, the limitations of traditional fixed HMI are becoming increasingly prominent, and mobile terminals have become a new direction for replacement and upgrading.

1. ETV series control panel (onboard CPU)

When there are certain limitations on application expansion, the ETV series all-in-one machine can serve as the central control unit. This multifunctional control panel is designed to be compact, integrating control, visual interface, and operation. It is equipped with an integrated CPU and a color resistive touch screen, using a low-power EDGE technology processor (800MHz), with 8 switch inputs and 8 switch outputs.

The ETV series offers three specifications to choose from: 5.7, 8.4, and 12.1. Through the integrated real-time Ethernet VARAN port, fast data transmission can be ensured. This series supports multiple standard interfaces, such as Ethernet port, CAN port, and USB port. These interfaces distributed at the bottom of the screen allow the control panel to be easily integrated into the customer's mechanical system. For simple applications, the ETV series integrated control panel is the most suitable, with small panel sizes starting from 3.5 inches for operation and monitoring. At the software level, LASAL, as a unified programming tool, greatly simplifies customer application development and enables a set of programming tools to simultaneously handle application control and visualization.

2. HGT, HBG, and HGW series mobile terminals

If you want a mobile operation display terminal, SIGMATEK's mobile panel will be the right choice. These panels feature 8.4-inch, 10.1-inch, or 10.4-inch true color touch screens that allow for wireless remote control of the machine through a mobile HMI.

HBG panel: equipped with a classic operating system and interface, using an integrated communication cable, capable of lossless data transmission within 100 meters.

HGT panel: It uses the second-generation EDGE2 processor and is equipped with interfaces such as VARAN, Ethernet, and USB.

HGW1033 Wireless Panel: This is a new member of the mobile terminal family. It is equipped with a 10.1-inch LCD screen, an EDGE2 processor, and an integrated battery pack weighing only 1350g. The security function has also been integrated into the terminal, and security data can also be transmitted through wireless signals.

All mobile terminals are equipped with a three-level confirmation button, an emergency stop button, and a key switch for use by robots, machines, or systems without security restrictions. Considering the comfort of on-site operation, through reasonable ergonomic design, all human-machine interface mobile terminals can perfectly fit the palm of the human body, even a left-handed person can operate smoothly and comfortably like a right-handed person.

Collaboration between HMI Link Remote Solution and Configuration Software

In scenarios where the layout of large factories or equipment is scattered, replacing HMI often faces the problem of the distance between the control cabinet and the operation console being too far. Traditional display cables are prone to interference and have high costs during long-distance transmission. SIGMATEK's HMI-LINK remote solution perfectly solves this pain point.

1. HMI Link: Remote deployment within 100 meters

Single cable, high power, and long distance are the core advantages of HMI-LINK remote solutions. Paired with a standard Cat5e or Category 6 cable, the full HD LCD screen, audio, and USB signals can achieve lossless communication between the operating terminal and the 400 series industrial computer within a distance of 100 meters.

HMI Link is a pure hardware solution and independent operating system. There is no processor inside the HMI Link panel, so it is more mechanical and economical. As the front-end panel does not include a processor, the computing power of the control unit can be fully released for logical control. This is a highly innovative replacement strategy for projects that wish to upgrade old industrial computers to high-performance central control units while retaining on-site operation panels. In the selection of modular operation panels, the TAE series (such as TAE 1044, TAE 1244, etc.) is a widescreen multi touch operation panel that integrates HMI-LINK, supports IP65 protection, and is suitable for rocker arm installation or embedded installation.

2. LASAL SCREEN and VISUDesigner configuration tools

The ultimate implementation of hardware replacement relies on software support. SIGMATEK provides powerful visual interface design software Screen and a new web-based visualization software VISUDesigner, which are important components of the engineering environment LASAL.

Efficient visualization programming: In software editors, existing functional blocks can be directly created and pulled to complete visualization view programming without the need for programming basics. Pre constructed templates and universal operation blocks, graphics, and design elements can facilitate engineers in designing and creating visual programs.

Web based modern technology: LASAL VISUDesigner software is based on current web technologies: HTML5, CSS3, and JavaScript. For engineers, the advantage is that the display of visual views is largely hardware independent and can run on a large number of HMIs. Logical control and visual configuration are independent of each other. In VISUDesigner, the perfect presentation of scalable vector graphics (. svg) can be achieved.

Complete management functions: alarm and event management, trend display, text and recipe management, as well as language and unit conversion functions are integrated into these two HMI development software. Support for all languages and ASCII and Uni Code text input in one project, which is particularly important for HMI replacement in export equipment or multinational factories.

Implementation suggestions and precautions for upgrading and replacing projects

When carrying out the replacement and upgrade project of SIGMATEK HMI, engineers need to pay attention to the following key technical details:

Protection level matching: Select the appropriate front panel protection level based on the on-site environment. For example, in the food and beverage industry, frequent washing is required. It is recommended to choose the ETT series with a front panel protection level of IP65 (such as ETT 0833, ETT 1033, ETT 1233, etc.), which uses 4mm glass and black frame, and is sturdy and durable. In general industrial environments, IP54 or IP30 plastic panels or anodized aluminum panels (such as ETV 0552, ETT 731, etc.) can meet the demand.

Interface compatibility assessment: When replacing, it is necessary to verify the communication interface of the existing PLC or controller. The SIGMATEK panel provides a wide range of communication interfaces, including Ethernet, CAN, USB 2.0, USB-OTG, RS232, RS485/Modbus RTU, and more. For distributed systems, the VARAN real-time Ethernet port can provide efficient data transmission.

Storage and memory configuration: Ensure that the newly replaced HMI has sufficient storage space for programs, recipes, and log files. For example, 512MB of RAM and 512MB of SD card are standard configurations, while x86 widescreen series (such as ETT 1044, ETT 1244) offer 2GB DDR4 and 32GB of storage, suitable for high-performance demand scenarios.

Remote security and emergency stop function: For the replacement of mobile terminals, the security function must be strictly evaluated. The HGT, HBG, and HGW series all come with emergency stop buttons, confirmation buttons, and key switches to ensure safety during wireless or wired mobile operations.