SIGMATEK S-DIAS Control System Replacement and Upgrade Guide

SIGMATEK S-DIAS Control System Replacement and Upgrade Guide

In the field of industrial automation, equipment updates and system performance upgrades are the norm that engineers must face. When the original control system encounters bottlenecks due to its large size, processing capacity, or inability to meet the safety and networking requirements of modern Industry 4.0, finding an alternative solution that can significantly save control cabinet space, seamlessly integrate with the existing production line network, and have high scalability becomes the key to project success. The S-DIAS system launched by SIGMATEK provides a highly valuable reference solution for the replacement and upgrade of traditional control systems with its "pocket format" ultra compact design and powerful modular functionality.

The core driving force for replacement and upgrade: why choose the S-DIAS architecture

When replacing old control systems, engineers often face three major pain points: insufficient control cabinet space, poor system scalability, and lack of safety features. The S-DIAS system provides a disruptive design for these pain points.

1. Ultimate space compression and high-density integration

Traditional control systems often require larger control cabinets for upgrades, but S-DIAS breaks this routine. Its single module size is only 12.5 x 104 x 72 millimeters, yet it can integrate up to 20 channels on a single DIN rail module, achieving an astonishing packaging density of only 63 square millimeters per channel. This means that up to 64 modules can be installed on an 80 centimeter wide rail, providing up to 1280 I/O points. For projects that require the replacement of old distributed I/O or dense cabling, this miniaturized design directly means a significant reduction in the size of the control cabinet, thereby significantly reducing hardware and installation space costs.

2. Real time communication and multi CPU architecture for Industry 4.0

S-DIAS adopts a hard real-time Ethernet bus VARAN, with a communication speed of up to 100 Mbit/s. The access time of individual I/O modules is only 1.12 microseconds, and the update cycle is less than 60 microseconds, making it perfect for extremely fast and high dynamic application scenarios. When replacing centralized old PLCs, S-DIAS supports flexible multi CPU concepts. By dividing machines or systems into multiple electromechanical functional units and directly equipping them with processing intelligence on site, engineers can easily achieve distributed control. This architecture allows the system to flexibly adjust according to customer needs at any time, avoiding the risk of single CPU solutions reaching performance limits due to program expansion.

3. Stable and reliable mechanical and electrical design

The reliability of hardware connections is crucial when replacing old systems. S-DIAS integrates electronic components, buses, and DIN rails into a stable housing. The module power supply and bus connection are completed through sturdy multi contact plugs, and its unique mechanical interlocking function creates seamless and vibration resistant connections. In addition, the module is delivered with standard push in spring terminals, which can be quickly wired without the need for tools. It supports 1, 2, or 3-wire connection technology, with a maximum wire diameter of 1.5 square millimeters, greatly simplifying on-site replacement and wiring work.

Core hardware selection: replacement strategy for CPU and I/O modules

The primary task when replacing a system is to select the appropriate CPU and I/O modules. S-DIAS offers a complete product line from economical to high-performance.

1. Flexible and versatile CPU modules

The CPU modules of S-DIAS are divided into compact and high-end types. For general control and motion tasks, a compact CPU equipped with high-performance EDGE2 technology processor is an ideal choice. For example, modules such as CP 102, CP 111-2, CP 112-2, and CP 311 offer options ranging from economical single core to high-performance dual core (2 x 800 MHz). These modules integrate interfaces such as Ethernet, VARAN, CAN, and USB. The network connection uses industrial grade Mini I/O connectors, and its dual point contact principle ensures precise and vibration resistant connections. For complex control, tuning, and motion control tasks, the 730, 800, and 900 series CPU units are equipped with powerful Intel Atom dual core/quad core or Intel Core i3 dual core processors. These high-end CPUs not only serve as central control platforms in the multi CPU concept, but also provide rich interfaces such as Ethernet, VARAN, EtherCAT, CAN, USB, S-DVI, and Displayport. Their bus interfaces are located on the side and can directly connect to S-DIAS I/O modules.

2. Rich I/O and diagnostic functions

When replacing the old I/O system, the channel level diagnostic function of S-DIAS greatly simplifies maintenance work. Its status LED provides communication status information, and each channel connection point is equipped with a signal LED next to it, which can clearly indicate the contact status. The module labels support personalized labeling, which improves the clarity of the control cabinet. The I/O modules of S-DIAS include digital input (DI), digital output (TO), relay output (RO), hybrid digital module (DM), and analog input/output (AI/AO). Whether it is 24V DC standard signal, 0-20mA, ± 10V analog signal, or special measurement signals such as PT100/1000, thermocouple, strain gauge, etc., S-DIAS has corresponding module support. Through separators and interface modules such as VARAN, Ethernet, EtherCAT, CAN, Profinet, the S-DIAS system can be seamlessly integrated into system combinations from different manufacturers, which is particularly critical for the replacement and upgrade of hybrid production lines.