SIGMATEK S-DIAS Control System Replacement and Upgrade Guide

Replacement and integration of motion control and safety modules

Modern production line replacement not only involves logic control, but also upgrades to servo drives and safety systems. S-DIAS has also demonstrated outstanding integration capabilities in both fields.

1. Compact motion control scheme

The motion module of S-DIAS allows engineers to compactly control servo motors, brushed DC motors, and stepper motors on DIN rails.

Servo drive: S-DIAS DC series ultra compact fully integrated servo amplifier, rated power close to 300-480W, designed for controlling synchronous servo motors with continuous currents up to 6A or 10A (peak 15A or 20A) at 48V DC. Supports standard rotary transformers, incremental encoders, or universal encoder interfaces. The integrated+24V DC output is used to control the brake and provides 2-channel enable input, which can achieve STO (safe torque cutoff) safety function (SIL 3, PL e).

DC brushed motor: The SR 011/012 module is used to control and regulate economical DC brushed motors, with phase currents up to 5A and peak currents of 15A or 10A. The SR 011 is equipped with an integrated brake chopper and switchable incremental encoder.

Stepper motors: ST 151 and ST 152 are used to control 2-phase stepper motors, supporting continuous currents up to 5A. The output stage of a stepper motor can operate in full, half, or micro steps (up to 64 or 256). ST 152 also provides closed-loop regulation. The integrated dual channel enable input allows for the implementation of STO safety functions.

2. Programmable integrated security system

S-DIAS provides an extremely flexible and cost-effective integrated safety solution when replacing old safety relays or safety PLCs. This scheme consists of a safety controller and safety I/O. SCP 111 and SCP 211 safety controllers monitor and control applications, and provide bus interfaces to safety I/O modules. Of particular note is that the SCP 211 module provides the master station function for the FSoE (Safety over EtherCAT) safety protocol. Through this master station function, various FSoE slave station devices from different manufacturers can be integrated into S-DIAS security applications and safely controlled and monitored. Secure data is transmitted through VARAN, TCP/IP, and wireless networks (WiFi) according to the black channel principle. The system has passed TUV certification (up to SIL 3, Cat. 4, PL e), and through full integration, it can achieve the shortest response time (in milliseconds). Within a width of only 25 millimeters, a mini safety solution (such as SCP 111 paired with SDM 081 digital hybrid module) can be achieved, which is very suitable for emergency stop, door contact or grating replacement upgrades.

Application of high-precision measurement and special functional modules

For upgrade projects that require precise monitoring or special communication, S-DIAS offers a range of high-precision measurement modules and special functional modules.

Measurement technology: The S-DIAS measurement module supports current, voltage, frequency, temperature (PT 100/PT 1000), strain gauge weighing sensors, absolute and differential pressure, SSI absolute value encoders, energy recording (predictive maintenance), and IEPE analysis (status monitoring). Through modular construction, engineers can configure measurement values for specific applications without having to pay for unnecessary features.

Communication and Interface: S-DIAS provides a rich range of interface modules, including CAN, IO Link (SDCI port compliant with IEC 61131-9), Profinet, RS232/RS485, Ethernet switches, EtherCAT, and VARAN splitters. These modules enable S-DIAS to easily connect to existing upper level systems or heterogeneous networks, making it an ideal choice for replacing outdated communication gateways.

Software Configuration and Engineering Implementation: LASAL Platform

The success of hardware replacement cannot be achieved without strong software support. The S-DIAS system is fully compatible with SIGMATEK's object-oriented engineering tool LASAL. LASAL integrates control, visualization, motion control, safety, service, and remote maintenance into an integrated platform based on the IEC 61131-3 standard.

LASAL supports modular and mechatronic machine design methods. Machine components are simulated in software objects, and code and data are combined into logical units (objects). The graphical representation provides extremely high clarity, and through object-oriented technology, achieves the highest modularity and reusability, significantly reducing development time and costs. The graphical hardware editor supports project development, parameterization, and diagnostics. Even security projects can be designed comfortably in LASAL SAFETY Designer. For replacement projects, this means that engineers can complete all the work of migrating from old system logic to new hardware configuration on a unified platform, greatly reducing learning costs and engineering risks.

Common troubleshooting and maintenance suggestions

During the daily maintenance and debugging of the S-DIAS system after replacement, engineers may encounter some typical problems. The following are targeted troubleshooting suggestions: