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.

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:

1. Abnormal I/O signal

Troubleshooting direction: First, check the signal LED on the side of the module. There are independent signal LEDs next to each channel. If the signal LED is not lit, it indicates that the signal has not arrived at the module correctly.

Solution: Check if the wiring of the push in spring terminal is secure. Due to the support for tool free wiring, sometimes the cable may not be fully inserted. Use cables within 1.5mm ² to ensure proper insertion. Check if the mechanical interlock of the module is fully engaged and ensure that the bus contacts are well connected.

2. Communication failure (VARAN/EtherCAT, etc.)

Troubleshooting direction: Check the status LED of the module and confirm if communication is normal. If using VARAN bus, it is necessary to check whether the number of nodes exceeds the limit (a single CPU module or VARAN bus interface can support up to 64 participants and 1280 I/O points).

Solution: Check if the dual point contact of the industrial Mini I/O connector is damaged. Confirm whether the wiring of the VARAN bus in the control cabinet is far away from strong interference sources. If it is integrated into a third-party EtherCAT or Profinet network, it is necessary to check whether the configuration parameters of the interface module (such as EC 121/122 or IPN 021) are correct.

3. The security function cannot be activated

Troubleshooting direction: Configuration errors in the security controller SCP 111/211 are a common cause.

Solution: Use LASAL SAFETYDesigner to check the security logic. Confirm whether communication between the FSoE master station (SCP 211) and the slave station devices has been established. Check the wiring of safety I/O modules (such as SDI 081, SDO 081) to ensure that the dual channel input and output signals are normal. Confirm whether the power supply and enable input of the safety module comply with the wiring requirements of SIL 3/PL e.

4. Error in motion control module

Troubleshooting direction: Errors in servo or stepper motor modules are usually related to encoder feedback or enable signals.

Solution: Check if the encoder interface (such as the universal encoder interface of DC 064/104) is securely connected. Confirm if the STO function is triggered correctly (check the dual channel enable input). For the closed-loop control error of stepper motor ST 152, it is necessary to check whether the position feedback signal is disturbed.