SIGMATEK CCP 521 C-DIAS processor module

SIGMATEK CCP 521 C-DIAS processor module

Product Overview

Core positioning: Execute control programs and be the core unit of automation systems; Built in VARAN bus manager, capable of building high-performance VARAN real-time bus systems, connecting distributed I/O, driver, and communication modules.

Compatibility: X86 architecture, using standard AMI PC BIOS, no need for SIGMATEK dedicated BIOS, pre installed LASAL operating system.

Online debugging interfaces: CAN, Ethernet Mini‑USB Device；

Program update method: USB Host (USB flash drive, keyboard); Pluggable microSD card enables quick replacement of the entire control program; The project backup is saved inside the microSD card.

Status indicator: 2-digit 7-segment digital display, 4 status LEDs including DCOK, ERROR, Ethernet, and VARAN; Equipped with SET and RESET buttons.

Key hardware performance parameters

Project parameters

Processor EDGE X86 compatible, 16 bit data bus, 500 MHz

Cache L1 Cache 32 KB; L2 Cache 256 KB

Memory DDR2 RAM 64 MB

Maintain SRAM 512 KB in case of power failure (simulated through SD card)

Built in storage 512MB microSD card (order number 12-630-051)

Addressable I/O VARAN bus: 65280 points; CAN bus: 32 stations; C-DIAS backplane: 8 modules

Real time clock built-in, battery buffer for about 10 days

Electrical Specifications

Power supply: 18-30 VDC; North American UL requires the use of a Class-2 power supply;

Power consumption: typical 150   mA, maximum 500   mA; instantaneous surge current of about 30A (continuous~20ms) upon power on;

The C-DIAS backplane is powered by this CPU, and the maximum output current of the backplane is 1.2   A.

Default network parameters: Ethernet IP 10.10.150.1, subnet mask 255.0.0.0; CAN bus station number 00, baud rate 500   kbit/s.

Important Network Reminder: If connected to an IP network containing non SIGMATEK devices, broadcast packets will cause high, medium, and intermittent loads, leading to real-time operational errors; Router/firewall packet filtering and isolation are required.

Environment and Machinery

Working temperature: 0~+60 ℃; Storage -10~+85 ℃; Humidity of 10-90% without condensation;

EMC: EN 61000-6-2 Industrial Environment; Impact EN 60068-2-27 (150 m/s ²); Protection IP20 (UL for open devices); Pollution level 2; UL508 certification E247993.

Dimensions: 129  × 109.2  × 24.90   mm; DIN rail vertical installation; A forced air cooling fan must be added for inclined installation.

All external interface definitions

The front panel of the whole machine integrates all interfaces:

X1 USB Device Mini-B (1.1): Download for upper computer debugging.

X2 USB Host Type-A (2.0): connected to USB flash drive and keyboard; ⚠️ Non compliant USB devices on the market may fail to recognize and must be tested before use.

X3 Ethernet RJ45: Ethernet debugging communication.

X4 VARAN Out RJ45: VARAN bus manager output, maximum bus length of 100 meters.

X5 CAN-Bus (6-pin Weidm ü ller B2L terminal): CAN-A (Low)/CAN-B (High)/GND; Terminal resistors are required at both ends of the bus; CCP521, as a terminal station, requires an external 150 Ω resistor.

X6 power terminal (Phoenix spring/screw terminal):+24V, GND; Wire 0.14-1.5 mm ².

X7 microSD card slot: located under the LED flip cover; Press to pop up, recommended original SD card; The number of reads and writes directly affects the lifespan of the SD card.

CAN bus baud rate - cable length table (120 Ω twisted pair)

Maximum baud rate bus length

1 Mbit/s 30 m

615 kbit/s 60 m

500 kbit/s 80 m

250 kbit/s 160 m

125 kbit/s 320 m

100 kbit/s 400 m

50 kbit/s 800 m

20 kbit/s 1200 m

Status LED, digital display, and button operation

LED status

DCOK (green): Power supply is normal;

ERROR (red): Fault, abnormal backup power supply;

Ethernet: Link green light link established; Active yellow light data transmission and reception;

VARAN: Link green light link establishment; Active yellow light data transmission and reception.

Usage of two 7-segment digital tubes

CPU configuration mode: display configuration parameters;

Running error: alternate display of Er+error codes, LASAL software status bar synchronously outputs the same code;

User program: System variable _cpuDisplay outputs 0-99 digits; The digital tube will turn off if it is greater than 99.

SET/RESET button configuration operation

Power on and press SET to enter the local configuration menu;

Short press SET to switch menu items; Long press for about 1.5 seconds to enter parameter modification;

After modification, press SET to save for about 5 seconds; Press the RESET button to abandon modifications and restart;

IP、 Subnet mask and gateway use hexadecimal input; Modify and write AUTOEXEC.LSL, the original file will be automatically backed up to AUTOEXEC.BAK;

Configurable items: CAN station number, CAN baud rate IP、 Subnet mask, gateway.

Wiring, grounding, shielding, ESD requirements

Grounding: The CPU must be grounded with low impedance through the DIN rail cabinet backplane or C-DIAS module bracket to ensure high-frequency noise discharge.

Shielding: CAN, Ethernet, and VARAN cables must use shielded cables; The shielding layer is grounded on the large surface at the entrance of the control cabinet (grounding clip, cable crimping sheath).

ESD anti-static: Before plugging or unplugging cable modules, personnel touch the cabinet floor to release static electricity; Installation and maintenance must comply with ESD protection regulations.

VARAN Wiring Special Specification

Recommend CAT5e S-FTP industrial Ethernet cable; Stay away from power cables and avoid parallel wiring;

Anti vibration fixation of cables within 20cm of the connector;

The document provides 5 typical scenarios for shielding grounding: inside cabinet outside, all external wiring, inside cabinet wiring, near noise power devices, and interconnection between two control cabinets.

System power on startup process

Power on; Distinguish whether it is connected to the LASAL upper computer online;

Reset the peripheral module and clear the designated data area;

Verify program storage medium; Verification failure output CHKSUM/POINT ER fault;

If the verification is normal, copy the project to RAM; Enter RUN-RAM and call the user application.

List of fault codes

The digital tube and LASAL software output a unified fault code, covering the following categories:

Startup self-test: 88 startup freezes, BIOS/SD/OS is damaged;

Running status: RUN-RAM, RUN-ROM;

Runtime errors: RUNTIME timeout, POINT pointer error, CHKSUM checksum error, WATCHDOG watchdog, zero division, memory out of bounds, interrupt exception;

Bus failure: DIAS-ERROR, VARAN-MANGER-ERROR, VARAN-ERROR;

Storage SRAM/SD card error SRAM ERROR; The operating system is missing NO-OPERATION SYSTEM;

Links, downloads, breakpoints, single step debugging status codes, etc.

Important Limitations Explanation

Prohibiting writing SRAM power down hold variables in interrupt service subroutines can directly cause system crashes;

SD card simulation SRAM: default data changes are cyclically written to the SD card, frequent writes will significantly consume the lifespan of the SD card; The new version supports backup only in case of power failure; LASAL provides a Flash media lifespan calculation tool to evaluate erase loss;

The microSD file system does not support dynamically changing file size during runtime, otherwise power failure will damage the file system;

This CPU does not support hardware data breakpoint debugging.

SRAM power down memory mechanism

CCP521 has no hardware SRAM and 512KB remnant data is implemented through microSD card software simulation, with two modes:

Default: Data changes are cyclically written to the SD card; The system crashes and loses up to about 1 minute of changed data, but high-frequency write operations can quickly deplete SD lifespan.

Version 01.02.195 onwards: Backup is only performed for PowerFail power failure events, relying on hardware transient power down buffering.

Engineering optimization suggestion: For variables that do not change frequently, use RamEx/StringRam objects to store them in file form on SD, reduce circular erasure, and require corresponding version library support.