SIGMATEK S-DIAS Control System

SIGMATEK S-DIAS Control System

Overall characteristics of the system

The ultimate compact hardware module has a unified size of 12.5   mm (width) × 104   mm (height) × 72   mm (depth), with a maximum of 20 channels per module, each channel occupying only 63   mm ² of area; The 80cm guide rail can accommodate up to 64 modules, with a total of 1280 I/O points, greatly reducing the volume of the control cabinet.

Mechanical and wiring advantages

Tool free DIN rail buckle installation; Multi contact mechanical interlocking between modules, resistant to vibration;

Spring push in terminal block, tool free wiring, supports 1-3 wire system, with a maximum wire size of 1.5 mm ²;

Each channel is equipped with independent status LEDs, module status indicator lights, and supports custom module labels for convenient fault location and on-site diagnosis.

Real time bus VARAN proprietary hard real-time Ethernet VARAN, with a speed of 100 Mbit/s; Single I/O module access time 1.12 µ s; single bus up to 64 nodes, maximum 1280I/O, bus refresh time<60 µ s; supports hot swapping. The interface module can interface with third-party buses such as EtherCAT, PROFINET, CAN, Ethernet, etc.

Engineering support: Provide EPLAN macro files for electrical design convenience.

CPU controller module

The CPU is divided into two gears, all of which support DIN rail installation:

S-DIAS Compact CPU (EDGE2 ARM) CP102, CP111-2, CP112-2, CP311-CP313; EDGE2 processor, single/dual core 800 MHz; Integrated VARAN, CAN, Ethernet USB‑OTG/USB Host； Some models integrate power supply and can be directly plugged into S-DIAS I/O modules.

High performance x86 CPU unit (730/800/900 series)

CP73x: Intel Atom dual core;

CP83x: Intel Atom quad core;

CP93x: Intel Core i3 dual core;

Rich interfaces: Multi channel Ethernet, VARAN Manager, EtherCAT driver interface CAN、USB3.x、S‑DVI、DisplayPort；

Suitable for complex motion control and multi CPU distributed projects, it can be used as a central controller.

The system natively supports multi CPU distributed intelligent architecture: the machine is split into multiple electromechanical units, each unit is locally configured with a CPU, and computing power is expanded as needed to adapt to modular machine design.

S-DIAS security system (yellow shell security module)

Certified by T Ü V, achieving SIL3, Cat.4, PL e safety levels, it can be integrated into a complete automation system or operate independently.

safety controller

SCP 111: Small safety controller, suitable for simple safety solutions such as emergency stop, safety door, safety light barrier, etc;

SCP 211: Equipped with FSoE (Safety over EtherCAT) master station, capable of connecting to third-party FSoE slave station devices.

Secure data transmission: Based on the Black Channel principle, it supports VARAN, TCP/IP, WiFi wireless transmission of secure signals.

Safety I/O categories: Safety Digital Input SDI, Safety Digital Output STO, Hybrid Safety IO Module SDM, Safety Relay Output SRO, Safety SSI Encoder Module SSI, etc.

Motion control module (DIN rail servo/stepper/DC drive)

All modules support STO (Safe Torque Off), SIL3/PL e.

DC series servo drive (48V DC servo) DC061/062/064, DC101/102/104; Power 300-480W; continuous current 6A/10A, peak 15A/20A; Support feedback from Resolvers, Incremental Encoders, and Universal Absolute Value Encoders; Built in brake output and dual channel enable input.

SR series brushed DC motor modules SR011-1 and SR012; Maximum 5A continuous current; Equipped with a brake chopper, encoder interface, and limit input.

ST series two-phase stepper motor module ST151 (open-loop), ST152 (closed-loop); Maximum 5A phase current; Support full step, half step, and up to 256 sub steps; Equipped with an incremental encoder interface, the digital input can be used for zero and limit positions.

Measurement and Analog Module

Covering various industrial measurement scenarios: voltage, current, PT100/PT1000 temperature, strain gauge weighing sensors, IEPE vibration sensors, pressure, SSI absolute value encoder, electrical energy acquisition (predictive maintenance).

AI simulation input: voltage, current, temperature, vibration, weighing;

AO analog output: voltage/current signal output;

AM mixed analog module with input and output simultaneously;

EE121 electric energy acquisition module, used for energy consumption monitoring;

FC counting, SSI encoder interface module.

Digital I/O module

Complete categories: pure DI digital input, pure TO digital output, DM hybrid input/output, relay output RO; some modules support high-speed counting and PWM output; There are regular versions, optocoupler isolation versions, and some support high-speed 0.5ms response.

Interface and Special Function Modules

Bus interface: VARAN splitter SV, EtherCAT, Profinet, CAN, IO Link, RS232/RS485/TTY serial port module; Ethernet switch SE;

Specialized industry: Euromap injection molding machine interface EZ series; Pressure measurement DM811/DM822;

Auxiliary: Potential distribution module KL (24V/0V distribution), RGB strip driver PL221, real-time clock RC001, extended power supply PSB001, VARAN bus analyzer VA011, placeholder module BL011.

Software development platform LASAL

Unified development environment with SIGMATEK HMI human-machine interface, compliant with IEC 61131-3 standard:

Object oriented programming, mechatronics design concept, software objects correspond to mechanical units, improve code reuse rate, and shorten development cycle.

Includes graphic hardware editor, module configuration, parameterization, and online diagnostics.

LASAL SAFETYDesigner: specifically designed for programming and configuring security projects.

A set of software for unified processing of logic control, motion control, safety programs, HMI visualization, and remote maintenance.

Overall system architecture

HMI connects to CPU via TCP-IP Ethernet;

The CPU is connected to the local and distributed S-DIAS I/O, motion module, and safety module through the VARAN bus;

Servo drive and safety IO can be distributed to achieve centralized or decentralized control of the entire device.