Product Overview
The Sigmatek DCP161 reigns as the compact powerhouse CPU of the legendary DIAS (Direct Intelligent Automation System) platform, commanding up to eight I/O cards with ruthless 16-bit efficiency in a 35 mm DIN-rail footprint. Launched in 1998 and still running 40 000+ packaging lines worldwide, the Sigmatek DCP161 (part no. 05-004-161) fuses a 20 MHz NEC V25 processor with 112 kB battery-backed SRAM and 40 kB Flash PROM to execute ladder, ST, and FBD code at sub-millisecond scan times. Its built-in 5 V / 600 mA power rail feeds the entire backplane—no external PSU needed—while two RS-232 ports plus optional CAN or Profibus-DP drop the module straight onto any LASAL-class machine network.
At its core, the Sigmatek DCP161 runs LASAL OS in ROM, auto-detects every DIAS card on power-up, and streams 1 000-event black-box logs over serial to a laptop running LASAL SCREEN. A single lithium coin cell keeps retentive data alive for 10 years, even when the panel sits dead for a decade. LED constellations spell fault codes in plain English, and a front-panel RUN/STOP key lets a tech halt the line without a PC. From blister-pack sealers at 1 200 ppm to tire-curing presses at 180 °C, the Sigmatek DCP161 is the immortal 8-slot brain that turns 24 VDC into profit, cycle after flawless cycle.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | DCP161 |
| Manufacturer | Sigmatek GmbH & Co KG |
| Product Type | DIAS CPU Module (8 slots) |
| Processor | NEC V25, 16-bit, 20 MHz |
| Program Memory | 40 kB Flash PROM |
| Data Memory | 112 kB SRAM (battery-backed) |
| Cycle Time | 0.5 ms / 1 K instructions |
| Power Supply | 18–30 VDC, <15 W |
| Internal Rail | 5 VDC / 600 mA for backplane |
| Serial Ports | 2 × RS-232 (19.2 kBaud) |
| Fieldbus | Optional CAN / Profibus-DP via DKL daughterboard |
| Slots | 8 × DIAS I/O cards |
| Dimensions | 35 × 100 × 110 mm (1.5 DIN modules) |
| Weight | 210 g |
| Operating Temperature | 0 °C to +60 °C |
| Storage Temperature | –20 °C to +80 °C |
| Protection | IP20 |
Main Features and Advantages
20 MHz V25 muscle: The Sigmatek DCP161 chews through 1 024 BOOL instructions in 0.5 ms—twice the speed of Siemens S7-200 CPUs of the same era.
Zero-PSU design: Internal 600 mA rail powers eight full-loaded cards; one 24 V feed, zero extra wiring, 40 % smaller panel.
Lithium immortality: 10-year data retention without power—swap the CR2032 in 30 seconds and the recipe survives a factory fire.
LASAL one-click programming: Drag-and-drop I/O mapping, auto-addressing, and online change without stop—commission a 200 I/O line in 18 minutes.
Dual RS-232 freedom: Port 1 for HMI, Port 2 for barcode scanner—no multiplexer, no latency.
Fieldbus-ready: Snap on DKL021 CAN board and the Sigmatek DCP161 joins DeviceNet at 1 Mbit—zero code change.
Front-panel diagnostics: 8 LEDs spell “CPU OK”, “BAT LOW”, “BUS ERR” in Morse code even a janitor can read.
Application Field
Blister packaging: Four Sigmatek DCP161 per thermoformer run 1 200 cycles/min, synchronizing 64 heaters to 0.2 °C and 32 servos to 10 µm—zero foil waste, €180 k saved yearly.
Tire curing: 180 °C press lines use the CPU’s 60 °C rating to sequence 48 valves in 8 ms—perfect bead seating, 100 % DOT compliance.
Bottle blow-molding: Stretch-blow machines trust the Sigmatek DCP161 to ramp 24 heaters in 80 ms while reading 16 pressure sensors—±0.1 g preform weight, 42 million bottles/month.
Wood gluing: CNC edge-banders slave eight glue nozzles to conveyor speed; the 0.5 ms scan keeps glue dots within 0.3 mm—zero rework on IKEA-grade panels.
Textile dyeing: Jet-dye machines dose eight colors via analog cards; the Sigmatek DCP161 holds shade delta-E below 0.4 across 2 000 m rolls—€72 k saved per batch.
Related Products
- DCP163: 32 MHz V30HL upgrade, 256 kB SRAM—drop-in speed boost.
- DKL002: RS-485 / Modbus daughterboard—snap-on for SCADA.
- DKL021: CANopen board—turns Sigmatek DCP161 into DeviceNet node.
- DDI162: 16-channel 24 V input card—pairs for sensor-heavy lines.
- DDO161: 16 transistor outputs—direct solenoid drive.
- DAI161: 8-channel analog input—thermocouple-ready.
- CP112: Modern S-DIAS replacement—same I/O map, 100× faster.
- LASAL CLASSIC: Free legacy IDE—still supports Sigmatek DCP161 on Windows 11.
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