DIGICON Repair Services India
DIGICON is an Indian industrial electronics manufacturer specialising in digital control systems, programmable logic controllers (PLCs), human-machine interfaces (HMIs), and process automation solutions. Founded in 1998, DIGICON has established itself as a trusted supplier to Indian manufacturing, textiles, pharmaceuticals, and food processing sectors. Their equipment is widely deployed across small to mid-scale industrial operations in Gujarat, Maharashtra, Tamil Nadu, and other manufacturing hubs.
DIGICON is an Indian industrial electronics manufacturer specialising in digital control systems, programmable logic controllers (PLCs), human-machine interfaces (HMIs), and process automation solutions. Founded in 1998, DIGICON has established itself as a trusted supplier to Indian manufacturing, textiles, pharmaceuticals, and food processing sectors. Their equipment is widely deployed across small to mid-scale industrial operations in Gujarat, Maharashtra, Tamil Nadu, and other manufacturing hubs.
Synchronics Electronics repairs the complete DIGICON product portfolio including DG-series PLCs, D-Touch HMI panels, DIG-Drive variable frequency drives, and DIG-Servo motion control systems. With 180+ engineers and 30 years of industrial electronics expertise, we diagnose and repair DIGICON faults that many service centres overlook. We maintain stock of common DIGICON replacement modules and offer same-week turnaround on most repairs across India.
30 years repairing DIGICON automation control systems across Indian manufacturing plants.
DIGICON Product Lines We Repair
Our engineers are trained on the full DIGICON product range. Below are the major product families we service.
DG-Series Programmable Logic Controllers
Compact and modular PLCs for discrete and process automation. Common issues include memory corruption, communication port failures (RS-485), and power supply degradation in high-temperature production environments.
D-Touch HMI Panel Series
7-inch to 15-inch touchscreen operator interfaces with integrated logic. Frequent faults: touchscreen unresponsiveness, Ethernet connectivity loss, internal battery failure affecting real-time clock, and flash memory corruption from power surges.
DIG-Drive Variable Frequency Drives
Single and three-phase VFDs for motor speed control in pumps, fans, and conveyors. Typical repair needs: IGBT module burnout, capacitor bank failure causing DC bus voltage instability, and encoder signal loss in closed-loop applications.
DIG-Servo Motion Control Modules
Stepper and servo drive controllers for precision positioning in textile machinery, packaging lines, and CNC equipment. Common failures: phase loss detection circuit malfunction, thermal shutdown sensor drift, and step-pulse signal interpretation errors.
DIG-Comms Communication Gateway
Protocol converter and industrial Ethernet hub supporting Modbus RTU, TCP/IP, and CANopen. Repair issues: port isolation transformer failure, oscillator crystal drift causing baud rate errors, and firmware corruption in boot memory.
DIG-Power Switching Power Supply Units
24VDC and 48VDC regulated supplies for PLC and sensor networks. Typical faults: capacitor dry-out in tropical Indian climates, optocoupler failure causing loss of feedback control, and thermal stress leading to solder joint cracking on PCB.
Why Choose Synchronics for DIGICON Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on DIGICON equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common DIGICON Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in DIGICON equipment arriving at our workshop.
- ✓DIGICON PLC memory corruption and program loss — Extended power surges from Indian grid instability or inadequate UPS backup cause EEPROM degradation. Thermal stress in non-air-conditioned factories accelerates memory cell failure, especially in DG-series legacy units.
- ✓D-Touch HMI touchscreen becomes unresponsive or shows dead zones — Moisture ingress from high humidity textile mills and food processing plants corrodes the touchscreen controller IC. Voltage spikes from motor starting transients also damage the capacitive sensing circuit in D-Touch units without galvanic isolation.
- ✓DIG-Drive VFD shows 'DC Bus Over-Voltage' fault code repeatedly — Electrolytic capacitors in the DC bus section degrade in high ambient temperatures (40-50C common in Indian foundries and steel mills), losing capacitance and allowing voltage ripple to exceed 850V. Regenerative braking without load dump resistors worsens overshoot.
- ✓DIG-Servo stepper drive loses step pulses during production run — Vibration from heavy machinery or inadequate cable shielding causes EMI coupling into the step/direction signal wires. DIGICON servo modules use single-ended logic which is vulnerable in noisy environments common in Indian textile and packaging lines.
- ✓DIG-Comms gateway drops Modbus RTU communication intermittently — Transformer isolation failure on RS-485 port allows ground loop currents and signal reflections. Extended periods of salt-air exposure in coastal Indian factories (Kutch, Goa, Tamil Nadu) corrode isolation transformer terminals.
- ✓DIG-Power 24V supply shuts down under peak load after 5-10 seconds — Thermal runaway in the output feedback optocoupler causes loss of regulation feedback loop. In unventilated electrical cabinets in Indian plants, internal temperatures exceed 70C, accelerating semiconductor aging and optocoupler failure.
How We Repair Your DIGICON Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using DIGICON Equipment
We serve plant maintenance teams across all major industries where DIGICON automation is deployed.
Frequently Asked Questions — DIGICON Repairs
Do you repair DIGICON equipment anywhere in India?+
Yes. Synchronics repairs the full DIGICON product range — PLCs, HMI panels, VFDs, servo drives, communication gateways, and power supplies. We offer PAN-India door pickup from Mumbai, Delhi, Pune, Bangalore, Chennai, Hyderabad, Ahmedabad, Surat, and all other major cities. Repairs are done at our 180-engineer facility in Vadodara, Gujarat with same-week turnaround on most faults.
What is the typical repair cost and turnaround time for DIGICON DG-series PLC faults?+
DG-series PLC repairs typically cost between Rs. 3,500-8,500 depending on fault severity (memory restoration, port replacement, power module replacement). Standard turnaround is 5-7 working days including comprehensive testing. We offer fast-track 48-hour service for critical production shutdowns at a 25% premium. Advance diagnosis is free — we provide a detailed fault report and cost estimate before authorizing repair.
Can Synchronics recover my lost DIGICON PLC program if the device has no backup?+
Partial recovery is often possible. If the EEPROM chip itself is readable, we can dump the program logic. We can then help you reconstruct critical control sequences and safety interlocks using your process documentation. In cases of complete chip failure, we rebuild the essential logic based on your system flowcharts and equipment manual. We always recommend maintaining offline backups on USB — we can provide training on DIGICON backup procedures.
Why does my D-Touch HMI panel keep losing Ethernet connection in my food processing plant?+
High humidity and moisture mist from pasteurization or cleaning cycles corrode the Ethernet jack solder joints and isolation transformer windings inside D-Touch panels. Additionally, multiple heavy motors starting up create voltage transients that damage the Ethernet port PHY IC. Synchronics replaces the Ethernet module, applies conformal coating, and supplies a shielded Ethernet cable with ferrite clamps. We also recommend a network surge suppressor and cabinet-level humidity control (silica desiccant or dehumidifier).
What warranty do you offer on DIGICON repairs?+
All Synchronics repairs carry a 12-month warranty on parts and workmanship. If your repaired DIGICON equipment fails again due to the same fault within 12 months, we repair it free (excluding repeated user error or external damage). We provide a written test report and component serial numbers for traceability. Extended 24-month warranty is available on VFD and servo drive repairs for an additional 8% cost.
How do I send my DIGICON unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a DIGICON drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on DIGICON repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your DIGICON unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
DIGICON Repair Catalog
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Don't See Your DIGICON Model Listed?
We repair the full range of DIGICON industrial electronics — even if the specific model is not yet in our catalog. Send us the unit details and we'll confirm repairability within 24 hours.
Free evaluation • 6-month warranty • PAN India pickup
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Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service