Siemens SIPLUS HCS Series User manual

SIPLUS HCS4300 PROFINET/PROFIBUS DP

IO systems for heating elements
Heating control system
SIPLUS HCS4300
PROFINET/PROFIBUS DP
Operating Instructions
10/2019
A5E35452705A/005
Introduction
1
Safety guidelines
2
System overview
3
Application planning
4
Installing/mounting
5
Wiring
6
Commissioning
7
Configuring/Programming
8
Functions
9
Communications
10
Process and system
messages, error handling
11
Servicing and maintenance
12
Technical specifications
13
Appendix
A

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E35452705A/005
Ⓟ
11/2019 Subject to change
Copyright © Siemens AG 2014 - 2019.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 3
Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Introduction ...............................................................................................................................9
2 Safety guidelines................................................................................................................................... 11
2.1 Safety notes ............................................................................................................................11
2.2 Security information ................................................................................................................13
2.3 Protective measures for the HCS4300 ...................................................................................13
3 System overview................................................................................................................................... 15
3.1 Area of application ..................................................................................................................15
3.2 Features..................................................................................................................................16
3.3 System configuration ..............................................................................................................18
3.4 Central interface module (CIM)...............................................................................................19
3.4.1 Function and design................................................................................................................19
3.5 Power output module (POM) ..................................................................................................21
3.5.1 Function and design................................................................................................................21
3.6 I/O modules.............................................................................................................................25
3.6.1 PM4000 DI/DO........................................................................................................................25
3.6.2 PM4000 U/I .............................................................................................................................26
3.6.3 PM4000 Temperature.............................................................................................................27
3.7 EM4315 expansion module ....................................................................................................28
3.7.1 Design.....................................................................................................................................28
4 Application planning.............................................................................................................................. 29
4.1 Shipping ..................................................................................................................................29
4.2 Storage ...................................................................................................................................29
4.3 Scope of delivery ....................................................................................................................30
4.4 Installation location .................................................................................................................31
4.5 POM4320 power rating...........................................................................................................34
4.6 Power rating of the POM4320 Highend ..................................................................................36
4.7 POM4320 Highend power rating ............................................................................................38
4.7.1 POM4320 Highend for busbar adapter...................................................................................38
4.7.2 POM4320 Highend for wall mounting .....................................................................................40

Table of contents
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4Operating Instructions, 10/2019, A5E35452705A/005
5 Installing/mounting................................................................................................................................ 43
5.1 Requirements......................................................................................................................... 43
5.2 Installing the Power Output Module (POM) ........................................................................... 44
5.2.1 Busbar mounting.................................................................................................................... 44
5.2.1.1 Preparations........................................................................................................................... 44
5.2.1.2 Adjusting the busbar adapter................................................................................................. 45
5.2.1.3 Mounting the POM (busbar adapter) ..................................................................................... 47
5.2.2 Panel mounting ...................................................................................................................... 48
5.2.2.1 POM mounting (panel mounting)........................................................................................... 48
5.3 Installing the Central Interface Module .................................................................................. 49
5.4 Installing the EM4315 expansion module .............................................................................. 50
5.5 Installing the I/O module (PM) ............................................................................................... 51
6 Wiring ................................................................................................................................................... 53
6.1 Safety instructions and guidelines ......................................................................................... 53
6.2 Connecting the protective conductor ..................................................................................... 54
6.3 Connecting PROFINET and PROFIBUS fieldbus.................................................................. 55
6.4 Connect 24 V DC power supply............................................................................................. 55
6.5 Connecting the heating elements and three-phase line supply............................................. 57
6.5.1 Connecting the three-phase line supply ................................................................................ 57
6.5.2 Connecting heating elements ................................................................................................ 58
6.6 Block diagram POM4320 ....................................................................................................... 60
6.7 Block diagrams POM4320 Highend....................................................................................... 61
6.7.1 Overview of connection types ................................................................................................ 61
6.7.2 Connection between phase and phase (400/480 V).............................................................. 62
6.7.3 Connection between phase and neutral conductor (230/277 V) ........................................... 70
6.8 Connecting system interfaces................................................................................................ 72
6.9 Connecting I/O modules ........................................................................................................ 74
6.9.1 PM4000 DI/DO....................................................................................................................... 74
6.9.2 PM4000 U/I ............................................................................................................................ 76
6.9.3 PM4000 Temperature ............................................................................................................ 78
7 Commissioning ..................................................................................................................................... 81
7.1 Requirements......................................................................................................................... 81
7.2 Commissioning....................................................................................................................... 81
7.3 Insulation test ......................................................................................................................... 82

Table of contents
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Operating Instructions, 10/2019, A5E35452705A/005 5
8 Configuring/Programming ..................................................................................................................... 83
8.1 Integrating the HCS4300 into the PROFINET configuration ..................................................83
8.2 Integrating the HCS4300 into the PROFIBUS configuration ..................................................83
8.3 Device/hardware configuration in the TIA Portal ....................................................................84
8.3.1 PROFINET device configuration.............................................................................................84
8.3.2 PROFIBUS device configuration ............................................................................................85
8.3.3 Configuration parameters .......................................................................................................86
8.3.3.1 CIM / POM configuration parameters .....................................................................................86
8.3.3.2 Configuration parameters for I/O modules .............................................................................89
8.4 Software tools for commissioning support ..............................................................................91
8.4.1 Overview of tools for commissioning support .........................................................................91
8.5 Configuration control...............................................................................................................93
8.5.1 Configuration control...............................................................................................................93
8.5.2 Configuring..............................................................................................................................94
8.5.3 Control ....................................................................................................................................94
8.5.3.1 Slot assignment ......................................................................................................................94
8.5.3.2 Control data record .................................................................................................................95
8.5.3.3 Feedback data record.............................................................................................................97
8.5.3.4 Transferring control data record in the startup program of the CPU ......................................98
8.5.3.5 Behavior during operation.....................................................................................................100
8.5.4 Examples of configuration control.........................................................................................100
8.5.4.1 Station master HCS4300 ......................................................................................................100
9 Functions ............................................................................................................................................ 105
9.1 Function overview.................................................................................................................105
9.2 Status and actual displays ....................................................................................................106
9.3 Power output control.............................................................................................................106
9.3.1 Half-wave control ..................................................................................................................106
9.3.2 Phase angle control ..............................................................................................................108
9.3.3 Soft starting function .............................................................................................................109
9.3.4 Switch on heating..................................................................................................................110
9.3.5 Soft start during heater operation .........................................................................................111
9.3.6 Channel control via setpoints................................................................................................111
9.3.7 Channel control via fields......................................................................................................112
9.3.8 Line voltage compensation ...................................................................................................113
9.3.9 Behavior of the power outputs ..............................................................................................113
9.3.10 Power control ........................................................................................................................114
9.3.11 Parallel connection of channels ............................................................................................115
9.4 Digital inputs/outputs.............................................................................................................116
9.5 Recording of analog measured line values...........................................................................117
9.6 Recording of analog measured values .................................................................................118

Table of contents
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6Operating Instructions, 10/2019, A5E35452705A/005
9.7 Monitoring functions............................................................................................................. 119
9.7.1 Phase connection monitoring............................................................................................... 119
9.7.2 Rotating-field test ................................................................................................................. 119
9.7.3 Line supply voltage monitoring ............................................................................................ 120
9.7.4 Monitoring of the 24 V DC supply voltage ........................................................................... 120
9.7.5 Frequency monitoring .......................................................................................................... 120
9.7.6 Temperature monitoring....................................................................................................... 121
9.7.7 Power channel monitoring ................................................................................................... 122
9.7.8 Power channel monitoring for loads connected in parallel .................................................. 123
9.7.9 Current load monitoring ....................................................................................................... 123
9.7.10 Fault current monitoring ....................................................................................................... 123
9.7.11 Power control monitoring ..................................................................................................... 124
9.7.12 Monitoring of adaptive soft start........................................................................................... 124
10 Communications ..................................................................................................................................125
10.1 Cyclic data exchange........................................................................................................... 125
10.1.1 Cyclic output data................................................................................................................. 125
10.1.2 Cyclic input data................................................................................................................... 128
10.2 Acyclic data exchange ......................................................................................................... 131
10.2.1 Acyclic data exchange - Overview....................................................................................... 131
10.2.2 Acyclic output data............................................................................................................... 132
10.2.3 Acyclic input data ................................................................................................................. 137
10.3 Transfer of diagnostic alarms to the controller..................................................................... 140
10.3.1 Transferring diagnostic alarms to the controller: PROFINET .............................................. 140
10.3.2 Transferring diagnostic alarms to the controller: PROFIBUS .............................................. 141
10.3.3 Manufacturer-specific error codes ....................................................................................... 141
11 Process and system messages, error handling ....................................................................................145
11.1 Central Interface Module (CIM)............................................................................................ 145
11.2 Power Output Module (POM)............................................................................................... 146
11.2.1 LED operating display for POM ........................................................................................... 146
11.2.2 Fault reporting through diagnostics data ............................................................................. 146
11.3 I/O modules.......................................................................................................................... 148
12 Servicing and maintenance ..................................................................................................................149
12.1 Maintenance work................................................................................................................ 149
12.2 Firmware update .................................................................................................................. 149
12.2.1 PROFINET firmware update ................................................................................................ 149
12.2.2 PROFIBUS firmware update................................................................................................ 151
12.3 Fuse replacement ................................................................................................................ 152
12.4 Replace fan .......................................................................................................................... 156
12.5 Replacing the Power Output Module (POM) ....................................................................... 158
12.6 Replacing the Central Interface Module (CIM) .................................................................... 160
12.7 Replacing an I/O module ..................................................................................................... 161
12.8 Recycling and disposal ........................................................................................................ 162

Table of contents
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13 Technical specifications ...................................................................................................................... 163
13.1 Technical specifications for CIM ...........................................................................................163
13.2 Technical Specifications POM4320 ......................................................................................166
13.3 Technical Specifications POM4320 Highend .......................................................................176
13.4 Technical specifications for I/O module................................................................................182
13.5 Technical specifications for EM4315 expansion module......................................................192
13.6 Dimension drawings..............................................................................................................195
A Appendix............................................................................................................................................. 199
A.1 Certificates and approvals ....................................................................................................199
A.1.1 Certificates and approvals ....................................................................................................199
A.2 Article numbers for spare parts/accessories.........................................................................200
A.2.1 Ordering data ........................................................................................................................200
A.3 ESD Guidelines.....................................................................................................................201
A.4 Service & Support .................................................................................................................203
A.4.1 Application example..............................................................................................................204
A.4.2 Frequently asked questions (FAQ) .......................................................................................204
Index................................................................................................................................................... 205

Table of contents
SIPLUS HCS4300 PROFINET/PROFIBUS DP
8Operating Instructions, 10/2019, A5E35452705A/005

SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 9
Introduction
1
1.1 Introduction
Purpose of this documentation
These operating instructions contain the information you require to commission, operate and
service the HCS4300 heating control system.
Target group
The documentation is intended for qualified personnel in the following specialist fields:
●Operators, project engineers, programmers
●Electrically skilled personnel who assemble, connect and start up the device.
Required basic knowledge
●These operating instructions require prior knowledge of programming an S7 controller or
SIMOTION.
●Knowledge of working with the PROFINET or PROFIBUS fieldbus is also necessary.
History
The following earlier release versions of these operating instructions have been published:
Edition
Comment
11/2014
First edition
10/2015 Expansion with POM with panel mounting, PROFIBUS, I/O modules, expansion
module for additional 2 × 8 POMs
12/2016 Expansion with configuration control
Commissioning support using PRONETA
04/2018
Expansion with phase control functionality for POM4320
10/2019
Expansion with POM4320 Highend

Introduction
1.1 Introduction
SIPLUS HCS4300 PROFINET/PROFIBUS DP
10 Operating Instructions, 10/2019, A5E35452705A/005
Scope of the document
This document is valid for all components of the SIPLUS HCS4300 specified below and
describes the current delivery state.
Note
Applicable for devices up to firmware version 1.x of the CIM:
•
A maximum of 6 POMs can be operated.
•
Expansion module, PMs and the DP connection are not available
•
The following applies for reading data records 152, 200 and 201: The information that is
read is always for the full configuration, i.e. for 54 channels or 6 POMs.
•
The data records 160, 190 and 202 are not available.
Applicable for devices up to firmware version 2.1 of the CIM:
•
No phase control can be configured for a POM4320.
•
Data record 50 is not available.
Applicable for devices up to firmware version 2.3 of the CIM:
•
POM4320 Highend cannot be configured.
Applicable for devices as of firmware version 2.3 of the CIM:
•
The "Phase control" mode is only available for POM4320 with MLFB -0AA2 as of
HW version 02.
Naming conventions and abbreviations
Instead of product labels, the following abbreviations are also used in this document.
The following product labels and abbreviations are used:
Product label
Abbreviation
Central Interface Module
CIM
I/O module
PM
Power Output Module
POM
SIPLUS HCS4300
HCS
Registered trademarks
SIPLUS ® is a registered trademark of Siemens AG.

SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 11
Safety guidelines
2
2.1 Safety notes
This device corresponds to the approvals printed on the type plate. If you have questions
about whether it is permissible to install the device in the planned environment, contact your
service representative.
NOTICE
•Alterations to the devices are not permitted. Failure to observe these guidelines shall
constitute a revocation of the approvals and manufacturer's warranty.
•The HCS4300 heating control system is not a safety product. In the event of a fault, the
machine must be brought to the safe state on the plant side.
Warning symbols on the device
WARNING
Electric shock hazard
Can cause death or serious injury
When this warning symbol appears on the device, you must consult the operating
instructions for the device. The operating instructions contain information about the
potential risks and enable you to recognize risks and implement countermeasures.
Note before connecting the device
WARNING
Electric shock hazard
Can cause death or serious injury
The supply system to which the heating control system is connected must have a circuit
breaker. The device must be switched off and secured against switching on again, before
connecting to the line voltage. Otherwise, there is a risk of electric shock.

Safety guidelines
2.1 Safety notes
SIPLUS HCS4300 PROFINET/PROFIBUS DP
12 Operating Instructions, 10/2019, A5E35452705A/005
Working on the device or on components connected to it
WARNING
Electric shock hazard
Can cause death or serious injury
•Voltages of more than 60 V can occur in the control cabinet. Suitable safety precautions
to prevent contact must therefore be taken before and during commissioning and
maintenance work.
•Before working on the heating control system or the connected components, ensure the
system is disconnected.
Fuse replacement
NOTICE
Use only the prescribed fuse types. If you operate a heating controller with unapproved
fuses, the device could be destroyed.
Repairs
WARNING
No user-serviceable parts
Can cause death or serious injury
Incorrectly performed repairs can result in substantial damage to equipment or endanger
the user. Return the device to Siemens for repair.

Safety guidelines
2.2 Security information
SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 13
2.2 Security information
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be
connected to an enterprise network or the internet if and to the extent such a connection is
necessary and only when appropriate security measures (e.g. firewalls and/or network
segmentation) are in place.
For additional information on industrial security measures that may be implemented, please
visit (https://www.siemens.com/industrialsecurity).
Siemens' products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends that product updates are applied as soon as they are
available and that the latest product versions are used. Use of product versions that are no
longer supported, and failure to apply the latest updates may increase customers' exposure
to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security
RSS Feed visit (https://www.siemens.com/industrialsecurity).
2.3 Protective measures for the HCS4300
Protective measures for the HCS4300 heating control system
NOTICE
Only authorized personnel are permitted to access the system and make changes to it.

Safety guidelines
2.3 Protective measures for the HCS4300
SIPLUS HCS4300 PROFINET/PROFIBUS DP
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SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 15
System overview
3
3.1 Area of application
The SIPLUS HCS 4300 heating control system is used to activate and switch heating
elements in industry, such as quartz, ceramic, flash, halogen or infrared emitters. It is of
modular design and can be flexibly adapted to suit the specific requirements of the
respective application.
Typical application areas are:
●PET blow molding
●Drying of enamels and coatings
●Thermal treatment of fabric and plastics
●Welding of plastic parts
●Handling of carbon materials
In general, the HCS4300 can be used wherever compact or modular concepts are required
with high levels of power output.

System overview
3.2 Features
SIPLUS HCS4300 PROFINET/PROFIBUS DP
16 Operating Instructions, 10/2019, A5E35452705A/005
3.2 Features
An HCS4300 system comprises one Central Interface Module (CIM) and up to
24 Power Output Modules (POM). As an option, one I/O module can be operated on
the CIM.
The following figure shows an example of an HCS4300, consisting of a CIM4310 for
PROFINET, a POM4320, as well as a POM4320 Highend for busbar mounting.
Figure 3-1 HCS4300 consisting of CIM ①, POM4320 ②and POM4320 Highend ③

System overview
3.2 Features
SIPLUS HCS4300 PROFINET/PROFIBUS DP
Operating Instructions, 10/2019, A5E35452705A/005 17
The following types of system component are available:
System component
Version
Description
Central Interface Module
(CIM)
•CIM4310 PROFINET
•CIM4310 PROFIBUS
A maximum of 8 POM4320 or 6
POM4320 Highend can be operated at
a CIM.
I/O module •PM4000 DI/DO 8 digital outputs and 8 configurable
inputs/outputs.
•PM4000 U/I Inputs for measuring line voltage and
line current.
•PM4000 Temperature 4 analog inputs for 0 mA to 20 mA and
4 measuring inputs for temperature
Power Output Module
(POM)
•POM4320 busbar mounting 9 power outputs with diagnostic func-
tion and fault indication per channel.
•POM4320 panel mounting
•POM4320 Highend busbar
mounting
6 power outputs with diagnostics and
error display per channel.
•POM4320 Highend for panel
mounting
Expansion module •EM4315 Enables operation of up to 8 additional
POM4320 or 6 POM4320 Highend.
Features
●Modular (centralized) and compact (distributed) configurations possible
●Communication via PROFINET/PROFIBUS
●Parameter assignment, commissioning, visualization and diagnostics via
Siemens TIA Portal
●Support of configuration and commissioning of the PROFINET network with PRONETA
●Integrated diagnostics and monitoring functions
●Control modes: Half-wave control, soft start and phase control
●Line voltage compensation for smoothing line voltage fluctuations integrated
●Only one 24 V power supply required for up to 8 POM4320 or 6 POM4320 Highend
●Slot for one I/O module (PM)
●Expansion module (optional) with 24 V power supply for operation of an additional
2 x 8 POM4320 or 2 x 6 POM4320 Highend

System overview
3.3 System configuration
SIPLUS HCS4300 PROFINET/PROFIBUS DP
18 Operating Instructions, 10/2019, A5E35452705A/005
3.3 System configuration
System components
A complete heating control system with HCS4300 includes the following components:
●Central Interface Module (CIM) 4310 with PROFINET or PROFIBUS
●Power Output Module (POM) 4320 for busbar or panel mounting
●Higher-level controller, e.g. SIMATIC S7-1500 automation system with
PROFINET/PROFIBUS
●Field PG, optional for commissioning and diagnostics
●HMI panel, optional, e.g. SIMATIC HMI TP1500
●Heat emitter array
Figure 3-2 System components
Centralized and distributed heating application
A maximum of 8 POM4320 or 6 POM4320 Highend can be operated at a CIM. In the
maximum configuration with 2 expansion modules, up 24 POM4320 or
18 POM4320 Highend can be operated.
System configurations can be realized for distributed, decentralized heating applications,
such as PET blow molding, where the heating controller is located below the heating boxes,
as well as central heating applications, for example, in thermoforming, where the heating
elements are implemented in numerous arrays and the modular heating control system is
located in a central control cabinet.