Siemens SIPLUS HCS Series User manual

SIPLUS HCS4200 PROFINET/PROFIBUS DP

IO systems for heating elements
Heating control system
SIPLUS HCS4200
PROFINET/PROFIBUS DP
Operating Instructions
07/2019
A5E35066204A/006
Introduction
1
Security information
2
System overview
3
Application planning
4
Installation/mounting
5
Connecting
6
Commissioning
7
Configuration
8
Functions
9
Communications
10
Process and system
messages, error handling
11
Service and maintenance
12
Technical specifications
13
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E35066204A/006
Ⓟ
07/2019 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 HCS4200 PROFINET/PROFIBUS DP
Operating Instructions, 07/2019, A5E35066204A/006 3
Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Introduction ...............................................................................................................................9
2 Security information .............................................................................................................................. 13
2.1 Safety information ...................................................................................................................13
2.2 Security information ................................................................................................................15
3 System overview................................................................................................................................... 17
3.1 Area of application ..................................................................................................................17
3.2 Features..................................................................................................................................18
3.3 Combination mode..................................................................................................................21
3.4 System configuration ..............................................................................................................22
3.5 Central Interface Module (CIM) ..............................................................................................23
3.5.1 Function and design................................................................................................................23
3.6 Power Output Module (POM) .................................................................................................26
3.6.1 POM4220................................................................................................................................26
3.6.2 POM4320................................................................................................................................29
3.7 I/O modules.............................................................................................................................30
3.7.1 PM4000 DI/DO........................................................................................................................30
3.7.2 PM4000 U/I .............................................................................................................................31
3.7.3 PM4000 Temperature.............................................................................................................32
4 Application planning.............................................................................................................................. 33
4.1 Shipping ..................................................................................................................................33
4.2 Storage ...................................................................................................................................33
4.3 Scope of delivery ....................................................................................................................34
4.4 Installation location .................................................................................................................35
4.4.1 General requirements for the location of use .........................................................................35
4.4.2 Double frame construction......................................................................................................40
4.4.3 Combined mode configuration................................................................................................42
4.5 Power ratings ..........................................................................................................................43
4.5.1 POM4220 power rating ...........................................................................................................43
4.5.2 POM4320 power rating ...........................................................................................................50
5 Installation/mounting ............................................................................................................................. 53
5.1 Requirements..........................................................................................................................53
5.2 Mounting the rack ...................................................................................................................53
5.3 Mounting the fan module ........................................................................................................56
5.4 Installing the central interface module (CIM) ..........................................................................57

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5.5 Installing the I/O module (PM) ............................................................................................... 58
5.6 Mounting a POM4220 power output module ......................................................................... 59
5.7 Mounting and dismantling CIM4210C PROFINET ................................................................ 60
5.8 Mounting the blanking covers ................................................................................................ 61
5.9 Double frame setup................................................................................................................ 61
5.10 Mounting a POM4320 power output module ......................................................................... 63
5.10.1 Busbar mounting.................................................................................................................... 63
5.10.1.1 Preparations........................................................................................................................... 63
5.10.1.2 Adjusting the busbar adapter................................................................................................. 64
5.10.1.3 Mounting the POM (busbar adapter) ..................................................................................... 66
5.10.2 Panel mounting ...................................................................................................................... 67
5.10.2.1 POM mounting (panel mounting)........................................................................................... 67
6 Connecting ........................................................................................................................................... 69
6.1 Safety information and guidelines.......................................................................................... 69
6.2 Connecting the protective conductor ..................................................................................... 71
6.3 Combined mode with POM4320 - Connecting system interfaces ......................................... 74
6.4 Connecting the PROFINET/PROFIBUS fieldbus................................................................... 76
6.5 Connect 24 V DC power supply............................................................................................. 77
6.6 Connecting the heating elements and three-phase line supply............................................. 79
6.6.1 Connecting the heating elements and three-phase line supply............................................. 79
6.6.2 POM4220 Lowend block diagram.......................................................................................... 86
6.6.3 Block diagram POM4220 Midrange phase angle control and POM4220 Flexible ................ 87
6.6.4 POM4220 Highend block diagram......................................................................................... 88
6.6.5 Block diagram POM4320 ....................................................................................................... 93
6.7 Connecting I/O modules ........................................................................................................ 94
6.7.1 PM4000 DI/DO....................................................................................................................... 94
6.7.2 PM4000 U/I ............................................................................................................................ 96
6.7.3 PM4000 Temperature ............................................................................................................ 98
7 Commissioning ....................................................................................................................................101
7.1 Requirements....................................................................................................................... 101
7.2 Commissioning..................................................................................................................... 101
7.3 Insulation test ....................................................................................................................... 102
8 Configuration .......................................................................................................................................103
8.1 Integrating the HCS4200 components into the PROFINET configuration........................... 103
8.2 Integrating the HCS4200 components into the PROFIBUS configuration .......................... 104
8.3 Device configuration and configuration parameters in the TIA Portal ................................. 105
8.3.1 Device configuration PROFINET HCS4200 ........................................................................ 105
8.3.2 Device configuration PROFINET HCS4200 combination mode.......................................... 106
8.3.3 PROFIBUS device configuration.......................................................................................... 107
8.3.4 Configuration parameters .................................................................................................... 108
8.3.4.1 Configuration parameters for CIM and POM ....................................................................... 108
8.3.4.2 Configuration parameters for I/O modules........................................................................... 112

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8.4 Software tools for commissioning support ............................................................................114
8.4.1 Overview of tools for commissioning support .......................................................................114
8.5 Configuration control (option handling).................................................................................115
8.5.1 Configuration control.............................................................................................................115
8.5.2 Configuring............................................................................................................................117
8.5.3 Controller ..............................................................................................................................117
8.5.3.1 Slot assignment ....................................................................................................................117
8.5.3.2 Control data record ...............................................................................................................118
8.5.3.3 Feedback data record...........................................................................................................119
8.5.3.4 Transferring control data record in the startup program of the CPU ....................................121
8.5.3.5 Behavior during operation.....................................................................................................123
8.5.4 Examples of configuration control.........................................................................................124
8.5.4.1 Station master HCS4200 ......................................................................................................124
8.5.4.2 Station master HCS4200 combined mode ...........................................................................128
9 Functions ............................................................................................................................................ 131
9.1 Overview of functions............................................................................................................131
9.2 Status and actual displays ....................................................................................................132
9.3 Power output control.............................................................................................................132
9.3.1 Half-wave control ..................................................................................................................132
9.3.2 Phase angle control ..............................................................................................................134
9.3.3 Soft starting function .............................................................................................................135
9.3.4 Switch on heating..................................................................................................................137
9.3.5 Soft start during heater operation .........................................................................................137
9.3.6 Channel control via setpoints................................................................................................137
9.3.7 Channel control via fields......................................................................................................138
9.3.8 Line voltage compensation ...................................................................................................139
9.3.9 Power control ........................................................................................................................140
9.3.10 Behavior of the power outputs ..............................................................................................141
9.4 Digital inputs/outputs.............................................................................................................142
9.5 Recording of analog measured line values...........................................................................143
9.5.1 Recording of analog measured line values with PM4000 U/I ...............................................143
9.5.2 Recording of analog measured line values with POM4220 Highend ...................................144
9.6 Recording of analog measured values .................................................................................145
9.7 Monitoring functions..............................................................................................................146
9.7.1 Monitoring phase connection................................................................................................146
9.7.2 Rotating field check...............................................................................................................146
9.7.3 Line supply voltage monitoring .............................................................................................147
9.7.4 Monitoring of the 24 V DC supply voltage ............................................................................148
9.7.5 Frequency monitoring ...........................................................................................................149
9.7.6 Temperature monitoring........................................................................................................149
9.7.7 Monitoring power channels...................................................................................................150
9.7.8 Monitoring power channels with loads connected in parallel................................................151
9.7.9 Total current monitoring........................................................................................................152
9.7.10 Fault current monitoring........................................................................................................152
9.7.11 Monitoring of output control ..................................................................................................153
9.7.12 Monitoring of adaptive soft start............................................................................................153

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10 Communications ..................................................................................................................................155
10.1 Cyclic data exchange........................................................................................................... 155
10.1.1 Cyclic output data................................................................................................................. 155
10.1.2 Cyclic input data................................................................................................................... 159
10.2 Acyclic data exchange ......................................................................................................... 163
10.2.1 Acyclic output data............................................................................................................... 164
10.2.2 Acyclic input data ................................................................................................................. 169
10.3 Transfer of diagnostic alarms to the controller..................................................................... 174
10.3.1 Transferring diagnostic alarms to the controller: PROFINET .............................................. 174
10.3.2 Transferring diagnostic alarms to the controller: PROFIBUS .............................................. 175
10.3.3 Manufacturer-specific error codes ....................................................................................... 175
11 Process and system messages, error handling ....................................................................................179
11.1 Central Interface Module (CIM)............................................................................................ 179
11.1.1 LED operating display for CIM ............................................................................................. 179
11.2 Power Output Module (POM)............................................................................................... 180
11.2.1 LED operating display for POM ........................................................................................... 180
11.2.2 Fault reporting through diagnostics data ............................................................................. 180
11.3 I/O modules.......................................................................................................................... 182
12 Service and maintenance.....................................................................................................................185
12.1 Maintenance work................................................................................................................ 185
12.2 Firmware update .................................................................................................................. 185
12.2.1 PROFINET firmware update................................................................................................ 185
12.2.2 PROFIBUS firmware update................................................................................................ 187
12.3 Fuse replacement ................................................................................................................ 188
12.3.1 POM4220 Fuse Replacement.............................................................................................. 188
12.3.2 POM4320 Fuse Replacement.............................................................................................. 190
12.4 Replace fan .......................................................................................................................... 194
12.4.1 Replacing a FM4240 fan module......................................................................................... 194
12.4.2 POM4320 and CIM4210C PROFINET – Replacing fans .................................................... 196
12.5 Replacing a power output module (POM)............................................................................ 197
12.5.1 Safety information ................................................................................................................ 197
12.5.2 Replacing the POM4220...................................................................................................... 198
12.5.3 Replacing the POM4320...................................................................................................... 199
12.6 Replacing the Central Interface Module (CIM) .................................................................... 201
12.7 Replacing an I/O module ..................................................................................................... 202
12.8 Recycling and disposal ........................................................................................................ 203
13 Technical specifications .......................................................................................................................205
13.1 Technical specifications for Rack4200 ................................................................................ 205
13.2 Technical Specifications CIM4210....................................................................................... 207
13.3 Technical Specifications CIM4210C .................................................................................... 210

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13.4 Technical specifications of POM...........................................................................................213
13.4.1 Technical specifications of POM4220...................................................................................213
13.4.2 Technical Specifications POM4320 ......................................................................................225
13.5 Technical specifications for I/O module................................................................................235
13.6 Technical specifications for fan module................................................................................245
13.7 Technical specifications of expansion module EM4315 (for combined mode only).............247
13.8 Dimension drawings..............................................................................................................250
13.8.1 HCS4200 components..........................................................................................................250
13.8.2 HCS4300 components..........................................................................................................253
A Appendix............................................................................................................................................. 257
A.1 Certificates and approvals ....................................................................................................257
A.1.1 Certificates and approvals ....................................................................................................257
A.2 Ordering data ........................................................................................................................258
A.3 ESD guidelines .....................................................................................................................260
A.4 Service & Support .................................................................................................................262
Index................................................................................................................................................... 265

Table of contents
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SIPLUS HCS4200 PROFINET/PROFIBUS DP
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Introduction
1
1.1 Introduction
Purpose of this documentation
These operating instructions contain the information you require to commission, operate and
service the HCS4200 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 commission the device.
Required basic knowledge
●These operating instructions require prior knowledge of programming a SIMATIC S7
controller or SIMOTION.
●Knowledge of working with the PROFINET / PROFIBUS fieldbus is also necessary.
Naming conventions and abbreviations
A synonym, an abbreviation, or the term "device" is sometimes used in this documentation
instead of the full product name.
The following terms and abbreviations are used:
Heating control system
HCS
Power Output Module
POM
Central Interface Module
CIM
Rack Rack
SIMATIC S7
S7
I/O module
PM

Introduction
1.1 Introduction
SIPLUS HCS4200 PROFINET/PROFIBUS DP
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History
The following earlier release versions of these operating instructions have been published:
Edition
Note
12/2014
First edition
10/2015 Expansion for operation of 24 POMs and one I/O module; rack for 4 POMs;
connection to PROFIBUS DP
12/2016 •Expansion with operation of POM4320 (combined mode)
•POM4220 Midrange phase angle control
•Configuration control (option handling)
•Commissioning support using PRONETA
10/2017 Expansion with POM4220 Highend and POM4220 Flexible
09/2018 Expansion with additional switching options and operating modes for
POM4220 Highend
07/2019
Extension with CIM4210C PROFINET

Introduction
1.1 Introduction
SIPLUS HCS4200 PROFINET/PROFIBUS DP
Operating Instructions, 07/2019, A5E35066204A/006 11
Scope of the document
This document is valid for all components of the SIPLUS HCS4200 specified in these
operating instructions and describes the current delivery state.
Note
Notes for devices through FW version 1.x of the CIM
•
A maximum of 12 POMs can be operated in one 12-unit rack.
•
PMs and the DP connection are not available.
•
The following applies to the reading data records 152, 200 and 201
(Acyclic input data (Page 169)):
The information that is read is always for the full configuration, which means for
192 channels or 12 POMs.
•
The data records 160, 190 and 202 are not available.
Notes for devices through FW version 2.0 of the CIM
•
Configuration control is not available.
•
The POM4220 Midrange phase angle control cannot be configured.
•
No combination mode is supported.
Notes for devices through FW version 2.1 of the CIM
•
POM4220 Highend and Flexible cannot be configured.
•
Data record 50 is not available.
Notes for devices through FW version 2.2 of the CIM
The following functions of the POM
4220 Highend are not available:
•
Power control
•
2-pin switching
•
Economy circuit
•
Adaptive soft start
Registered trademarks
SIPLUS ® is a registered trademark of Siemens AG.

Introduction
1.1 Introduction
SIPLUS HCS4200 PROFINET/PROFIBUS DP
12 Operating Instructions, 07/2019, A5E35066204A/006

SIPLUS HCS4200 PROFINET/PROFIBUS DP
Operating Instructions, 07/2019, A5E35066204A/006 13
Security information
2
2.1 Safety information
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, please
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.
Warning symbols on the device
WARNING
Electric shock hazard
May 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
May 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.

Security information
2.1 Safety information
SIPLUS HCS4200 PROFINET/PROFIBUS DP
14 Operating Instructions, 07/2019, A5E35066204A/006
Working on the device or on components connected to it
WARNING
Electric shock hazard
May cause death or serious injury
•Voltages of more than 60 V can occur in the control cabinet. Suitable safety precautions
preventing contact must therefore be taken 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
May cause death or serious injury
Incorrectly performed repairs may result in substantial damage to equipment or endanger
the user. Return the device to Siemens for repair.

Security information
2.2 Security information
SIPLUS HCS4200 PROFINET/PROFIBUS DP
Operating Instructions, 07/2019, A5E35066204A/006 15
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.
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.
Protective measures for the HCS4200 heating control system
NOTICE
Only authorized personnel are permitted to access the system and make changes to it.

Security information
2.2 Security information
SIPLUS HCS4200 PROFINET/PROFIBUS DP
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SIPLUS HCS4200 PROFINET/PROFIBUS DP
Operating Instructions, 07/2019, A5E35066204A/006 17
System overview
3
3.1 Area of application
The SIPLUS HCS 4200 heating control system is used to control and switch heaters in
industry control und operation e.g. quartz, ceramic, flash, halogen or infrared heaters. It is of
modular design and can be flexibly adapted to suit the specific requirements of the
respective application.
Typical application areas are:
●Thermal treatment of fabrics and plastics
●Drying of enamels and paint coats
●PET blow molding
●Welding of plastic parts
●Handling of carbon materials
In general, the HCS4200 can be used wherever compact or modular concepts are required
with low to medium levels of power output.

System overview
3.2 Features
SIPLUS HCS4200 PROFINET/PROFIBUS DP
18 Operating Instructions, 07/2019, A5E35066204A/006
3.2 Features
SIPLUS HCS4200
An HCS4200 system consists of at least one rack with 4 or 12 slots, one Central Interface
Module (CIM) and a maximum of 24 Power Output Modules (POM). As an option, one
I/O module can be operated on the CIM. Fan modules can be mounted on the rack. Each fan
module serves 4 slots or POMs.
Figure 3-1 Heating control system HCS4200 with rack for 12/4 POMs
SIPLUS HCS4200 Compact
HCS4200 Compact consists of a rack with integrated CIM4210 and two slots for Power
Output Modules (POM). The fan is already mounted on the rack.
Figure 3-2 Heating control system CIM4210C PROFINET