Siemens SIPLUS HCS3200 User manual

SIPLUS HCS3200
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Heating Control Systems
Heating control system
SIPLUS HCS3200
Operating Instructions
07/2014
A5E31278506C/002
Introduction
1
Safety notes
2
Description
3
Application planning
4
Mounting
5
Connection
6
Commissioning
7
Functions
8
Communication
9
Error handling
10
Service and maintenance
11
Technical data
12
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E31278506C/002
Ⓟ
08/2014 Subject to change
Copyright © Siemens AG 2013 - 2014.
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 HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 5
Table of contents
1 Introduction............................................................................................................................................. 7
1.1 Introduction ...............................................................................................................................7
2 Safety notes............................................................................................................................................ 9
2.1 Safety notes ..............................................................................................................................9
2.2 IT security ...............................................................................................................................11
3 Description............................................................................................................................................ 13
3.1 Area of application of HCS3200 .............................................................................................13
3.2 Features..................................................................................................................................13
3.3 Structure .................................................................................................................................14
3.4 System configuration ..............................................................................................................15
4 Application planning.............................................................................................................................. 17
4.1 Shipping ..................................................................................................................................17
4.2 Unpacking and checking the delivery .....................................................................................17
4.3 Requirements regarding the mounting location......................................................................18
5 Mounting............................................................................................................................................... 21
5.1 Preparations............................................................................................................................21
5.2 Mounting the device................................................................................................................22
5.3 Final work................................................................................................................................23
6 Connection ........................................................................................................................................... 25
6.1 Preparations............................................................................................................................25
6.2 Block diagram .........................................................................................................................26
6.3 Connection element locations.................................................................................................27
6.4 X1 (mains connection / grounding) .........................................................................................28
6.5 X2 (heating element connection .............................................................................................30
6.6 X3/X4 (PROFIBUS DP / 24 V DC)..........................................................................................32
6.7 RS232 interface ......................................................................................................................34
7 Commissioning ..................................................................................................................................... 35
7.1 Requirements..........................................................................................................................35
7.1.1 Hardware requirements ..........................................................................................................35
7.1.2 Integrating the GSD file...........................................................................................................35
7.1.3 Configuring the device-specific parameters............................................................................36
7.1.4 Setting the bus address ..........................................................................................................37

Table of contents
SIPLUS HCS3200
6Operating Instructions, 07/2014, A5E31278506C/002
7.2 Commissioning....................................................................................................................... 38
7.2.1 Commissioning steps ............................................................................................................. 38
8 Functions.............................................................................................................................................. 39
8.1 Power output control .............................................................................................................. 39
8.2 Power output diagnostics....................................................................................................... 40
8.3 Line supply voltage monitoring .............................................................................................. 41
8.4 Line voltage compensation .................................................................................................... 42
8.5 Frequency monitoring ............................................................................................................ 42
8.6 Temperature monitoring......................................................................................................... 43
9 Communication..................................................................................................................................... 45
9.1 Cyclic data transfer ................................................................................................................ 45
9.2 Cyclic input data..................................................................................................................... 45
9.3 Cyclic output data................................................................................................................... 46
9.4 Diagnostics data..................................................................................................................... 47
10 Error handling ....................................................................................................................................... 49
10.1 Status and fault display with LEDs......................................................................................... 49
10.2 Fault reporting through diagnostics data ............................................................................... 50
11 Service and maintenance...................................................................................................................... 51
11.1 Maintenance work.................................................................................................................. 51
11.2 Firmware update .................................................................................................................... 52
11.3 Fuse replacement .................................................................................................................. 54
11.4 Fan replacement .................................................................................................................... 57
11.5 Replacing the device.............................................................................................................. 60
11.6 Recycling and disposal .......................................................................................................... 60
12 Technical data ...................................................................................................................................... 61
12.1 Technical specifications ......................................................................................................... 61
12.2 Dimension drawings............................................................................................................... 65
A Appendix .............................................................................................................................................. 67
A.1 Certificates and approvals ..................................................................................................... 67
A.2 Order numbers for spare parts/accessories .......................................................................... 68
A.2.1 Ordering data ......................................................................................................................... 68
A.3 Service & Support .................................................................................................................. 69
A.3.1 Application example............................................................................................................... 70
Index .................................................................................................................................................... 71

SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 7
Introduction
1
1.1
Introduction
Purpose of this documentation
These operating instructions contain all the information you require to commission and
operate the HCS3200 heating controller.
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 PROFIBUS DP fieldbus is also necessary.
History
The following earlier release versions of these operating instructions have been published:
Edition
Note
07/2014
First edition
Registered trademarks
SIPLUS ® is a registered trademark of Siemens AG.

Introduction
1.1 Introduction
SIPLUS HCS3200
8Operating Instructions, 07/2014, A5E31278506C/002

SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 9
Safety notes
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, 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
disconnecting means. 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 notes
2.2 IT security
SIPLUS HCS3200
10 Operating Instructions, 07/2014, A5E31278506C/002
Working on the device or on components connected to it
WARNING
Electric shock hazard
May cause death or serious injury
•Before opening the enclosure door, you must disconnect the line voltage and secure it
against switching on again.
•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.

Safety notes
2.2 IT security
SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 11
2.2
IT security
IT security guidelines
Siemens offers IT security mechanisms for its automation and drive product portfolio in order
to support the safe operation of the plant/machine. We recommend that you inform yourself
regularly on the IT security developments regarding your products. For information on this
topic, refer to: http://support.automation.siemens.com. Here, you can register for a product-
specific newsletter.
For the secure operation of a plant/machine, however, it is necessary to integrate the
automation components in a full IT security concept for the entire plant/machine that
represents the state of the art in IT technology. You can find information on this at:
http://www.siemens.com/industrialsecurity.
Products used from other manufacturers should also be taken into account here.

Safety notes
2.2 IT security
SIPLUS HCS3200
12 Operating Instructions, 07/2014, A5E31278506C/002

SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 13
Description
3
3.1
Area of application of HCS3200
The HCS3200 heating controller is used for controlling heating elements used in industry.
The preferred area of application for the HCS3200 is in the control of infrared emitters in
PET stretch blow molding machines.
In principle, the HCS3200 can be used wherever resistive loads have to be switched and
monitored.
3.2
Features
Features
HCS3200 heating controller
Features
•9 power outputs with a maximum switching power of 4 kW
at 400 V AC
•Total switching power of the device: 25200 W
•15 A fuse per power output (internally accessible)
•Connection of the line voltage, heating elements and
PROFIBUS DP/24V DC via connectors underneath the de-
vice
•Diagnostics per power output, for detecting internal and
external faults
•Internal temperature monitoring through NTC thermistor
•Voltage monitoring
•Line voltage compensation
•
PROFIBUS DP address setting with rotary switch (internally
accessible)
•Station status LED indicators (internally accessible)
•Serial interface for firmware updates (internally accessible)

Description
3.3 Structure
SIPLUS HCS3200
14 Operating Instructions, 07/2014, A5E31278506C/002
3.3
Structure
①
Enclosure door, grounded
②
Internal fan
③
RS232 interface for loading new software
④
X4: PROFIBUS DP and 24 V DC supply
⑤
LEDs: for displaying the system operating status
⑥
2 rotary switches: for setting the address of the PROFIBUS DP interface
⑦
X3: PROFIBUS DP and 24 V DC supply
⑧
X2: For controlling up to 9 heating elements
⑨
X1: Line voltage and protective earth PE
⑩
Lower fuse block: for fuses F111 (left) to F119 (right) along the incoming lines for heating ele-
ments 1 to 9.
⑪
Upper fuse block: for fuses F101 (left) to F109 (right) along the outgoing lines for heating ele-
ments 1 to 9.
Figure 3-1 HCS3200 structure

Description
3.4 System configuration
SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 15
3.4
System configuration
System components
The SIPLUS HCS3200 heating control system is a distributed I/O device. It communicates
via the PROFIBUS DP fieldbus with the SIMATIC S7 controller.
A complete system includes the following components:
●HCS3200 heating controller
●Higher-level control through SIMATIC S7 automation system with integrated interface for
PROFIBUS DP or SIMOTION
●PROFIBUS DP
●Cabling
●Heat emitter array
●HMI panel (optional)
System configuration
The following diagram shows an example of the interaction between the system components
described:
Figure 3-2 Example: System configuration

Description
3.4 System configuration
SIPLUS HCS3200
16 Operating Instructions, 07/2014, A5E31278506C/002

SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 17
Application planning
4
4.1
Shipping
NOTICE
Securing the device during transportation
Transport the device only in the original packaging which will give it the necessary
protection against shock and impact.
4.2
Unpacking and checking the delivery
Unpacking the device
1. Unpack the device and the supplied components.
2. Check the shipment for completeness.
3. Make a visual check of the device and the components for transport damage.
Keep the packaging material in case you have to return the device.
Scope of delivery
●HCS3200 device
●Mounting hardware
●Compact Operating Instructions

Application planning
4.3 Requirements regarding the mounting location
SIPLUS HCS3200
18 Operating Instructions, 07/2014, A5E31278506C/002
4.3
Requirements regarding the mounting location
Ambient conditions
SIPLUS HCS3200 may only be installed indoors. The main ambient requirements are
described below:
mounting position
vertical
Ambient temperature
•during operating °C 0 … 50
Installation altitude at a height over sea level maximum
m
2000
Vibration resistance
during operating phase
to IEC
60068-2-6
10 ... 58 Hz / 0.15 mm, 58 ... 150 Hz
/ 1g
Resistance against shock according to IEC 60068-2-27
15g / 11 ms / 3 shocks / axis
Relative humidity at 25 °C during operating maximum
%
95
Relative humidity at 50 °C during operating maximum
%
50
Incoming supply / cabling
WARNING
Electric shock hazard
May cause death or serious injury
•The line voltage to which the device is connected must have a disconnecting means.
The disconnecting means must be easily accessible and uniquely assigned to the
device. It is recommended that the disconnecting means is located close to the device.
The maximum current consumption for the device must be taken into consideration
when selecting the disconnecting means.
•Only use the device in circuits with a short-circuit limitation of 25 kA rms.
•An external 70 A Class CC fuse must be connected upstream of the device.
•Only use 60/75 °C copper cables for the cabling.

Application planning
4.3 Requirements regarding the mounting location
SIPLUS HCS3200
Operating Instructions, 07/2014, A5E31278506C/002 19
External lightning protector
NOTICE
An external lightning protector must be connected in the 24 V DC supply line:
Dehn, "Blitzductor BVT" type AD24, No. 918402 (or equivalent).
If other lightning protectors are used, you must ensure that the types are equivalent (check
with the manufacturer of the lightning protector).
The lighting protector must be installed and used in accordance with the instructions of the
manufacturer.
With a lightning protector, the following interference immunity in accordance with IEC 61000-
4-5 is achieved:
1.0 kV symm. with Ri = 2 Ω; evaluation criterion B
2.0 kV unsymmetrical with Ri = 12 Ω; evaluation criterion B
Without a lightning protector, the following interference immunity is achieved:
0.5 kV symm. with Ri = 2 Ω; evaluation criterion B
0.5 kV unsymmetrical with Ri = 12 Ω; evaluation criterion B

Application planning
4.3 Requirements regarding the mounting location
SIPLUS HCS3200
20 Operating Instructions, 07/2014, A5E31278506C/002