Siemens SIPLUS HCS User manual

SIPLUS HCS4300
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Heating control systems
Heating control system
SIPLUS HCS4300
Operating Instructions
11/2015
A5E35452705A/002
Introduction
1
Safety notes
2
System overview
3
Application planning
4
Installing/mounting
5
Connection
6
Commissioning
7
Planning/configuring
8
Functions
9
Communications
10
Process and system
messages, error handling
11
Service and maintenance
12
Technical data
13
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E35452705A/002
Ⓟ
12/2015 Subject to change
Copyright © Siemens AG 2014 - 2015.
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
Operating Instructions, 11/2015, A5E35452705A/002 5
Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Introduction ...............................................................................................................................9
2 Safety notes.......................................................................................................................................... 11
2.1 IT security ...............................................................................................................................11
2.2 Safety notes ............................................................................................................................12
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) ..................................................................................................20
3.5.1 Function and design................................................................................................................20
3.6 I/O modules.............................................................................................................................22
3.6.1 PM4000 DI/DO........................................................................................................................22
3.6.2 PM4000 U/I .............................................................................................................................23
3.6.3 PM4000 Temperature.............................................................................................................24
3.7 EM4315 expansion module ....................................................................................................25
3.7.1 Design.....................................................................................................................................25
4 Application planning.............................................................................................................................. 27
4.1 Shipping ..................................................................................................................................27
4.2 Storage ...................................................................................................................................27
4.3 Scope of delivery ....................................................................................................................28
4.4 Installation location .................................................................................................................29
4.5 POM4320 power rating...........................................................................................................31
5 Installing/mounting ................................................................................................................................ 33
5.1 Requirements..........................................................................................................................33
5.2 Installing the Power Output Module (POM) ............................................................................34
5.2.1 Busbar mounting.....................................................................................................................34
5.2.1.1 Preparations............................................................................................................................34
5.2.1.2 Adjusting the busbar adapter..................................................................................................35
5.2.1.3 Mounting the POM (busbar adapter) ......................................................................................37
5.2.2 Panel mounting .......................................................................................................................38
5.2.2.1 POM mounting (panel mounting)............................................................................................38
5.3 Installing the Central Interface Module ...................................................................................39

Table of contents
SIPLUS HCS4300
6Operating Instructions, 11/2015, A5E35452705A/002
5.4 Installing the EM4315 expansion module .............................................................................. 40
5.5 Installing the I/O module (PM) ............................................................................................... 40
6 Connection ........................................................................................................................................... 43
6.1 Safety instructions and guidelines ......................................................................................... 43
6.2 Connecting the protective conductor ..................................................................................... 45
6.3 Connect PROFINET / PROFIBUS fieldbus ........................................................................... 46
6.4 Connecting the 24 V DC power supply.................................................................................. 47
6.5 Connecting the heating elements and three-phase line supply............................................. 48
6.5.1 Connecting the three-phase line supply ................................................................................ 48
6.5.2 Connecting heating elements ................................................................................................ 49
6.5.3 Block diagram ........................................................................................................................ 50
6.6 Connecting system interfaces................................................................................................ 51
6.7 Connecting I/O modules ........................................................................................................ 52
6.7.1 PM4000 DI/DO....................................................................................................................... 52
6.7.2 PM4000 U/I ............................................................................................................................ 54
6.7.3 PM4000 Temperature ............................................................................................................ 56
7 Commissioning ..................................................................................................................................... 59
7.1 Requirements......................................................................................................................... 59
7.2 Commissioning....................................................................................................................... 59
7.3 Insulation test ......................................................................................................................... 59
8 Planning/configuring ............................................................................................................................. 61
8.1 Integrating the HCS4300 into the PROFINET configuration ................................................. 61
8.2 Integrating the HCS4300 into the PROFIBUS configuration ................................................. 61
8.3 Device/hardware configuration in the TIA Portal ................................................................... 62
8.3.1 PROFINET device configuration............................................................................................ 62
8.3.2 PROFIBUS device configuration............................................................................................ 63
8.3.3 Configuration parameters ...................................................................................................... 64
8.3.3.1 CIM / POM configuration parameters .................................................................................... 64
8.3.3.2 Configuration parameters for I/O modules............................................................................. 65
8.4 Software tools for commissioning support ............................................................................. 67
8.4.1 Overview of tools for commissioning support ........................................................................ 67
9 Functions.............................................................................................................................................. 69
9.1 Status and actual displays ..................................................................................................... 69
9.2 Power output control .............................................................................................................. 70
9.2.1 Half-wave control ................................................................................................................... 70
9.2.2 Soft starting function .............................................................................................................. 71
9.2.3 Switch on heating................................................................................................................... 72
9.2.4 Channel control via setpoints................................................................................................. 72
9.2.5 Channel control via fields....................................................................................................... 73
9.2.6 Line voltage compensation .................................................................................................... 74
9.2.7 Behavior of the power outputs ............................................................................................... 74

Table of contents
SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 7
9.3 Recording of analog measured values ...................................................................................75
9.4 Digital inputs/outputs...............................................................................................................76
9.5 Recording of analog measured line values.............................................................................77
9.6 Monitoring functions................................................................................................................78
9.6.1 Line supply voltage monitoring ...............................................................................................78
9.6.2 Rotating-field test ....................................................................................................................78
9.6.3 Monitoring of the 24 V DC supply voltage ..............................................................................78
9.6.4 Frequency monitoring .............................................................................................................79
9.6.5 Temperature monitoring..........................................................................................................79
9.6.6 Monitoring power channels.....................................................................................................80
9.6.7 Further diagnostics .................................................................................................................81
10 Communications ................................................................................................................................... 83
10.1 Cyclic data exchange..............................................................................................................83
10.1.1 Cyclic output data ...................................................................................................................83
10.1.2 Cyclic input data......................................................................................................................85
10.2 Acyclic data exchange ............................................................................................................87
10.2.1 Acyclic output data..................................................................................................................87
10.2.2 Acyclic input data ....................................................................................................................91
10.3 Transfer of diagnostic alarms to the controller .......................................................................94
10.3.1 Transferring diagnostic alarms to the controller: PROFINET .................................................94
10.3.2 Transferring diagnostic alarms to the controller: PROFIBUS.................................................95
10.3.3 Manufacturer-specific error codes ..........................................................................................96
11 Process and system messages, error handling...................................................................................... 99
11.1 Central Interface Module (CIM) ..............................................................................................99
11.2 Power Output Module (POM) ...............................................................................................100
11.2.1 LED operating display for POM ............................................................................................100
11.2.2 Fault reporting through diagnostics data ..............................................................................101
11.3 I/O modules...........................................................................................................................102
12 Service and maintenance.................................................................................................................... 103
12.1 Maintenance work.................................................................................................................103
12.2 Firmware update ...................................................................................................................104
12.2.1 PROFINET firmware update.................................................................................................104
12.2.2 PROFIBUS firmware update.................................................................................................106
12.3 Fuse replacement .................................................................................................................108
12.4 Replace fan...........................................................................................................................112
12.5 Replacing the power output module (POM) .........................................................................115
12.6 Replacing the central interface module (CIM) ......................................................................117
12.7 Replacing an I/O module ......................................................................................................118
12.8 Recycling and disposal .........................................................................................................120

Table of contents
SIPLUS HCS4300
8Operating Instructions, 11/2015, A5E35452705A/002
13 Technical data .....................................................................................................................................121
13.1 Technical specifications for POM......................................................................................... 121
13.2 Technical specifications for CIM .......................................................................................... 127
13.3 Technical specifications for I/O module ............................................................................... 129
13.4 Technical specifications for EM4315 expansion module..................................................... 137
13.5 Dimension drawings............................................................................................................. 139
A Appendix .............................................................................................................................................143
A.1 Certificates and approvals ................................................................................................... 143
A.1.1 Certificates and approvals ................................................................................................... 143
A.2 Article numbers for spare parts/accessories........................................................................ 144
A.2.1 Ordering data ....................................................................................................................... 144
A.3 ESD Guidelines.................................................................................................................... 145
A.4 Service & Support ................................................................................................................ 147
A.4.1 Application example............................................................................................................. 148
Index ...................................................................................................................................................149

SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 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
Note
11/2014 First edition
10/2015 Expansion to include POM with panel mounting, PROFIBUS, I/O modules, ex-
pansion module for additional 2 x 8 POMs

Introduction
1.1 Introduction
SIPLUS HCS4300
10 Operating Instructions, 11/2015, A5E35452705A/002
Scope of validity of this document
This documentation is valid for all components of the SIPLUS CMS4300 specified in these
operating instructions and describes the most recent delivery state at the time of writing.
Note
Note for devices up to firmware version 1.x
•
A maximum of 6 POMs can be operated.
•
Expansion module, PMs and the DP connection are not available
•
The following applies for reading datasets 152, 200 and 201: The information that is read
is always for the full configuration, i.e. for 54 channels or 6 POMs.
•
The datasets 160, 190 and 202 are not available.
Naming conventions and abbreviations
A synonym or an abbreviation is sometimes used in this documentation instead of the full
product name.
The followings terms and abbreviations are used:
SIPLUS HCS4300
HCS
Power Output Module
POM
Central Interface Module
CIM
I/O module
PM
Registered trademarks
SIPLUS ® is a registered trademark of Siemens AG.

SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 11
Safety notes
2
2.1
IT security
IT security guidelines
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components of a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
To ensure the secure operation of products and solutions from Siemens, it is necessary to
take suitable preventive action (e.g. cell protection concept) and integrate each component
into a holistic, state-of-the-art industrial security concept. Any third-party products that may
be in use must also be taken into account For more information about industrial security, visit
http://www.siemens.com/industrialsecurity.
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. For more information, visit http://support.automation.siemens.com.
Protective measures for the HCS4300 heating control system
NOTICE
Only authorized personnel are permitted to access the system and make changes to it.

Safety notes
2.2 Safety notes
SIPLUS HCS4300
12 Operating Instructions, 11/2015, A5E35452705A/002
2.2
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.
•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
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.

Safety notes
2.2 Safety notes
SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 13
Working on the device or on components connected to it
WARNING
Electric shock hazard
May cause death or serious injury
•In the control cabinet, voltages of > 60 V occur. Suitable safety precautions must
therefore be taken before 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.

Safety notes
2.2 Safety notes
SIPLUS HCS4300
14 Operating Instructions, 11/2015, A5E35452705A/002

SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 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 paint coats
●Thermal treatment of fabrics and plastics
●Welding of plastic parts
●Treatment 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
16 Operating Instructions, 11/2015, A5E35452705A/002
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 picture below shows an example of an HCS4300, consisting of one CIM4310 for
PROFINET and one POM4320 for busbar mounting.
Image 3-1 HCS4300 comprising CIM ①and POM ②
The following types of system component are available:
System component
Version
Description
Central Interface Mod-
ule (CIM)
•CIM 4310 PROFINET
•CIM 4310 PROFIBUS
-
I/O module •PM4000 DI/DO 8 digital outputs and 8 configurable in-
puts/outputs.
•PM4000 U/I Inputs for measuring line voltage and line
current.
•PM4000 Temperature 4 analog inputs for 0...20 mA and
4 measuring inputs for temperature
Power Output Module
(POM)
•POM4320 busbar mounting: 9 power outputs with diagnostic function
and fault indication per channel.
•POM4320 panel mounting
Expansion module •EM4315 Permits the operation of as many as 8
additional POMs.

System overview
3.2 Features
SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 17
Features
●Modular (centralized) and compact (distributed) configurations possible
●Communication via PROFINET/PROFIBUS
●Parameterization, commissioning, visualization and diagnostics via the Siemens TIA
Portal
●Commissioning and diagnostics tool for on-site diagnostics directly at the heating control
system
●Integrated diagnostics and monitoring functions
●Control modes: Half-wave control and soft-starting
●Line voltage compensation for smoothing line voltage fluctuations integrated
●Only one 24 V infeed is required for up to 8 Power Output Modules (POM)
●Slot for one I/O module (PM)
●Expansion module (optional) with 24 V infeed for operating additional 2 x 8 POMs

System overview
3.3 System configuration
SIPLUS HCS4300
18 Operating Instructions, 11/2015, A5E35452705A/002
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
Image 3-2 HCS 4300 system configuration
Centralized/distributed system configuration
You can operate up to 8 POMs on one CIM. Up to 24 POMs can be operated in the
maximum configuration with two expansion modules. Configurations are possible for both
distributed heating applications, such as PET blow molding, in which the heating control
system is located below the heat boxes, and centralized applications, such as
thermoforming, in which emitters are assembled into multi-tier arrays and the modular
heating control system is located in a central control cabinet.
Communication via PROFINET or PROFIBUS
PROFIBUS has been established for years as the fieldbus for machines and plants. Based
on serial bus technology, it is the foundation for the distributed concepts that are common
today.
PROFINET unites the industrial experience of PROFIBUS with the openness and flexible
options of Ethernet. PROFINET enables high-speed and secure data exchange at all levels,
thus making it possible to implement innovative machine and plant concepts.

System overview
3.4 Central interface module (CIM)
SIPLUS HCS4300
Operating Instructions, 11/2015, A5E35452705A/002 19
3.4
Central interface module (CIM)
3.4.1
Function and design
Function
The Central Interface Module (CIM) handles the communication with the higher-level
controller and with the connected Power Output Modules (POM). The CIM also provides the
24 V DC power supply for the connected POMs. The CIM is available in two versions: with a
PROFINET interface or with a PROFIBUS interface.
Design
CIM 4310 PROFINET
CIM 4310 PROFIBUS
①
Status LEDs
①
Status LEDs
②
System interface to POM
②
System interface to POM
③PROFINET interface X1, X2 ③Address selection switch S1 / S2 for
PROFIBUS
④24 V DC power supply X3 ④•PROFIBUS DP interface X1
•Service interface X2
⑤
Slot for I/O module
⑤
24 V DC power supply X3
⑥Slot for I/O module

System overview
3.5 Power output module (POM)
SIPLUS HCS4300
20 Operating Instructions, 11/2015, A5E35452705A/002
3.5
Power output module (POM)
3.5.1
Function and design
Function
The Power Output Module (POM) offers 9 power outputs for resistive loads and can be
operated in TN and TT networks. The Power Output Module is available in different versions
for busbar or panel mounting.
POM4320 design for busbar mounting
Power Output Module POM
①
Fans
②
Busbar adapter
③
Protective conductor connector
④
3 x 3 power outputs including
feedback
error LED for each power out-
put
⑤HCS system interface
⑥
Status LEDs