Siemens SIPLUS HCS User manual

SIPLUS HCS4200
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Heating control systems
Heating control system
SIPLUS HCS4200
Operating Instructions
11/2015
A5E35066204A/RS
-AA/002
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/RS-AA/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 HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 5
Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Introduction ...............................................................................................................................9
2 Security information .............................................................................................................................. 11
2.1 IT security ...............................................................................................................................11
2.2 Safety information...................................................................................................................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) ..............................................................................................20
3.4.1 Function and design................................................................................................................20
3.5 Power Output Module (POM) .................................................................................................21
3.5.1 Function and design................................................................................................................21
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
4 Application planning.............................................................................................................................. 25
4.1 Shipping ..................................................................................................................................25
4.2 Storage ...................................................................................................................................25
4.3 Scope of delivery ....................................................................................................................26
4.4 Installation location .................................................................................................................27
4.5 Performance profile of the POM4220 .....................................................................................32
5 Installation/mounting ............................................................................................................................. 35
5.1 Requirements..........................................................................................................................35
5.2 Mounting the rack ...................................................................................................................35
5.3 Mounting the fan module ........................................................................................................38
5.4 Installing the central interface module (CIM) ..........................................................................40
5.5 Installing the I/O module (PM) ................................................................................................41
5.6 Installing the power output module (POM) .............................................................................42
5.7 Mounting the blanking covers .................................................................................................43
5.8 Double frame setup.................................................................................................................44

Table of contents
SIPLUS HCS4200
6Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
6 Connecting ........................................................................................................................................... 45
6.1 Safety information and guidelines.......................................................................................... 45
6.2 Connecting the protective conductor ..................................................................................... 46
6.3 Connecting PROFINET / PROFIBUS fieldbus....................................................................... 47
6.4 Connecting the 24 V DC power supply.................................................................................. 48
6.5 Connecting the heating elements and three-phase line supply............................................. 50
6.5.1 Block diagram ........................................................................................................................ 53
6.6 Connecting I/O modules ........................................................................................................ 56
6.6.1 PM4000 DI/DO....................................................................................................................... 56
6.6.2 PM4000 U/I ............................................................................................................................ 58
6.6.3 PM4000 Temperature ............................................................................................................ 60
7 Commissioning ..................................................................................................................................... 63
7.1 Requirements......................................................................................................................... 63
7.2 Commissioning....................................................................................................................... 63
7.3 Insulation test ......................................................................................................................... 63
8 Configuration ........................................................................................................................................ 65
8.1 Integrating the HCS4200 into the PROFINET configuration ................................................. 65
8.2 Integrating the HCS4200 into the PROFIBUS configuration ................................................. 65
8.3 Device/hardware configuration in the TIA Portal ................................................................... 66
8.3.1 PROFINET device configuration............................................................................................ 66
8.3.2 PROFIBUS device configuration............................................................................................ 67
8.3.3 Configuration parameters ...................................................................................................... 68
8.3.3.1 CIM / POM configuration parameters .................................................................................... 68
8.3.3.2 Configuration parameters for I/O modules............................................................................. 69
8.4 Software tools for commissioning support ............................................................................. 71
8.4.1 Overview of tools for commissioning support ........................................................................ 71
9 Functions.............................................................................................................................................. 73
9.1 Status and actual displays ..................................................................................................... 73
9.2 Power output control .............................................................................................................. 74
9.2.1 Half-wave control ................................................................................................................... 74
9.2.2 Soft starting function .............................................................................................................. 75
9.2.3 Switch on heating................................................................................................................... 76
9.2.4 Channel control via setpoints................................................................................................. 76
9.2.5 Channel control via fields....................................................................................................... 77
9.2.6 Line voltage compensation .................................................................................................... 78
9.2.7 Behavior of the power outputs ............................................................................................... 79
9.3 Digital inputs/outputs.............................................................................................................. 80
9.4 Recording of analog measured line values............................................................................ 81
9.5 Recording of analog measured values .................................................................................. 83
9.6 Monitoring functions............................................................................................................... 84
9.6.1 Monitoring phase connection ................................................................................................. 84

Table of contents
SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 7
9.6.2 Line supply voltage monitoring ...............................................................................................84
9.6.3 Monitoring of the 24 V DC supply voltage ..............................................................................85
9.6.4 Frequency monitoring .............................................................................................................85
9.6.5 Temperature monitoring..........................................................................................................86
9.6.6 Monitoring power channels.....................................................................................................87
9.6.7 Further diagnostics .................................................................................................................88
10 Communications ................................................................................................................................... 89
10.1 Cyclic data exchange..............................................................................................................89
10.1.1 Cyclic output data ...................................................................................................................89
10.1.2 Cyclic input data......................................................................................................................92
10.2 Acyclic data exchange ............................................................................................................95
10.2.1 Acyclic output data..................................................................................................................95
10.2.2 Acyclic input data ....................................................................................................................99
10.3 Transfer of diagnostic alarms to the controller .....................................................................102
10.3.1 Transferring diagnostic alarms to the controller: PROFINET ...............................................102
10.3.2 Transferring diagnostic alarms to the controller: PROFIBUS ...............................................103
10.3.3 Manufacturer-specific error codes ........................................................................................104
11 Process and system messages, error handling.................................................................................... 107
11.1 Central Interface Module (CIM) ............................................................................................107
11.1.1 LED operating display for CIM..............................................................................................107
11.2 Power Output Module (POM) ...............................................................................................108
11.2.1 LED operating display for POM ............................................................................................108
11.2.2 Fault reporting through diagnostics data ..............................................................................109
11.3 I/O modules...........................................................................................................................110
12 Service and maintenance.................................................................................................................... 111
12.1 Maintenance work.................................................................................................................111
12.2 Firmware update ...................................................................................................................112
12.2.1 PROFINET firmware update.................................................................................................112
12.2.2 PROFIBUS firmware update.................................................................................................114
12.3 Fuse replacement .................................................................................................................116
12.4 Replacing the fan module .....................................................................................................118
12.5 Replacing the Power Output Module (POM) ........................................................................120
12.6 Replacing the Central Interface Module (CIM) .....................................................................122
12.7 Replacing an I/O module ......................................................................................................124
12.8 Recycling and disposal .........................................................................................................126
13 Technical specifications ...................................................................................................................... 127
13.1 Technical specifications for Rack4200 .................................................................................127
13.2 Technical specifications for CIM ...........................................................................................129
13.3 Technical specifications for POM .........................................................................................131
13.4 Technical specifications for I/O module................................................................................134
13.5 Technical specifications for fan module................................................................................142

Table of contents
SIPLUS HCS4200
8Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
13.6 Dimension drawings............................................................................................................. 144
A Appendix .............................................................................................................................................147
A.1 Certificates and approvals ................................................................................................... 147
A.1.1 Certificates and approvals ................................................................................................... 147
A.2 Ordering data ....................................................................................................................... 148
A.3 ESD guidelines..................................................................................................................... 149
A.4 Service & Support ................................................................................................................ 151
Index ...................................................................................................................................................153

SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/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 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 start up 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 followings 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
10 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
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
Scope of validity of this document
This documentation is valid for all components of the SIPLUS CMS4200 specified in these
operating instructions and describes the current delivery state.
Note
Note for devices up to firmware version 1.x
•
A maximum of 12 POMs can be operated in one 12-unit rack.
•
PMs as well as the DP connection are not available.
•
The following applies to the reading data sets 152, 200 and 201 (Acyclic input data
(Page 99)): The information that is read is always for the full configuration, i.e. for 192
channels or 12 POMs.
•
The data sets 160, 190 and 202 are not available.
Registered trademarks
SIPLUS ® is a registered trademark of Siemens AG.

SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 11
Security information
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 HCS4200 heating control system
NOTICE
Only authorized personnel are permitted to access the system and make changes to it.

Security information
2.2 Safety information
SIPLUS HCS4200
12 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
2.2
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
2.2 Safety information
SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 13
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 Safety information
SIPLUS HCS4200
14 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002

SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 15
System overview
3
3.1
Area of application
The SIPLUS HCS 4200 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:
●Thermal treatment of fabrics and plastics
●Drying of enamels and paint coats
●PET blow molding
●Welding of plastic parts
●Treatment 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
16 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
3.2
Features
An HCS4200 system comprises one rack with 4 or 12 slots, 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. Fan modules can be mounted on the rack. Each fan module serves 4
slots or POMs.
Image 3-1 HCS4200 heating control system with rack for 12 POMs
The following types of system component are available:
System component
Version
Rack •Rack 4200 for 12
POMs
•Rack 4200 for 4
POMs
The module racks can be combined as
follows:
12 / 4 / 12+12 / 12+4 / 4+4
Central Interface Module
(CIM)
•CIM 4210
PROFINET
•CIM 4210
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 Tempera-
ture
4 analog inputs for 0...20 mA and 4 measur-
ing inputs for temperature
Power Output Module
(POM)
•POM 4220 low-end 230 V AC, 16 power outputs, max. 1449 W
per power output
•POM 4220 mid-range 277 V AC, 12 power outputs, max. 4432 W
per power output
Fan module •FM4220 Fan module for ventilation of 4 power output
modules

System overview
3.2 Features
SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 17
Features
●Modular (central) design
●Communication over PROFINET or PROFIBUS
●Parameterization, commissioning, visualization and diagnostics via the Siemens TIA
Portal
●Integrated diagnostic and monitoring functions
●Control modes: Half-wave control and soft start
●Connection of incoming supply through 3-pole connector on the front of the POM
●Connection of power outputs via two 8-pin or 6-pin connectors on the front of the POM
●Only one 24 V feed is necessary for up to 12 POMs (when using one rack) or 24 POMs
(when using a double rack)
●Slot for an I/O module

System overview
3.3 System configuration
SIPLUS HCS4200
18 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
3.3
System configuration
System components
A complete HCS4200 heating control system includes the following components:
●Central Interface Module (CIM) 4210 with PROFINET / PROFIBUS
●Power Output Module (POM) 4220
●Rack
●Fan module (optional)
●Higher-level controller (e.g. SIMATIC S7-1500 automation system with PROFINET /
PROFIBUS)
●Field PG (optional, for commissioning and diagnostics)
●Industrial PC (optional, e.g. Panel PC SIMATIC IPC 477D)
●Heat emitter array
Image 3-2 HCS4200 system configuration
System configuration
Several POMs can be operated on one CIM. This supports the implementation of centralized
heating applications, for example, in thermoforming, where the heating elements are
implemented in numerous arrays and the modular heating controller is located in a central
control cabinet.

System overview
3.3 System configuration
SIPLUS HCS4200
Operating Instructions, 11/2015, A5E35066204A/RS-AA/002 19
Communication over 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 HCS4200
20 Operating Instructions, 11/2015, A5E35066204A/RS-AA/002
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 and fan modules. The CIM is available in
two versions: with a PROFINET-interface or with a PROFIBUS-interface.
Design
CIM 4210 PROFINET
CIM 4210 PROFIBUS
①
Status LEDs
①
Status LEDs
②System interface to rack ②System interface
to rack
③
PROFINET interface X1, X2
③
Address 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
⑥
Slot for I/O module