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Siemens SIPLUS HCS Operating Instructions Manual

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Summary of Contents for Siemens SIPLUS HCS

  • Page 3 ___________________ SIPLUS HCS4300 Introduction ___________________ Safety notes ___________________ Heating control systems System overview ___________________ Application planning Heating control system SIPLUS HCS4300 ___________________ Installing/mounting ___________________ Connection Operating Instructions ___________________ Commissioning ___________________ Planning/configuring ___________________ Functions ___________________ Communications ___________________ Process and system messages, error handling ___________________ Service and maintenance ___________________...
  • Page 4 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.

  • Page 5: Table Of Contents

    Table of contents Introduction ............................. 9 Introduction ..........................9 Safety notes ............................11 IT security ..........................11 Safety notes ..........................12 System overview ........................... 15 Area of application ........................15 Features ..........................16 System configuration ......................18 Central interface module (CIM) ....................19 3.4.1 Function and design........................
  • Page 6 Table of contents Installing the EM4315 expansion module ................40 Installing the I/O module (PM) ....................40 Connection ............................43 Safety instructions and guidelines ..................43 Connecting the protective conductor ..................45 Connect PROFINET / PROFIBUS fieldbus ................46 Connecting the 24 V DC power supply .................. 47 Connecting the heating elements and three-phase line supply ..........
  • Page 7 Table of contents Recording of analog measured values ................... 75 Digital inputs/outputs....................... 76 Recording of analog measured line values................77 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 ......................
  • Page 8 Table of contents 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 Appendix .............................

  • Page 9: Introduction

    Introduction 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 ●...
  • Page 10 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 Power Output Module Central Interface Module I/O module Registered trademarks SIPLUS ® is a registered trademark of Siemens AG. SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 11: Safety Notes

    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.

  • Page 12: Safety Notes

    Safety notes 2.2 Safety notes 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 •...
  • Page 13 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. SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...
  • Page 14 Safety notes 2.2 Safety notes SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 15: System Overview

    System overview 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.

  • Page 16: Features

    System overview 3.2 Features 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.
  • Page 17 3.2 Features 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 ●...

  • Page 18: System Configuration

    System overview 3.3 System configuration 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 ●...

  • Page 19: Central Interface Module (Cim)

    System overview 3.4 Central interface module (CIM) 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.

  • Page 20: Power Output Module (Pom)

    System overview 3.5 Power output module (POM) 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.
  • Page 21 System overview 3.5 Power output module (POM) POM4320 design for panel mounting Power Output Module POM ① Fans ② Mains connection L1/L2/L3 ③ Protective conductor connector ④ 3 x 3 power outputs including feedback error LED for each power out- ⑤...

  • Page 22: I/O Modules

    System overview 3.6 I/O modules I/O modules 3.6.1 PM4000 DI/DO Function The I/O module PM4000 DI/DO provides 8 digital outputs and 8 configurable inputs/outputs. The digital I/O modules are controlled by the S7-CPU using the process image. NOTICE The PM4000 DI/DO may not be used for safety-related functions. Design PM4000 DI/DO Item...

  • Page 23: Pm4000 U/I

    System overview 3.6 I/O modules 3.6.2 PM4000 U/I Function The I/O module PM4000 U/I provides inputs for measuring line voltage and line current. ● Voltage measurement: Either the supplied line-to-line voltage or the star voltage is measured (parameterizable) The rms effective value is calculated from the measured values.

  • Page 24: Pm4000 Temperature

    System overview 3.6 I/O modules 3.6.3 PM4000 Temperature Function Temperature I/O module for HCS Central Interface Module (CIM). ● Four measuring inputs for temperature in two-wire technology or two measuring inputs for temperature in four-wire technology. ● Four analog inputs for 0...20 mA The measured values are transferred via the fieldbus and can be evaluated and further processed by the user.

  • Page 25: Em4315 Expansion Module

    System overview 3.7 EM4315 expansion module EM4315 expansion module 3.7.1 Design Function In the basic configuration, a maximum of 8 POMs can be operated with a CIM. The operation of up to 8 additional POMs is possible with an EM4315 expansion module.In the maximum configuration, two expansion modules can be used, making it possible to operate 24 POMs with a single CIM.

  • Page 27: Application Planning

    Siemens AG. SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 28: Scope Of Delivery

    Application planning 4.3 Scope of delivery Scope of delivery Depending on the components ordered, the scope of delivery includes: Component Included in the scope of supply SIPLUS HCS4300 POM Connecting cable for system interface • 6 plug connectors for connecting the heating •...

  • Page 29: Installation Location

    Application planning 4.4 Installation location Installation location Installation location requirements Note Installation in control cabinet/device connection box The SIPLUS HCS4300 heating control system is intended for installation in a control cabinet or a device connection box. • In these cases, only the LEDs on the front of the device will remain visible during commissioning.
  • Page 30 If flash emitters with an output of more than 4000 W at 400 V are used, switching operations can result in extremely high currents and the triggering of the channel fuses. We therefore recommend that you have these emitters gauged by Siemens AG. Derating of fuses Note that fuses are subject to derating at high ambient temperatures, i.e.

  • Page 31: Pom4320 Power Rating

    Application planning 4.5 POM4320 power rating POM4320 power rating POM4320 IEC power rating Image 4-1 POM4320 IEC power rating POM 4320 UL power rating Image 4-2 POM4320 UL power rating SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...
  • Page 32 Application planning 4.5 POM4320 power rating SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 33: Installing/Mounting

    Installing/mounting Requirements Safety guidelines WARNING Hazardous voltages on the heating control system May cause death, serious injury or damage to property Before starting installation or connection work on the HCS4300 heating control system, you must isolate the heating control system and secure it against reclosing. SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 34: Installing The Power Output Module (Pom)

    Busbar system The mains infeed for the power output module is connected via a 3-phase busbar system. Suitable for the following busbar systems, for example: ● Siemens (SENTRON 60 mm) ● Wöhner (60 mm-EQUES) WARNING Dangerous voltages on the busbar system May cause death, serious injury or damage to property Dangerous voltages can be present on the busbar system.

  • Page 35: Adjusting The Busbar Adapter

    Installing/mounting 5.2 Installing the Power Output Module (POM) 5.2.1.2 Adjusting the busbar adapter Tool You will need a slot head screwdriver of size 0.6 x 3.5 mm Adjusting the busbar adapter to the thickness of the busbar The busbar adapter of the POM can be adjusted for the following busbar thicknesses: ●...
  • Page 36 Installing/mounting 5.2 Installing the Power Output Module (POM) Proceed as follows for each of the four fixing blocks: Steps Use the screwdriver to push out ① the fixing block Position the fixing block in ac- cordance with the rail thickness (5 mm / 10 mm) Push the fixing block back until it latches in place.

  • Page 37: Mounting The Pom (Busbar Adapter)

    Installing/mounting 5.2 Installing the Power Output Module (POM) 5.2.1.3 Mounting the POM (busbar adapter) The POM can be mounted on the busbar without the need for tools, using the POM busbar adapter. Mounting the POM Image 5-1 Mounting the POM Steps ①...

  • Page 38: Panel Mounting

    Installing/mounting 5.2 Installing the Power Output Module (POM) 5.2.2 Panel mounting 5.2.2.1 POM mounting (panel mounting) Installing the Power Output Module (POM) 1. Predrill the holes in the rear panel for mounting. The required hole spacing is shown in the diagram below. 2.

  • Page 39: Installing The Central Interface Module

    Installing/mounting 5.3 Installing the Central Interface Module Installing the Central Interface Module Tool You will need a Torx T10 screwdriver. Mounting the Central Interface Module (CIM) The CIM is screwed directly onto the POM. The mounting procedure is described below: Image 5-3 Mounting the CIM Steps...

  • Page 40: Installing The Em4315 Expansion Module

    Installing/mounting 5.4 Installing the EM4315 expansion module Installing the EM4315 expansion module Tool You will need a Torx T10 screwdriver. Installing the EM4315 expansion module Proceed as described in Section Installing the Central Interface Module (Page 39). Installing the I/O module (PM) The CIM is equipped with a receptacle for one I/O module.
  • Page 41 Installing/mounting 5.5 Installing the I/O module (PM) Installing the I/O module The procedure for installing an I/O module is described below: Image 5-4 Installing the I/O module Remove the blanking cover from the CIM receptacle. Insert the I/O module into the receptacle and push it in as far as it will go. ①...
  • Page 42 Installing/mounting 5.5 Installing the I/O module (PM) SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 43: Connection

    Connection Safety instructions and guidelines Safety instruction WARNING Hazardous voltages from the mains power input or heating element feeder cables Will cause death, serious injury or damage to property Hazardous voltages may be present on the mains power input and heating element feeder cables.
  • Page 44 Connection 6.1 Safety instructions and guidelines WARNING Electric shock hazard May cause death or serious injury The line voltage to which the device is connected must have a circuit breaker. The circuit breaker must be easily accessible and uniquely assigned to the device. It is advisable to locate the circuit breaker near to the device.

  • Page 45: Connecting The Protective Conductor

    Connection 6.2 Connecting the protective conductor Connecting the protective conductor Connecting the protective conductor Connect the POM to the protective conductor (PE). An M6 threaded bolt is provided on the front of the POM for connection of the protective conductor. WARNING Electric shock hazard May cause death or serious injury...

  • Page 46: Connect Profinet / Profibus Fieldbus

    Connection 6.3 Connect PROFINET / PROFIBUS fieldbus Connect PROFINET / PROFIBUS fieldbus Connecting PROFINET CIM PROFINET connection X1 / X2 Connect X1 / X2 to the higher-level controller and/or the next PROFINET device using an Ethernet cable according to the PROFINET specification. Use shielded Ethernet cables for this purpose.

  • Page 47: Connecting The 24 V Dc Power Supply

    Connection 6.4 Connecting the 24 V DC power supply Connecting the 24 V DC power supply The Control Interface Module (CIM) and Expansion Module EM4315 are supplied from the external 24 V DC power supply. Use a power supply unit which conforms to IEC 60536, protection class III (PELV).

  • Page 48: Connecting The Heating Elements And Three-Phase Line Supply

    Connection 6.5 Connecting the heating elements and three-phase line supply 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).

  • Page 49: Connecting Heating Elements

    Connection 6.5 Connecting the heating elements and three-phase line supply 6.5.2 Connecting heating elements Heating elements are connected to the POM using six 3-pole connectors. NOTICE The connected loads (heating elements) must not exceed the maximum permissible line current of 83 A. Note The maximum admissible length of the leads to the heating elements is 30 m.

  • Page 50: Block Diagram

    Connection 6.5 Connecting the heating elements and three-phase line supply 6.5.3 Block diagram Block diagram The figure below shows the main connections between the HCS4300 heating controller and the main supply and heating elements. The power outputs are protected internally with two fuses per power output.

  • Page 51: Connecting System Interfaces

    Connection 6.6 Connecting system interfaces Connecting system interfaces Connecting system interfaces (front) System interface CIM or EM4315 to POM Attach the connecting cable between the CIM ① / EM4315 and POM . You can operate up to 8 POMs on one CIM / EM4315. Additional POMs can be connected with a ribbon cable to the preceding POM.

  • Page 52: Connecting I/O Modules

    Connection 6.7 Connecting I/O modules Connecting I/O modules 6.7.1 PM4000 DI/DO Connecting digital inputs/outputs The connection is made by means of two 18-pin plug connectors of the PM4000 DI/DO. Image 6-2 PM4000 DI/DO pin assignment Note The connection cables are to be shielded if longer than 30 m. For every connector there is one pin for connecting or looping through the 24 V supply voltage and the 0 V.
  • Page 53 Connection 6.7 Connecting I/O modules X1: Digital outputs: 18-pin connector with spring-loaded connection and interlock. The mating connectors are included in the scope of supply. Assignment Digital output 1 Digital output 2 Digital output 3 Digital output 4 Digital output 5 Digital output 6 Digital output 7 Digital output 8...

  • Page 54: Pm4000 U/I

    Connection 6.7 Connecting I/O modules 6.7.2 PM4000 U/I Connecting line measurement inputs The line current is connected by means of the 8-pin X1 plug connector of the PM4000 U/I. The line voltage is connected by means of the 6-pin X2 plug connector of the PM4000 U/I. WARNING Voltage hazards Danger to life...
  • Page 55 Connection 6.7 Connecting I/O modules X1: Current measurement 8-pin connector with spring-loaded connection and interlock. The mating connectors are included in the scope of supply. Assignment I1 - I1 + I2 - I2 + I3 - I3 + Reserved Reserved Note The connection cable for the current measurement must not be longer than 30 m.

  • Page 56: Pm4000 Temperature

    Connection 6.7 Connecting I/O modules 6.7.3 PM4000 Temperature Connecting the measurement inputs The analog inputs 0...20 mA are connected by means of the 8-pin plug connector X1 of the PM4000 Temperature. The measurement inputs for temperature are connected by means of the 8-pin plug connector X2 of the PM4000 Temperature.
  • Page 57 Connection 6.7 Connecting I/O modules X2: Temperature measuring inputs 8-pin connector with spring-loaded connection. The mating connectors are included in the scope of supply. 2-wire measurement Assignment Temperature channel 1 - Temperature channel 1 + Temperature channel 2 - Temperature channel 2 + Temperature channel 3 - Temperature channel 3 + Temperature channel 4 -...

  • Page 59: Commissioning

    Commissioning Requirements Before commissioning starts, the system components must be installed and wired up. The following is necessary: ● A SIMATIC S7 CPU / SIMOTION with PROFINET/PROFIBUS interface ● A SIPLUS HCS4300 heating control system, comprising one central interface module (CIM) and at least one power output module (POM).
  • Page 60 Commissioning 7.3 Insulation test SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 61: Planning/Configuring

    You can download the GSDML file "GSDML-V2.3-Siemens-002A-HCS4300- " from the Siemens Service & Support website (http://www.siemens.com/automation/service&support). If a non-Siemens PROFINET controller is used, install the GSDML file as described in the manufacturer's instructions. Integrating the HCS4300 into the PROFIBUS configuration Procedure with SIMATIC S7 If the hardware catalog of your configuration software does not feature the HCS4300 yet, it can be integrated by installing the GSD file.

  • Page 62: Device/Hardware Configuration In The Tia Portal

    Planning/configuring 8.3 Device/hardware configuration in the TIA Portal Device/hardware configuration in the TIA Portal 8.3.1 PROFINET device configuration Device configuration In the case of PROFINET, the structure of the hardware is mirrored in the TIA device configuration: POM 1 POM 2 POM 3 Final POM Slot...

  • Page 63: Profibus Device Configuration

    Planning/configuring 8.3 Device/hardware configuration in the TIA Portal 8.3.2 PROFIBUS device configuration Device configuration In the case of PROFIBUS, the structure of the hardware is mirrored in the TIA device configuration as follows: POM 1 POM 2 POM 3 Final Slot number The configuration rules are as follows: The CIM module includes the PROFIBUS-connection and is permanently present in slot 1.

  • Page 64: Configuration Parameters

    Planning/configuring 8.3 Device/hardware configuration in the TIA Portal 8.3.3 Configuration parameters 8.3.3.1 CIM / POM configuration parameters The configuration parameters are directly assigned to the respective modules and are set during device configuration. They are transferred automatically on start-up and during re- parameterization.

  • Page 65: Configuration Parameters For I/O Modules

    Planning/configuring 8.3 Device/hardware configuration in the TIA Portal 8.3.3.2 Configuration parameters for I/O modules The configuration parameters are directly assigned to the respective I/O modules and are set during device configuration. They are transferred on start-up and during re-parameterization. PM4000 Temperature parameters Description Range of values Analog channel 1 measuring range...
  • Page 66 Planning/configuring 8.3 Device/hardware configuration in the TIA Portal PM4000 DI/DO parameters Description Range of values Digital channel 9 Input (default) • … Output • Digital channel 16 Output 1 Response to errors Switch off (default) • … Hold last value •...

  • Page 67: Software Tools For Commissioning Support

    Planning/configuring 8.4 Software tools for commissioning support Software tools for commissioning support 8.4.1 Overview of tools for commissioning support Listed below are the tools that can provide support with configuration and commissioning. SIMATIC WinCC A library in the TIA Portal for SIMATIC WinCC is available for integration in an HMI system. This library contains a specific number of channels and fields;...
  • Page 68 Planning/configuring 8.4 Software tools for commissioning support SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 69: Functions

    Functions Status and actual displays You can obtain information about the current state of the device/system/process as follows: Status display via LEDs The LEDs on the control interface module (CIM) as well as on the power output module (POM) provide information about the current operating status of the device or the heating system.

  • Page 70: Power Output Control

    Functions 9.2 Power output control Power output control 9.2.1 Half-wave control Half-wave control can be parameterized for activating the heating elements. This paramaterization is performed for each POM and applies to all channels of the POM. Principle of half-wave control The power outputs are controlled in half-waves: For each half-wave, the controller supplies On/Off information to the triac and this switches as specified.

  • Page 71: Soft Starting Function

    Functions 9.2 Power output control 9.2.2 Soft starting function Operating principle Soft starting can be parameterized for activating the channels in order to control loads with a high inrush current. This paramaterization is performed for each POM and applies to all channels of the POM.

  • Page 72: Switch On Heating

    Functions 9.2 Power output control 9.2.3 Switch on heating Switch on heating To control the power outputs, the heating must first be activated. This is done via the cyclic data. Heating status Description Channels are activated Channels are deactivated. Note A time-delayed start-up or channel soft start only occurs if heating is "On".

  • Page 73: Channel Control Via Fields

    Functions 9.2 Power output control 9.2.5 Channel control via fields It is possible to control the channels via fields. For this, it is necessary to combine the channels into fields, and to assign setpoints for channels and fields. Operating modes The operating mode can be pre-selected via the cyclic data.

  • Page 74: Line Voltage Compensation

    Functions 9.2 Power output control 9.2.6 Line voltage compensation Line voltage compensation Line voltage compensation makes it possible to achieve a balanced output on the power outputs, even when the voltage deviates from normal values. The function can be switched on or off by the user.

  • Page 75: Recording Of Analog Measured Values

    Functions 9.3 Recording of analog measured values Recording of analog measured values Note For the recording of analog measured values a PM4000 U/I Temperature must be available. No links of any kind to the functionality of the heating control are available. Analog inputs 0...20 mA Four inputs are available for recording of measured current values for a current measuring range of 0...20 mA.

  • Page 76: Digital Inputs/Outputs

    Functions 9.4 Digital inputs/outputs Digital inputs/outputs Note A PM4000 DI/DO must be available for the processing of digital inputs/outputs. No links of any kind to the functionality of the heating control are available. Digital outputs The PM4000 DI/DO provides 8 digital outputs that the user can control directly. What is more, 8 further digital outputs are available if no digital inputs are used (configurable).

  • Page 77: Recording Of Analog Measured Line Values

    Functions 9.5 Recording of analog measured line values Recording of analog measured line values Note For the recording of analog measured line values a PM4000 U/I must be available. No links of any kind are available to the functionality of the heating control system. Line current Three inputs are available for the recording of measured current values.

  • Page 78: Monitoring Functions

    Functions 9.6 Monitoring functions Monitoring functions 9.6.1 Line supply voltage monitoring Line supply voltage monitoring The Power Output Module (POM) can be operated in TN systems and TT systems. The admissible line supply voltage is between 360 V and 520 V AC. The active line voltage is measured and monitored for each POM and each phase.

  • Page 79: Frequency Monitoring

    Functions 9.6 Monitoring functions 9.6.4 Frequency monitoring Frequency monitoring The frequency of the applied line voltage is automatically detected and monitored. The frequency value can be read by the user. Frequency Valid range 50 Hz 47 Hz to 55 Hz 60 Hz 55 Hz to 63 Hz Frequency fault...

  • Page 80: Monitoring Power Channels

    Functions 9.6 Monitoring functions 9.6.6 Monitoring power channels Power output diagnostics The power output module (POM) has a diagnostics function to detect errors in the power outputs. In every half-wave, the status of the power output is requested and checked at a fixed point in time.

  • Page 81: Further Diagnostics

    Functions 9.6 Monitoring functions 9.6.7 Further diagnostics The following are also monitored, depending on the configuration level: ● Communication between the CIM and POM / PM ● Internal communication CIM ● Measuring range (PM4000 Temp) ● 24 V supply (PM4000 DI/DO) ●...
  • Page 82 Functions 9.6 Monitoring functions SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 83: Communications

    Communications The information provided in the section "Communication" refers to Siemens SIMATIC S7 controllers, but this also applies to other controllers with PROFINET/PROFIBUS due to the standardized PROFINET/PROFIBUS communication. 10.1 Cyclic data exchange 10.1.1 Cyclic output data Cyclic data exchange between the heating control system and the S7 takes place via the process/I/O address area of the CPU.
  • Page 84 Communications 10.1 Cyclic data exchange Cyclic output data for POM Byte Description Power output 1 setpoint Power output 2 setpoint Power output 3 setpoint Power output 4 setpoint Power output 5 setpoint Power output 6 setpoint Power output 7 setpoint Power output 8 setpoint Power output 9 setpoint Cyclic output data for PM4000 temperature...

  • Page 85: Cyclic Input Data

    Communications 10.1 Cyclic data exchange 10.1.2 Cyclic input data Cyclic data exchange between the heating control system and the S7 takes place via the process/I/O address area of the CPU. The cyclic data can be addressed in the S7 through the process image or I/O commands.
  • Page 86 Communications 10.1 Cyclic data exchange Cyclic input data for CIM PM4000 temperature Byte Description Analog channel 1 Analog channel 2 Analog channel 3 Analog channel 4 Temperature channel 1 10,11 Temperature channel 2 12,13 Temperature channel 3 14,15 Temperature channel 4 Cyclic input data for CIM PM4000 DI/DO Byte Description...

  • Page 87: Acyclic Data Exchange

    Communications 10.2 Acyclic data exchange 10.2 Acyclic data exchange S7 has system function blocks for writing / reading this data. The following data is transferred for addressing: Index Data record number Logical address of the PROFINET/PROFIBUS component For the datasets described below, the logical address is always the diagnostics address from the hardware configuration.
  • Page 88 Communications 10.2 Acyclic data exchange Note When a dataset 100 is written, it is no longer possible to use the datasets for field type 2. Dataset 101 to 132 "field type 2" Byte Description Number of channel 1 of field (dataset number minus 100) Number of channel 2 of field (dataset number minus 100) …...
  • Page 89 Communications 10.2 Acyclic data exchange Dataset 150 "Production field value" Byte Description Setpoint for field 1 Setpoint for field 2 … Setpoint for field 32 Definition is via an array [1..32] with one element of type "Byte". The field number corresponds to the array index. Dataset 151 "Standby field value"...
  • Page 90 Communications 10.2 Acyclic data exchange Each bit is assigned to one channel. The size of the array depends on the maximum configuration possible for the HCS (number of POMs, number of channels per POM). Dataset 160 "Control of internal fans" Byte Description Control of internal fans...

  • Page 91: Acyclic Input Data

    Communications 10.2 Acyclic data exchange 10.2.2 Acyclic input data The datasets/values described in section "Acyclic output data (Page 87)" can also be read. Dataset 100 "field type 1" One dataset of the maximum possible length (32 fields) is always returned. A non-assigned field is entered as channel number 0.
  • Page 92 Communications 10.2 Acyclic data exchange Dataset 200 "measured values" Byte Description Data POM 1 Internal temperature Reserved Frequency (with one decimal place) Voltage measured value L12 (with one decimal place) Voltage measured value L23 (with one decimal place) Voltage measured value L31 (with one decimal place) Data POM 2 …...
  • Page 93 Communications 10.2 Acyclic data exchange Dataset 202 "Measured values for PM4000 U/I" Byte Description Frequency (with one decimal place) Measured voltage value L1/L12 (in [V] with one decimal place) Measured voltage value L2/L23 (in [V] with one decimal place) Measured voltage value L3/L31 (in [V] with one decimal place) Measured current value RMS L1/L12 (in [A] with three decimal places) 10,11 Measured current value RMS L2/L23 (in [A] with three decimal places)

  • Page 94: Transfer Of Diagnostic Alarms To The Controller

    Communications 10.3 Transfer of diagnostic alarms to the controller 10.3 Transfer of diagnostic alarms to the controller 10.3.1 Transferring diagnostic alarms to the controller: PROFINET Diagnostics alarms Diagnostics alarms are transferred as diagnostic interrupts using the channel diagnostics (identifier 8000h) as the diagnostic type. The PROFINET device identification number is required for identifying a diagnostic interrupt.

  • Page 95: Transferring Diagnostic Alarms To The Controller: Profibus

    Communications 10.3 Transfer of diagnostic alarms to the controller 10.3.2 Transferring diagnostic alarms to the controller: PROFIBUS Diagnostic alarms Diagnostic alarms are transferred as diagnostic interrupts. The PROFIBUS device identification number is required for identifying a diagnostic interrupt. The HCS4300 has the identification number 81C5h. The evaluation in SIMATIC is performed via I/O_FLT1 (OB82) and RALRM (SFB54).

  • Page 96: Manufacturer-Specific Error Codes

    Communications 10.3 Transfer of diagnostic alarms to the controller 10.3.3 Manufacturer-specific error codes CIM / POM error codes Error code Description CIM4310 POM4320 5101 Communication error on HCS bus ✓ 5102 Line supply voltage is outside the permissible ✓ range (error message can be initiated by any POM) 5103 Frequency is outside the permissible range...
  • Page 97 Communications 10.3 Transfer of diagnostic alarms to the controller PM error codes Error code Description PM temperature PM DI/DO PM U/I (hex) 0001 Short-circuit ✓ 0006 Wire break ✓ ✓ 0007 Measurement range / upper limit ✓ exceeded 0008 Measurement range / lower limit ✓...
  • Page 98 Communications 10.3 Transfer of diagnostic alarms to the controller SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 99: Process And System Messages, Error Handling

    Process and system messages, error handling 11.1 Central Interface Module (CIM) The device has 3 LEDs on the front: The LEDs provide information about the operating status of the device/system. Meaning of LEDs READY HEATING ON ERROR green yellow Power OFF, device switched off Initialization: The LED flashes until the HCS is detected and accepted as a bus node by the higher-level control system.

  • Page 100: Power Output Module (Pom)

    Process and system messages, error handling 11.2 Power Output Module (POM) 11.2 Power Output Module (POM) 11.2.1 LED operating display for POM The device has 3 LEDs on the front: The LEDs provide information about the operating status of the device/system. Meaning of LEDs READY HEATING ON...

  • Page 101: Fault Reporting Through Diagnostics Data

    Process and system messages, error handling 11.2 Power Output Module (POM) 11.2.2 Fault reporting through diagnostics data The device-internal monitoring functions recognize specific faults in the power output module. The corresponding information is provided in the diagnostics data. Causes of error and possible remedies Error code Description Possible causes / Corrective action...

  • Page 102: I/O Modules

    Process and system messages, error handling 11.3 I/O modules 11.3 I/O modules LED status display The I/O module has 2 LEDs on the front. The LEDs provide information about the operating status of the device/system. Meaning of LEDs ERROR Description green Power OFF, device switched off Initialization: The LED flashes until the HCS is detected and accepted as a...

  • Page 103: Service And Maintenance

    Service and maintenance 12.1 Maintenance work The following work must be carried out at regular intervals to guarantee smooth operation of the device. Maintenance work Check regularly that the fan is functional. Remove dust deposits with a Power output module (POM) cleaning brush and vacuum cleaner.

  • Page 104: Firmware Update

    Service and maintenance 12.2 Firmware update 12.2 Firmware update 12.2.1 PROFINET firmware update Delivery condition The current firmware version is already loaded on the module when the HCS4300 is shipped. Firmware update If required, a PC tool and the necessary update files for updating the firmware are available to you at Customer Support (Page 147).
  • Page 105 Service and maintenance 12.2 Firmware update POM: In a firmware update, new firmware is downloaded to all power output modules (POMs) operated on a Central Interface Module (CIM). After the update, the HCS4300 restarts automatically. Only in the event of a fault when the update has not been correctly completed do you have to restart the HCS4300.

  • Page 106: Profibus Firmware Update

    Service and maintenance 12.2 Firmware update 12.2.2 PROFIBUS firmware update Delivery condition The current firmware version is already loaded on the module when the HCS4300 is shipped. Firmware update If required, a PC tool and the necessary update files for updating the firmware are available to you at Customer Support .
  • Page 107 Service and maintenance 12.2 Firmware update I/O module PM: In the event of a firmware update, new firmware is loaded into the inserted PM. After the update, the HCS4300 restarts automatically. Only in the event of a fault, if the update has not been correctly completed, is it necessary to restart the HCS4300.

  • Page 108: Fuse Replacement

    Service and maintenance 12.3 Fuse replacement 12.3 Fuse replacement Safety guidelines WARNING Voltage hazards May cause death or serious injury • The fuse board must only be disconnected and connected in the de-energized state. • Before changing a fuse, you must isolate the load circuit from the supply and secure it against switching on again.
  • Page 109 Service and maintenance 12.3 Fuse replacement Removing the fuse board To replace the channel fuses, the board on which the fuse to be replaced is located must be removed from the POM. NOTICE ESD-sensitive components Before you remove the board, please note the ESD information in Section ESD Guidelines (Page 145).
  • Page 110 Service and maintenance 12.3 Fuse replacement Position of fuses on the board Image 12-2 Position of fuses on the board Checking/replacing fuses NOTICE Electronic components are fitted to the rear of the board. When replacing fuses, ensure that these components are not damaged. 1.
  • Page 111 Service and maintenance 12.3 Fuse replacement 2. Remove the defective fuse with a suitable tool (e.g. flat-nose pliers) and insert the fuse in the fuse holder. Replacing a fuse Remove the defective fuse Insert the new fuse Re-installing the fuse board Proceed as follows: Steps Place board in the guides...

  • Page 112: Replace Fan

    Service and maintenance 12.4 Replace fan 12.4 Replace fan Requirements WARNING Electric shock hazard The device is energized. Before you begin to replace components, you must: • Disconnect the power supply of the busbar system and secure it against reclosing. •...
  • Page 113 Service and maintenance 12.4 Replace fan Replacing the fan Proceed as follows to replace the fan: Image 12-3 Replacing the fan Procedure for removing the fan ① Remove the four plastic rivets of the fan grille. Use a screwdriver Remove the fan grille ②...
  • Page 114 Service and maintenance 12.4 Replace fan Procedure for installing the new fan ② Re-insert the four plastic rivets of the fan grille - Insert sleeve - Push in pin ③ Plug in 24 V DC connector of the new fan SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 115: Replacing The Power Output Module (Pom)

    Service and maintenance 12.5 Replacing the power output module (POM) 12.5 Replacing the power output module (POM) Requirements ● The power bus system or the incoming supply is disconnected at the mounting location of the device and secured against being switched on again. ●...
  • Page 116 Service and maintenance 12.5 Replacing the power output module (POM) Steps ① From the front, insert a screwdriver in the opening in the busbar adapter . The button on top of the busbar adapter must snap upwards. ② Remove the busbar adapter by first pushing it upwards , and then pulling it forwards ③...

  • Page 117: Replacing The Central Interface Module (Cim)

    Service and maintenance 12.6 Replacing the central interface module (CIM) 12.6 Replacing the central interface module (CIM) Requirements ● The AC power supply is disconnected from the supply at the mounting location of the device and secured against switching on again. ●...

  • Page 118: Replacing An I/O Module

    Service and maintenance 12.7 Replacing an I/O module 12.7 Replacing an I/O module Requirement ● The AC power supply must be disconnected from the supply at the mounting location of the device and secured against switching on again. ● The 24 V DC supply voltage must be disconnected. Preparations Remove all connectors from the PM before dismantling the I/O module.
  • Page 119 Service and maintenance 12.7 Replacing an I/O module Removing the I/O module Image 12-6 Removing the PM ① 1. Undo the two fixing screws on the PM ② 2. Release the PM using the ejector lever and pull PM out 3.

  • Page 120: Recycling And Disposal

    Service and maintenance 12.8 Recycling and disposal 12.8 Recycling and disposal Note The POM and CIM modules of the HCS4300 heating control system fulfill the requirements of RoHS-II and REACH. The components can be recycled due to their lack of harmful materials. Contact a certified electronic scrap disposal company in order to ensure the environmentally-friendly recycling and disposal of your used device.

  • Page 121: Technical Data

    Technical data 13.1 Technical specifications for POM Technical specifications for POM4320 busbar mounting product brand name SIPLUS Product designation POM4320 BUSBAR POM4320 BUSBAR MOUNTING (IEC) MOUNTING (UL) General technical data: Type of load Ohmic load Equipment marking / acc. to DIN EN 81346-2 Supply voltage: Type of voltage / of the supply voltage Supply voltage / at AC / rated value...
  • Page 122 Technical data 13.1 Technical specifications for POM Power Electronics: Control version / of heat emitters Half-wave control and soft start Number of outputs / for heating power Number of heat emitters / per output / maximum Output voltage / at output / for heating power 400 V Power capacity / per output 200 W ...
  • Page 123 Technical data 13.1 Technical specifications for POM Mechanical data: Mounting position vertical Mounting type Busbar mounting Type of ventilation Self-ventilation Vibration resistance 10 ... 58 Hz / 0.075 mm, 58 ... 150 Hz / 1g during operation / acc. to IEC 60068-2-6 •...
  • Page 124 Technical data 13.1 Technical specifications for POM Technical specifications for POM4320 rear panel mounting product brand name SIPLUS Product designation POM4320 rear panel mounting POM4320 rear panel mounting (IEC) (UL) General technical data: Type of load Ohmic load Equipment marking / acc. to DIN EN 81346-2 Supply voltage: Type of voltage / of the supply voltage Supply voltage / at AC / rated value...
  • Page 125 Technical data 13.1 Technical specifications for POM Power Electronics: Control version / of heat emitters Half-wave control and soft start Number of outputs / for heating power Number of heat emitters / per output / maximum Output voltage / at output / for heating power 400 V Power capacity / per output 200 W ...
  • Page 126 Technical data 13.1 Technical specifications for POM Mechanical data: Mounting position vertical Mounting type Backplane mounting Type of ventilation Self-ventilation Vibration resistance 10 ... 58 Hz / 0.075 mm, 58 ... 150 Hz / 1g during operation / acc. to IEC 60068-2-6 •...

  • Page 127: Technical Specifications For Cim

    Technical data 13.2 Technical specifications for CIM 13.2 Technical specifications for CIM product brand name SIPLUS Product designation CIM4310 PROFINET CIM4310 PROFIBUS General technical data: Equipment marking / acc. to DIN EN 81346-2 Number of slots Type of power output / connectable POM4320 Supply voltage: Type of voltage / of the supply voltage...
  • Page 128 Technical data 13.2 Technical specifications for CIM Mechanical data: Mounting position vertical Mounting type Screw mounting to POM Type of ventilation Forced ventilation Vibration resistance 10 ... 58 Hz / 0.075 mm, 58 ... 150 Hz / 1g during operation / acc. to IEC 60068-2-6 •...

  • Page 129: Technical Specifications For I/O Module

    Technical data 13.3 Technical specifications for I/O module 13.3 Technical specifications for I/O module PM4000 DI/DO product brand name SIPLUS Product designation I/O4000 DI/DO General technical data: Equipment marking / acc. to DIN EN 81346-2 Digital Inputs: Number of digital inputs Type of electrical connection / at the digital inputs 1 x 18-pin connector with tension spring con- nection...
  • Page 130 Technical data 13.3 Technical specifications for I/O module 1x (24 ... 16) Type of connectable conductor cross-section / at the digital out- • puts / for AWG conductors Communication: Design of the interface system interface Display: Number of status displays Display version / as status display by LED LED green = Ready, LED red = Error display, 1 LED yellow per output: LED on - H status;...
  • Page 131 Technical data 13.3 Technical specifications for I/O module Ambient conditions: Ambient temperature 0 ... 55 °C during operation • -25 ... +70 °C during storage • -25 ... +70 °C during transport • Air pressure 860 ... 1 080 hPa during operation •...
  • Page 132 Technical data 13.3 Technical specifications for I/O module PM4000 U/I product brand name SIPLUS Product designation I/O4000 U/I General technical data: Equipment marking / acc. to DIN EN 81346-2 Measuring inputs for current: Product function / Current detection Current measuring range 0 ...
  • Page 133 Technical data 13.3 Technical specifications for I/O module Mechanical data: Mounting position vertical Mounting type Screw mounting to CIM Type of ventilation Forced ventilation Vibration resistance 10 ... 58 Hz / 0.075 mm. 58 ... 150 Hz / 1 g during operation / acc.
  • Page 134 Technical data 13.3 Technical specifications for I/O module PM4000 Temperature product brand name SIPLUS Product designation I/O4000 Temperature General technical data: Equipment marking / acc. to DIN EN 81346-2 Analog channels: Product component / input for analog temperature sensors Type of connection 2- and 4-wire technology Number of analog inputs / for 2-wire technology Number of analog inputs / for 4-wire technology...
  • Page 135 Technical data 13.3 Technical specifications for I/O module 1x (24 ... 16) Type of connectable conductor cross-section / at the measure- • ment inputs for current / for AWG conductors Communication: Design of the interface system interface Display: Number of status displays Display version / as status display by LED LED green = Ready, LED red = Error display Auxiliary circuit:...
  • Page 136 Technical data 13.3 Technical specifications for I/O module Ambient conditions: Ambient temperature 0 ... 55 °C during operation • -25 ... +70 °C during storage • -25 ... +70 °C during transport • Air pressure 860 ... 1 080 hPa during operation •...

  • Page 137: Technical Specifications For Em4315 Expansion Module

    Technical data 13.4 Technical specifications for EM4315 expansion module 13.4 Technical specifications for EM4315 expansion module product brand name SIPLUS Product designation EM4315 Expansion module General technical data: Equipment marking / acc. to DIN EN 81346-2 Number of slots Type of power output / connectable POM4320 Supply voltage: Type of voltage / of the supply voltage...
  • Page 138 Technical data 13.4 Technical specifications for EM4315 expansion module Width 56 mm Electromagnetic compatibility: EMC emitted interference Limit value in accordance with IEC 61000-6- 4:2007 + A1:2011 Conducted interference / due to burst / acc. to IEC 61000-4-4 2 kV power supply lines Conducted interference / due to surge / acc.

  • Page 139: Dimension Drawings

    Technical data 13.5 Dimension drawings 13.5 Dimension drawings Central Interface Module CIM4310 Image 13-1 Dimension drawing of CIM Dimension drawing of power output module POM4320 for busbar mounting Image 13-2 Dimension drawing of POM for busbar mounting SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...
  • Page 140 Technical data 13.5 Dimension drawings Dimension drawing of power output module POM4320 for rear panel mounting Image 13-3 Dimension drawing of POM for rear panel mounting SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...
  • Page 141 Technical data 13.5 Dimension drawings EM4315 expansion module Image 13-4 Dimension drawing for EM4315 expansion module SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...
  • Page 142 Technical data 13.5 Dimension drawings SIPLUS HCS4300 Operating Instructions, 11/2015, A5E35452705A/002...

  • Page 143: Appendix

    Appendix Certificates and approvals A.1.1 Certificates and approvals Note Approvals are only valid when marked on the product The specified approvals apply only when the corresponding mark is printed on the product. You can check which of the following approvals have been granted for your product by the markings on the type plate.

  • Page 144: Article Numbers For Spare Parts/Accessories

    Alternative: Cooper Bussmann (www.cooperindustries.com) • Article No.: C10G16 HCS fuse 15/500 V 10x38 CC (50 units) 6BK1943-6CA00-0AA0 Fan SIPLUS HCS Power Output Module 80 mm 6BK1700-2GA00-0AA0 Cable SIPLUS HCS4300 POM/POM 100 mm 6BK1943-5AA00-0AA0 Cable SIPLUS HCS4300 POM/POM 250 mm 6BK1943-5BA00-0AA0...

  • Page 145: Esd Guidelines

    Appendix A.3 ESD Guidelines ESD Guidelines Definition of ESD All electronic modules are equipped with large-scale integrated ICs or components. Due to their design, these electronic elements are highly sensitive to overvoltage, and thus to any electrostatic discharge. The electrostatic sensitive components/modules are commonly referred to as ESD devices. This is also the international abbreviation for such devices.
  • Page 146 Appendix A.3 ESD Guidelines Electrostatic charging Anyone who is not connected to the electrical potential of their surroundings can be electrostatically charged. The figure below shows the maximum electrostatic voltage which may build up on a person coming into contact with the materials indicated. These values correspond to IEC 801-2 specifications.

  • Page 147: Service & Support

    The online catalog and the online ordering system can also be found at Industry Mall Homepage (http://www.siemens.com/industrymall) SIPLUS HCS heating control systems on the Internet Current information on SIPLUS HCS is provided as part of our online presence (http://www.siemens.com/siplus-hcs). SIPLUS HCS4300...

  • Page 148: Application Example

    An example application for SIMATIC S7 and SIMOTION is available as a guide and basis for your own applications. This application example explains the mode of operation of the heater control. You can download the application example from the Siemens Service&Support website (http://support.automation.siemens.com/). SIPLUS HCS4300...

  • Page 149: Index

    Index Application example, 148 GSD file Approvals, 143 download, 61 GSDML file download, 61 Guidelines ESD guidelines, 145 Basic knowledge, 9 History, 9 Causes of error, 101 Cleaning work, 103 Connecting Safety guidelines, 12 Inrush current, 70 Installation Ambient conditions, 29 Device dimensions, 29 Delivery Minimum spacing, 29...
  • Page 150 Index Ordering data, 144 Power output diagnostics, 80 Power output fault Diagnostics function, 80 Power outputs Control, 70 Qualified personnel, 9 Recycling, 120 Registered trademarks, 10 Safety guidelines Changes to the devices, 12 Circuit breaker, 12 Connecting, 12 Fuse replacement, 13 Repairs, 13 Working on the device, 13 Scope of delivery, 28...

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