Summary of Contents for Siemens SIPLUS HCS4 00 Series
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Configuration of the SIPLUS HCS4x00 Heating Control in TIA Portal CIM4x10 PROFINET FW V2/CIM4x10 PROFIBUS FW V1 Siemens Support of the POM4220 Highend Industry Online https://support.industry.siemens.com/cs/ww/en/view/109478117 Support...
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1 Task Task Overview Introduction To increase the quality and the quantity of a heat-treated product, it is important to be able to precisely focus the required energy regarding time and space. Even small deviations in the heating process may have a tremendous adverse effect on the product quality.
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1 Task Overview of the automation task The figure below provides an overview of the automation task. Figure 1-1 SIMATIC SIPLUS S7-1200 HCS4300 PROFINET IE S7-1500 PROFIBUS DP HCS4200 HCS4x00Library Entry ID: 109478117, V2.2.1, 09/2018...
2 Solution Solution What will I get? The document on hand describes the LHcs4x00 V2.2 block library for the TIA Portal ≥ V14 SP1. The block library comes with tested code for controlling the SIPLUS 4200/4300 heating control system from a SIMATIC S7-1200 or S7-1500 CPU: ...
2 Solution 2.2 Hardware and software components Depending on the selected heating control, the following system limits result: Table 2-1 Maximum configuration HCS4200 HCS4300 (POM) of a heating control CIM4x10 PROFINET 24 (with 2 racks for 12 POMs each) 24 (with 2 expansion Firmware >= V2 modules) CIM4x10 PROFIBUS...
2 Solution 2.2 Hardware and software components CIM4x10 PROFIBUS firmware ≥ V1 STEP 7 as of V14 SP1 S7-1500 as of FW 2.0 / S7-1200 as of FW 4.2 2.2.2 Components used The application was generated and tested with the following components: Hardware components Table 2-2 Component...
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2 Solution 2.2 Hardware and software components Software components Table 2-3 Component Qty. Article number Note SIMATIC STEP 7 Prof. V14 SP1, 6ES7822-1AA04-0YC5 With update 5 Powerpack Basic V14 SP1 -> Professional V14 SP1 Floating License; Engineering Software in TIA Portal; SW and documentation on DVD;...
3 Basics 3.1 SIPLUS HCS systems Basics SIPLUS HCS systems SIPLUS HCS is the intelligent answer to sensitive thermal requirements in industry and ensures highly precise control of resistive loads. Depending on the requirements, such as output power or scalability, the following heating control systems are available: ...
3 Basics 3.2 Communication Communication 3.2.1 Cyclic data exchange The cyclic data exchange between heating control system and S7 is performed via the process / I/O address area of the CPU. Figure 3-1 POM4320 SIPLUS 9 bytes (setpoints) 9 bytes (actual values) CIM4310 HCS4300 SIMATIC...
3 Basics 3.2 Communication The input/output address area for the central interface module (CIM) is used for transferring the status and control bits (heating, operating mode, and power compensation). Additionally, the CIM4310 also supplies the measured system voltages of the three phases (opposing).
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3 Basics 3.2 Communication Field type 2 combines any output channels. You can specify up to 24 channels for each field. A total of 32 fields can be defined. The sequence of the list of channels is irrelevant. The list of channels has to be without gaps (“0” is interpreted as the end of the list).
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3 Basics 3.2 Communication Figure 3-2 Start/Stop Heating Channel value Field assignment setpoint Production Operating mode Standby Data record Field value Data record setpoint Resulting setpoint = field value setpoint * channel value setpoint/100 Without field assignment, the actual channel value results from the setpoint channel value via the output address area for the respective POM.
3 Basics 3.2 Communication When using a “PM4000 U/I”, data record 202 enables the reading of measured values. When using the POM 4220 Highend, you can change its configuration data (for detecting a partial load interruption in case of heating elements connected in parallel) for each channel during operation via data record 2.
4 Mode of Operation 4.1 General overview Mode of Operation General overview Figure 4-1 shows the time sequence of the block calls in the control part of the application project. Figure 4-1 Main LHcs4x00 LHcs4x00 [OB 1] _Control _Config RackOr Station LHcs4x00 LHcs4x00...
4 Mode of Operation 4.2 PLC data types PLC data types The data for calculating the HCS configuration as well as the data of the SIPLUS HCS to be written and to be read are stored in data blocks “LHcs4x00_Config”, “LHcs4x00_Put”...
4 Mode of Operation 4.2 PLC data types Name Data type Default Description value webDb1 UInt Web control DB (must match the web DB number for the user-defined web pages) webDb2 UInt Follow-up web control DB selectedHcsWeb UInt HCS to be displayed via the user-defined web pages dsWrite "LHcs4x00_...
4 Mode of Operation 4.2 PLC data types 4.2.5 "LHcs4x00_typeHwDataIn" The “LHcs4x00_typeHwDataIn” PLC data type contains the hardware ID of the configured HCS4x00. Table 4-5 Name Data type Description hwIoDevice HW_DEVICE HW ID of the HCS4x00 IO device 4.2.6 "LHcs4x00_typeHwDataOut" The “LHcs4x00_typeHwDataIn”...
4 Mode of Operation 4.2 PLC data types 4.2.7 "LHcs4x00_typePut" PLC data type “LHcs4x00_typePut” contains data to be written for the HCS4x00 heating control systems. Table 4-7 Name Data type Description Array[1..n] of Array with the entries for the configured HCS4x00 heating "LHcs4x00_typeRackDataPut"...
4 Mode of Operation 4.2 PLC data types 4.2.11 "LHcs4x00_typePmDataOut" The “LHcs4x00_typePmDataOut” PLC data type includes the data of the plugged and configured I/O module in the CIM to be written. Table 4-11 Name Data type Description diDoOut Array[1..16] of Bool Array with the output values of the PM4000 DI/DO compValueOut Compensation temperature for the PM4000 temperature...
4 Mode of Operation 4.2 PLC data types 4.2.14 "LHcs4x00_typeDs2" The “LHcs4x00_typeDs2” PLC data type includes the data for data record 2 “configuration data POM4220 Highend" (only for plugged and configured POM4220 Highend). Table 4-14 Name Data type Default Description value valid Bool...
4 Mode of Operation 4.2 PLC data types “LHcs4x00_typeDs100FieldDef” 4.2.18 The “LHcs4x00_typeDs100FieldDef” PLC data type includes the channel limits of a field of “field type 1" (data record 100). Table 4-18 Name Data type Description chanBegin Word Start channel of the field chanEnd Word End channel of the field...
4 Mode of Operation 4.2 PLC data types 4.2.22 "LHcs4x00_typeDs152DiagDef" The “LHcs4x00_typeDs152DiagDef” PLC data type contains the “channels without diagnostic interrupt” (data record 152) for each POM. Table 4-22 Name Data type Description channel Array[1..16] of Bool Array with channel selection 4.2.23 "LHcs4x00_typeDs160"...
4 Mode of Operation 4.2 PLC data types 4.2.26 "LHcs4x00_typeDs200" The “LHcs4x00_typeDs200” PLC data type includes the data for data record 200 “measured values”. Table 4-26 Name Data type Default Description value valid Bool false Validity Array[1..24] of Array with the measured values for each "LHcs4x00_typeDs200MeasData"...
4 Mode of Operation 4.2 PLC data types “LHcs4x00_typeDs201Version” 4.2.29 The “LHcs4x00_typeDs201Version” PLC data type contains the version details of the HCS4x00 (data record 201). Table 4-29 Name Data type Description fwVersionCimFieldBusControlChar Char FW version CIM field bus controller fwVersionCimFieldBusControlNum Array[0..2] of Byte fwVersionCimHeadMasterChar Char...
4 Mode of Operation 4.2 PLC data types 4.2.32 "LHcs4x00_typeDs202Value" The “LHcs4x00_typeDs202Value” PLC data type includes the measured values of the PM4000 U/I (only for plugged and configured PM4000 U/I). Table 4-32 Name Data Description type frequency Frequency (with one decimal place) voltageL12 Voltage reading L1/L12 (in [V] with one decimal place) voltageL23...
4 Mode of Operation 4.2 PLC data types 4.2.35 "LHcs4x00_typeGet" The “LHcs4x00_typeGet” PLC data type includes the read data of the HCS4x00 heating control systems. Table 4-35 Name Data type Description Array[1..n] of Array with the entries of the configured HCS4x00 heating "LHcs4x00_typeRackDataGet"...
4 Mode of Operation 4.2 PLC data types 4.2.38 "LHcs4x00_typeCimDataIn" The “LHcs4x00_typeCimDataIn” PLC data type includes the cyclic input data of the configured CIMs. Table 4-38 Name Data type Description heat Bool Switching the heating on/off (FALSE: off / TRUE: on) Operating mode (FALSE: "Production"...
4 Mode of Operation 4.2 PLC data types 4.2.42 "LHcs4x00_typeDiagDataCim" The “LHcs4x00_typeDiagDataCim” PLC data type includes die diagnostic data of the CIM or the PM. Table 4-42 Name Data type Description slotNumber Byte Slot number of the faulty module subSlotNumber Byte Slot number of the faulty sub-module fault...
4 Mode of Operation 4.3 FB “LHcs4x00_Control” FB “LHcs4x00_Control” The FB “LHcs4x00_Control” communicates with the configured HCS4x00 heating control systems. It is called in a cycle OB (e. g. OB1). Figure 4-2 HCS4x00Library Entry ID: 109478117, V2.2.1, 09/2018...
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4 Mode of Operation 4.3 FB “LHcs4x00_Control” Table 4-45 Name Data type Description Input firstRun Bool First cycle after restarting the CPU (e. g. parameter “Initial_Call” from the calling OB1) Read request for data record “dsNum” of HCS readData Bool “onHcs”...
4 Mode of Operation 4.3 FB “LHcs4x00_Control” 4.3.1 Program workflow Figure 4-3 Start/Stop firstRun? FC “LHcs4x00_Diag86” Delete diag buffer config.hcs[x].ioDataIn.hwIoDevice PN or DP ? get I/O addresses POMs status bits read I/O from voltage periphery PM inputs power output actual value control bits write I/O to PM outputs...
4 Mode of Operation 4.4 FB “LHcs4x00_Diag82” These addresses are required for the cyclic data exchange with the HCS. At first, the input data: status bits, voltage readings (if available) and actual power output values are read and stored in DB “LHcs4x00_Get”. Then, the output data: control bits and power output setpoints are written from DB “LHcs4x00_Put”...
4 Mode of Operation 4.4 FB “LHcs4x00_Diag82” 4.4.1 Program workflow Figure 4-5 Start/Stop RALRM AINFO (MODE:=2) PROFINET or PROFIBUS? AlarmSpecifier get fault SlotNum & SubSlotNum positions ChannelNumFault FaultNum exit conditions Calculate actual channel number CIM faults PM fault POM faults Start/Stop The diagnostic interrupt OB 82 is called for each coming and going interrupt of a diagnostics-capable I/O module.
4 Mode of Operation 4.5 FC “LHcs4x00_Diag86” For invalid values, termination is performed from FB “LHcs4x00_Diag82” via RETURN. For POM errors, the channel number is calculated in the diagnostic buffer. At an incoming event, the error information in the “diag” buffer of the respective HCS is written in DB “LHcs4x00_Get”...
4 Mode of Operation 4.5 FC “LHcs4x00_Diag86” 4.5.1 Program workflow Figure 4-7 Start/Stop enable? Incoming Start/Stop event i := 1 i <= numHcs Start/Stop Failure station Start/Stop numHcs Delete all diagnostic information i := i+1 Module rack failure OB 86 is called for each coming and going failure of an I/O module.
5 How to Work with the Library 5.1 Integrating the library into STEP 7 (TIA Portal) How to Work with the Library What will you learn here? This chapter includes instructions on how to integrate library LHcs4x00 into your STEP 7 project (TIA Portal). Note An example project for using the blocks is available on the same HTML page as this document (see \2\).
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5 How to Work with the Library 5.1 Integrating the library into STEP 7 (TIA Portal) 4. Select the global library LHcs4x00 V2.2. Write protection is enabled for the library. If you want to modify the global library, disable the "Open as read only" option. 5.
5 How to Work with the Library 5.2 Integrating the library blocks in the project Integrating the library blocks in the project 5.2.1 Overview of the library blocks The LHcs4x00 library structure is displayed in Figure 5-1. Global libraries contain the folders: ...
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5 How to Work with the Library 5.2 Integrating the library blocks in the project Figure 5-1 HCS4x00Library Entry ID: 109478117, V2.2.1, 09/2018...
5 How to Work with the Library 5.2 Integrating the library blocks in the project 5.2.2 Integrating the blocks into the project Below, you will find the steps of how to integrate the blocks of the LHcs4x00 library into your STEP 7 program. 1.
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5 How to Work with the Library 5.2 Integrating the library blocks in the project Result: The project data have been compiled. The correctly grouped library elements are now located in your TIA Portal project. Figure 5-3 Note By right-clicking the heading “Name”...
5 How to Work with the Library 5.2 Integrating the library blocks in the project 5.2.3 Calling the blocks in the project Main [OB1] The “LHcs4x00_Control” function block is called in cycle OB 1 “Main”. Move the block into OB “Main” and generate an instance block for the FB. Figure 5-4 Then interconnect the interface parameters according to the specification in Figure...
5 How to Work with the Library 5.3 Updating the library DiagnosticErrorInterrupt [OB82] / RackOrStationFailure [OB86] The FB “LHcs4x00_Diag82” is called in diagnostic interrupt OB 82 “DiagnosticErrorInterrupt” and the FC “LHcs4x00_Diag86” is called in module rack failure OB 86. 1. Add the OBs “Diagnostic error interrupt” and “Rack or station failure” as new organization blocks.
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5 How to Work with the Library 5.3 Updating the library Table 5-1 Action Note In STEP 7 V14 SP1, open your existing STEP 7 V14 project with library version 2.1. Start upgrading the project. Confirm the project upgrading. HCS4x00Library Entry ID: 109478117, V2.2.1, 09/2018...
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5 How to Work with the Library 5.3 Updating the library Action Note Overwrite the master copies in your project by moving the “Control&Diag” folder from the master copies of the V2.1 library to the following project folders via drag-and-drop: ...
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5 How to Work with the Library 5.3 Updating the library Action Note Open the call of FB "LHcs4x00_Control" in OB1 "Main". In the new version, the tags "LHcs4x00_Tags".control.retValDsReadWrite and "LHcs4x00_Tags".control.retValStartup no longer exist. For this reason, delete the link. Then, select the controller and start compiling.
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5 How to Work with the Library 5.3 Updating the library Action Note The version of the instructions "Serialize" and "Deserialize" has to be changed to V2.0. For this, open the “Basic instructions” in the instruction list and change the version of the “Move operations”...
6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 Configuration and Settings The steps listed here are required for the integration of the “LHcs4x00” block library into your existing project or when changing the example project. In the example project, these steps have already been carried out for the pre- defined configuration (Figure 7-1).
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6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 Action Select a firmware version ≥ V2.0. Note: For operating the POM4220 Highend or POM4220 Flexible, firmware V2.2 of the CIM4210 is required. Integrate the CIM from the hardware catalog into the “Network view” via double-click or via drag-and-drop.
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6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 Action Go to the device view of “HCS4x00” by double-clicking on the IO device. Select the respective PM/POM in the hardware catalog and add it to your “HCS4x00” IO device via double-click or drag-and-drop. Repeat this step depending on the number of POMs in your configuration.
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6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 Action For heating elements connected in parallel to the POM4220 Highend, you can specify the limits for detecting a partial load interruption in “Parameter parallel connection of loads”. However, this is also possible during operation via data record Note Make sure that the configured hardware setup of the SIPLUS HCS4x00 matches that of the actual one.
6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 6.1.2 PROFIBUS Table 6-2 Action Download the GSD file for your HCS (\13\) and unzip it. Open the “Manage general station description files (GSD)” item in the “Options” menu in the TIA Portal. Navigate to the storage of the unzipped GSD files, select the ones required and install them.
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6.1 Configuring the SIPLUS HCS4x00 Action Select the respective CIM in the hardware catalog in “Other field devices > PROFIBUS DP > General > SIEMENS AG > SIPLUS_HCS”. Integrate the CIM into the “Network view” via double-click or via drag-and-drop. HCS4x00Library Entry ID: 109478117, V2.2.1,...
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6 Configuration and Settings 6.1 Configuring the SIPLUS HCS4x00 Action Select the S7-1500 CPU DP (with PROFIBUS interface) as PROFIBUS master via “Not assigned” for “Slave_1”. Go to the device view of HCS4x00 DP by double-clicking on the slave. Split the window so that you can also see the device overview.
6 Configuration and Settings 6.2 Configuring the DB "LHcs4x00_Config" Configuring the DB "LHcs4x00_Config" For identifying the communication partner, the data block “LHcs4x00_Config” must be configured correspondingly. The following parameters must be stored in the DB as start values: Table 6-3 Action Open the “global”...
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6 Configuration and Settings 6.2 Configuring the DB "LHcs4x00_Config" Action Open the network view in “Devices & networks”, select the “HCS4x00” IO device and open the system constant in the properties. Enter the HW ID of the IO device of type “Hw_Device”...
7 Installation and Commissioning 7.1 Installing the hardware Installation and Commissioning In this chapter, the necessary steps are described for commissioning the example project with the hardware and software used (from chapter 2.2.2). Installing the hardware The figure below shows the hardware setup of the application. Figure 7-1 S7-1500 PC/PG...
7 Installation and Commissioning 7.2 Network connections Note Always follow the installation guidelines in order to connect all the components. SIMATIC S7-1500 (\8\) SIPLUS HCS 4200: Chapter "Safety information and guidelines" (\4\) SIPLUS HCS 4300: Chapter "Safety information and guidelines" (\5\) Table 7-1 Action Remark...
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7 Installation and Commissioning 7.2 Network connections Action Remark Select the “Internet Protocol Version 4 (TCP/IPv4)” element in “Networking” and open its properties. Choose “Use the following IP address”. Select an IP address in the CPU's subnet mask. ...
7 Installation and Commissioning 7.3 Downloading the program 7.2.1 Setting the PG/PC interface Table 7-3 Action Remark Open the PG/PC interface settings via “Start > Control Panel” to set the correct access path for STEP 7 V14 SP1. Select “S7ONLINE (STEP 7)” as the application's access point.
7 Installation and Commissioning 7.4 Commissioning Commissioning 7.4.1 PROFINET For correct communication between CPU and HCS via PROFINET, the name of the IO devices need to match the configured names. Table 7-5 Action Remark Open the device view of IO device “HCS4x00” and select module “0”.
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7 Installation and Commissioning 7.4 Commissioning Action Remark In the project tree in “Online access”, select the network card you used and update the accessible nodes. Identify the HCS via the MAC address and select “Online & diagnostics”. Select the “Assign name” menu in “Functions”.
7 Installation and Commissioning 7.4 Commissioning 7.4.2 PROFIBUS For correct communication between CPU and HCS via PROFIBUS DP, the PROFIBUS address of the DP slave has to match the configured address. Table 7-6 Action Remark Open the device view of the “Slave_1”...
8 Operating the Application 8.1 Operating the HCS4x00 Operating the Application The application is operated via watch tables: “LHcs4x00_WatchTablePut” serves for writing on the HCS “LHcs4x00_WatchTableGet” serves for reading out the data of the HCS Operating the HCS4x00 The heating control system is controlled via the watch table.
8 Operating the Application 8.1 Operating the HCS4x00 Action Remark STEP 7 (TIA Portal) connects online with the S7-1500, the “Monitor value” column shows the current value of the respective tag. In the “Modify value” column assign the value to be written. By selecting a tag and right-clicking >...
8 Operating the Application 8.1 Operating the HCS4x00 8.1.2 Diagnosing channel errors Occurring errors are displayed in DB “LHcs4x00_Get” in “hcs[x].diag” (see chapter 4.2.41). The cannel diagnostic is shown on the example of controlling a power output without connected consumer: Table 8-3 Action Remark...
8 Operating the Application 8.1 Operating the HCS4x00 8.1.4 Controlling the output channels without field assignment Without the assignment of the channels to fields you can control each power output channel of the POM individually, independent of the operating mode. Table 8-5 Action Remark...
8 Operating the Application 8.1 Operating the HCS4x00 8.1.5 Assigning the channels to fields To summarize output channels and controlling them with a setpoint value, you can assign them to field type 1 or 2. Field type 1 combines successive channels. Field type 2 combines any channels.
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8 Operating the Application 8.1 Operating the HCS4x00 Action Remark Write “150” or “151” to tag “LHcs4x00_Tags".control.dsNum for adopting the field value setpoints, and set bit “LHcs4x00_Tags".control.writeData. Then reset bit “LHcs4x00_Tags".control.writeData. Note Table 8-2 step 2. Open the “LHcs4x00_WatchTableGet” watch table.
8 Operating the Application 8.1 Operating the HCS4x00 “Field type 2” (data record 101 to 132) If the channel is assigned to field type 1, the HCS has to be reset via data record 190 (see chapter 8.1.7) or a restart of the HCS must be produced via voltage recovery (24 V).
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8 Operating the Application 8.1 Operating the HCS4x00 Action Remark Depending on operating mode “Production” or “Standby” you can now control the field value setpoints via data record 150, or 151 respectively. “setpoint[1]“ for field1 (data record 101) “setpoint[2]“ for field2 (data record 102) …...
8 Operating the Application 8.1 Operating the HCS4x00 8.1.6 Controlling internal fans The connected fans of HCS4x00 can be operated via data record 160: Table 8-8 Action Remark Open the “LHcs4x00_WatchTablePut” watch table in the project tree. Write “1” to parameter “LHcs4x00_Put”.hcs[x].datasets.ds16 0.value”...
8 Operating the Application 8.1 Operating the HCS4x00 8.1.7 System reset by user You can reset the selected HCS via data record 190. Table 8-9 Action Remark Open the “LHcs4x00_WatchTablePut” watch table in the project tree. The required command "RESET!" is specified as default value of data record 190 (see chapter 4.2.25).
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8 Operating the Application 8.1 Operating the HCS4x00 Action Remark The screen displays a current flow of 2.69 A (see chapter 4.2.16) and a power output of 555 W for the heating elements connected in parallel of channel 1. Read data record 2. Then reset the bit “LHcs4x00_Tags”.control.readData again.
9 Links & Literature Links & Literature Table 9-1 Topic Title Siemens Industry Online Support http://support.industry.siemens.com Download page of the entry https://support.industry.siemens.com/cs/ww/en/view/109478117 Updates for STEP 7 V14 SP1 and https://support.industry.siemens.com/cs/ww/en/view/109747387 WinCC V14 SP1 Heating control systems Heating https://support.industry.siemens.com/cs/ww/en/view/107685679 control system SIPLUS HCS4200 Heating control systems Heating https://support.industry.siemens.com/cs/ww/en/view/107197097...
10 Contacts Contacts Current information on the SIPLUS HCS heating control systems can be found at http://www.siemens.com/siplus-hcs. For questions concerning the SIPLUS HCS heating control, please contact: mailto: technical-assistance@siemens.com History Table 11-1 Version Date Modifications V1.0 11/2015 First version V2.0...
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