Heating under controlHeating Control Systems for controlling electrical heating elements

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SIPLUS HCS – I/O systems for industrial heating processes

SIPLUS HCS really turns up the heatFor precise temperature control

Precise heatMany products require exact temperatures during the manufacturing process, precisely focused in terms of time and space. The distributed I/O system SIPLUS HCS controls electrical heating elements like infrared, quartz, and flash heaters in compliance with individual requirements – without fail.

Intelligent efficiency Heat needs power. And the less the better, because energy is expensive, and both national and international standards are becoming increasingly stringent. This is where SIPLUS HCS helps with smart savings – through programmable heating programs, proportioning of the output power rat-ings, and optimization of production times.

Modular and compactNo matter how many heating elements are to be controlled and how high the required output power rating, SIPLUS HCS can be expanded on a modular basis and very flexibly adapted to specific requirements.

Simple integrationWith SIPLUS HCS, heating processes can be easily inte-grated into Totally Integrated Automation (TIA), industrial automation from Siemens. The open system architecture covers the entire production process and offers maximum interoperability across all automation components. This is made possible by consistent data management, global standards, and uniform interfaces for hardware and software.

From automobile painting and plastics molding to manufacturing PET bottles: reliable, pinpoint control and precise maintenance of temperatures is absolutely crucial to quality in many manufacturing processes. It must be exact and it must be guaranteed.

SIPLUS HCS, the industrial heating control systems from Siemens have been providing this service reliably for more than 25 years. And they’re getting smarter all the time.

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TIAFuses

SIPLUS HCS – All integratedAll-in-one

SIPLUS HCS heating control systems already contain all the components needed to control heating elements: switching elements, fuses, communication system, intelligent power controlling, Totally Integrated Automation, and detailed diagnostics.

System perturbations reducedThe power semiconductors switch at the zero crossing. This results in an enormous reduction in wear on the switching elements – and EMC faults and system pertur-bations are also decreased to a minimum.

Heating element cables: Individually protectedThe cables of every single heating element are fuse- protected with SIPLUS HCS. For easy fuse replacement fuses can be changed, for example, by simply pulling the plug-in fuse module.

PROFINET communication: For greater productivity Thanks to communication via PROFINET or PROFIBUS, setpoint values and diagnostic messages can be quickly exchanged with other bus devices.

Engineered with TIA Portal: Intuitive and efficientIn the Totally Integrated Automation Portal (TIA Portal), you can handle all automation devices – HMI, controllers, distributed I/O, motion control, and drives – in one project. Thanks to its intuitive user interface, its simple functions, and its complete data transparency, the TIA Portal enables you to focus on your engineering task instead of learning new software.

Intelligent routine: Reduced network loadingIntegrated control routines reduce current peaks because the heating elements are switched on with a time delay. Network voltage compensation enables variations in the input voltage to be equalized, so that the required output power can be guaranteed.

Fault detection with integrated fault diagnosticsPending faults are detected, localized, and reported within a single process cycle. This minimizes downtime and optimizes plant productivity.

Switching elements

Diagnostics Intelligence

Communication

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SIPLUS HCSThe “hot spots” of a hot family

The space savings of up to 80 percent in the control cabinet, as well as the reduction in cabling work …

… together with TIA “Totally Integrated Automation” …

… minimizes total costs by up to 70 percent.

From designing, commissioning, operating to maintain-ing SIPLUS HCS not only saves time, costs, and resources by up to 70 percent compared with a heating solution with individual components. SIPLUS HCS also improves the heating process – for less downtime and better product quality.

Simple:Integration of a heating process in Totally Integrated Automation.

Less:Reduces cabling work by up to 80 percent.

Intuitive:Engineered with Totally Integrated Automation Portal.

Intelligent and detailed: Diagnostics for rapid detection and localization of faults, also via Websites.

Smaller:Up to 80 percent space savings in the control cabinet.

Efficient:Optimal network utilization and avoidance of current peaks.

Better:Process quality thanks to intelligent fault diagnostics and reproducibility of the heating process.

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The perfect solution for diverse requirementsThere is a choice of three different heating control sys-tems depending on the requirements of the heating process: for example, the output power of the heating elements, diagnostic depth and the type of protection.

SIPLUS HCS3200 – the compact solution• Can be used as a distributed solution with

IP65 protection nearby the heating elements• For controlling 400-V heating elements• Ideal for the linear configuration of heater fields in the

manufacture of PET bottles

SIPLUS HCS4200 – the choice for flexibility• Exceptionally space-saving and cost-optimized

heating solutions with different output modules, I/O modules and racks

• For controlling 230-V/277-V heating elements

SIPLUS HCS4300 – the powerful solution• For controlling 400-V/480-V heating elements• With an output power of up to 69.1 kW per output

module• Highest level of production reliability thanks to detailed,

intelligent diagnostics

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• • •

• • •

SIPLUS HCS3200 comes with an IP65 type of protection and can be used nearby the heating elements, signifi-cantly reducing the time and effort required for cabling.

Special areaPET blow-molding

Functionality• For controlling 400-V heating elements• Compact design with IP65 type of protection• 9 power outputs up to a maximum of 4 kW per output• Up to 25 kW output power per device• External fan up to 500 W can be connected• Can be used in an ambient temperature up to

50° Celsius • Two integrated and automatically monitored fuses per

power output, for user-friendly fault diagnostics and increased process reliability

• Diagnostics via PROFIBUS DP without affecting the heating process

SIPLUS HCS3200 Super compact

SIMATIC HMI TP1200 Comfort

SIMATIC S7-1200

SIPLUS HCS3200

PROFINET

Heater field

PROFIBUS

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Ideal for space-saving installation in the control cabi-net – with up to 384 power outputs per PROFINET node and up to 16 A per output.

Special areasDrying paints and coatings, thermoforming – for example, car door interiors, refrigerator door interiors and suitcases – and welding plastics

Functionality• For energy-efficient control of

230-V/277-V heating elements• Up to 23 kW output power per power output module

(POM)• Max. 16 power outputs per POM• Quick installation and flexible expansion thanks to

various power output modules and rack sizes• Installation of the racks directly onto the rear control

cabinet wall• Intelligent and detailed diagnostics • Engineered with TIA Portal• PROFINET/PROFIBUS communication• I/O modules for additional functions

SIPLUS HCS4200 Extremely flexible

PROFINET

SIPLUS HCS4200

SIMATIC IPC 477DSIMATIC S7-1500F

SIMATIC ET 200SP failsafe

SINAMICS S120 with CU320-2

Heater fields

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SP01_00050

• • •

• • •

SIPLUS HCS4300 guarantees maximum production reliability thanks to its detailed diagnostics, which can detect problems like internal faults in the load circuit, blown fuses, and faulty heater cables. Monitoring includes parameters such as network voltage and internal temperature.

Special areasManufacturing PET bottles, treating carbon materials and thermoforming of plastic materials.

Functionality• For controlling 400-V/480-V heating elements • Up to 69.1 kW output power per power output module

(POM) at 480 V• 9 power outputs per POM• Max. 24 POMs per PROFINET/PROFIBUS node• Engineered with TIA Portal • Quick mounting on busbar or to rear

control cabinet wall• Network voltage compensation is integrated• Supply and return circuit of every heating element

protected by individual fuses • I/O modules for additional functions

SIPLUS HCS4300Powerful

SIMATIC S7-1500

SIMATIC Field PG

SIMATIC HMI TP1200 Comfort

PROFINET

SCALANCE X200-4P IRT

Heater field

SIPLUS HCS4300

PROFINET

PROFINET IRT

SINAMICS G120

SIMATIC ET 200SP SIMOTION D

SIMATIC ET 200SP

SIMATIC ET 200SP

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Totally Integrated Automation Efficiency driving productivity

The SIPLUS HCS I/O systems are an integral part of Totally Integrated Automation (TIA), Siemens’ in - dustrial automation. The open system architecture stands for the efficient interaction of all automation components.

Engineered with TIA Portal: Intuitive, efficient, provenThe Totally Integrated Automation Portal (TIA Portal) is the key to the full performance capability of Totally Integrated Automation (TIA). The innovative engineering framework for all automation tasks integrates HMI, controllers, dis-tributed I/O, motion control and drives seamlessly into one engineering environment. In heating processes, due to the perfectly harmonized system the TIA Portal enables maximum efficiency when used with the SIPLUS HCS I/O systems.

Simple remote monitoring: Rapid detection of faultsIf faults occur in the heating process, it is important to detect them as quickly as possible and to immediately initiate remedial action. That’s why the SIPLUS heating control data can be accessed via specific Websites from any location at any time. This makes it possible, for example, to identify the heating element that is faulty, or if there is a communications error, or which supply or return fuse has triggered.

Thermographic library: Simple visualization of heater fieldsWith the “Thermographic” library for WinCC advanced, heater fields can be simply and quickly visualized in the TIA Portal. Using these library elements can reduce the time and effort required for engineering by more than 90 percent.

SIPLUS HCS program library: Easy integration of heating processesUsing the SIPLUS HCS program library, heating processes can be easily integrated into the automation with SIMATIC S7-1500. The individual program blocks must only be adapted to the respective application.

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HCS300I HCS3200 HCS4200 HCS4300Article No. 6BK1700 ¹⁾ 6BK1932 ¹⁾ 6BK1942 ¹⁾ 6BK1943 ¹⁾ Article No.

Maximum output power per output

• Basic device: 3 relay outputs up to 5 A• DM6: 6 outputs each with 0.5 A

4 kW POM, low-end: 1.449 kW at 230 V POM, mid-range: 3.68 / 4.432 kW at 230 / 277 V

IEC: 6.4 / 7.68 kW at 400 / 480 V UL: 6 / 7.2 kW at 400 / 480 V

Maximum output power per output

Number of outputs per POM – 9 POM, low-end: 16 POM, mid-range: 12

POM: 9 Number of outputs per POM

Maximum output power per device/POM

– 25.2 kW at 400 V Per POM, low-end: 16.1 kW at 230 V Per POM, mid-range: 23 / 27.7 kW at 230 / 277 V

Per POM with IEC: 57.6 / 69.1 kW at 400 / 480 V Per POM with UL: 54 / 64.8 kW at 400 / 480 V

Maximum output power per device/POM

Number of max. possible outputs per bus node

– 9 384 216 Number of max. possible outputs per bus node

Bus topology PROFIBUS DP (max. 12 MBit/s) PROFIBUS DP (max. 12 MBit/s) PROFINET (max. 100 MBit/s); PROFIBUS DP (max. 12 MBit/s) PROFINET (max. 100 MBit/s); PROFIBUS DP (max. 12 MBit/s) Bus topologyDiagnostics Possible via current or current/voltage detection modules

(evaluation in higher-level controller)Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Diagnostics

I/O modules (PM) optional – – PM for temperature measurement, DI/DO, current and voltage measurement (line voltage compensation)

PM for temperature measurement, DI/DO, current and voltage measurement

I/O modules (PM) optional

Electrical specifications Electrical dataLine supply – Via 4-pin connector at the bottom Via 3-pin connector on the front Via rear busbar or 3-pin terminal

on the topLine supply

Power supply 24 V DC (20.4 to 28.8 V) Connection via terminals

400 V AC (360 to 440 V) Line frequency: 47 to 63 Hz Integrated line voltage compensation

230 V AC /277 V AC (207 to 300 V) Line frequency: 47 to 63 Hz Optional line voltage compensation with PM U/I

400 V AC / 480 V AC (360 to 520 V) Line frequency: 47 to 63 Hz Integrated line voltage compensation

Power supply

Load types Control of semiconductor switching devices, contactors, relays

Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With half-wave control: Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With soft start: All types of resistive loads possible

• With half-wave control: Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With soft start: All types of resistive loads possible

Load types

Control mode Control of digital outputs via higher-level controller Half-wave control with solid-state relay that switches at zero crossover

• POM, low-end: Half-wave control using triacs that switch at zero crossing

• POM, mid-range: Half-wave control using triacs that switch at zero crossing or soft start

• Half-wave control using triacs that switch at zero crossing or soft start

Control mode

Fuse Not required since digital outputs are short-circuit-proof • Short-circuit and overload protection of power outputs: 2 x 9 fuses in forward and reverse line

• Protection of the fan output: 1 fuse as short-circuit and overload protection

Short-circuit and overload protection of power outputs: • per POM, low-end: 16 fuses• per POM, mid-range: 12 fuses

Short-circuit and overload protection of power outputs: • per POM: 2 x 9 fuses in forward and reverse line

Fuse

Mechanical design Mechanical design Dimensions (W x H x D) Module size without DIN rail

• Basic unit: 45 x 106 x 120 mm• TM4: 22.5 x 102 x 120 mm• DM6/DCM: 22.5 x 92 x 120 mm

300 x 430 x 200 mm • CIM: 43 x 285 x 136 mm• POM: 36 x 285 x 281 mm• RACK for 12 POMs: 488 x 285 x 293 mm• RACK for 4 POMs: 204 x 285 x 293 mm• Rack with 3 fan modules and CIM: 502 x 347 x 309 mm

• CIM: 56 x 285 x 136 mm• POM busbar mounting: 104 x 340 x 250 mm• POM rear-wall mounting: 104 x 344 x 217 mm

Dimensions (W x H x D)

Fan – 1 output for external 230 V AC fan Fan module for 4 POMs each (option) Fan integrated FanEnvironmental conditions/standards Environmental conditions/standardsAmbient temperature (operation)

–25 to +60 °C 0 to +50 °C 0 to +55 °C 0 to +55 °C Ambient temperature (operation)

Transport/storage temperature –40 to +80 °C –40 to +70 °C –25 to +70 °C –25 to +70 °C Transport/storage temperatureRelative humidity Max. 95% at +25 °C Max. 95% at +25 °C Max. 95% at +25 °C Max. 95% at +25 °C Relative humidityType of protection IP20 IP65 IP20 IP20 Type of protectionCertifications CE, PROFIBUS, KC, EAC, C-Tick,

available soon: UL, CSACE, UL, PROFIBUS, KC, EAC, RCM CE, PROFINET, PROFIBUS, KC, EAC, RCM,

available soon: UL, CSACE, UL, CSA, PROFINET, PROFIBUS, KC, EAC, RCM Certifications

Subject to technical changes/improvements without prior notice. ¹⁾ You will find the current ordering data as well as sale and delivery

conditions on the Internet at siemens.com/industrymall

Overview of technical data

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HCS300I HCS3200 HCS4200 HCS4300Article No. 6BK1700 ¹⁾ 6BK1932 ¹⁾ 6BK1942 ¹⁾ 6BK1943 ¹⁾ Article No.

Maximum output power per output

• Basic device: 3 relay outputs up to 5 A• DM6: 6 outputs each with 0.5 A

4 kW POM, low-end: 1.449 kW at 230 V POM, mid-range: 3.68 / 4.432 kW at 230 / 277 V

IEC: 6.4 / 7.68 kW at 400 / 480 V UL: 6 / 7.2 kW at 400 / 480 V

Maximum output power per output

Number of outputs per POM – 9 POM, low-end: 16 POM, mid-range: 12

POM: 9 Number of outputs per POM

Maximum output power per device/POM

– 25.2 kW at 400 V Per POM, low-end: 16.1 kW at 230 V Per POM, mid-range: 23 / 27.7 kW at 230 / 277 V

Per POM with IEC: 57.6 / 69.1 kW at 400 / 480 V Per POM with UL: 54 / 64.8 kW at 400 / 480 V

Maximum output power per device/POM

Number of max. possible outputs per bus node

– 9 384 216 Number of max. possible outputs per bus node

Bus topology PROFIBUS DP (max. 12 MBit/s) PROFIBUS DP (max. 12 MBit/s) PROFINET (max. 100 MBit/s); PROFIBUS DP (max. 12 MBit/s) PROFINET (max. 100 MBit/s); PROFIBUS DP (max. 12 MBit/s) Bus topologyDiagnostics Possible via current or current/voltage detection modules

(evaluation in higher-level controller)Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Implicit voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements

Diagnostics

I/O modules (PM) optional – – PM for temperature measurement, DI/DO, current and voltage measurement (line voltage compensation)

PM for temperature measurement, DI/DO, current and voltage measurement

I/O modules (PM) optional

Electrical specifications Electrical dataLine supply – Via 4-pin connector at the bottom Via 3-pin connector on the front Via rear busbar or 3-pin terminal

on the topLine supply

Power supply 24 V DC (20.4 to 28.8 V) Connection via terminals

400 V AC (360 to 440 V) Line frequency: 47 to 63 Hz Integrated line voltage compensation

230 V AC /277 V AC (207 to 300 V) Line frequency: 47 to 63 Hz Optional line voltage compensation with PM U/I

400 V AC / 480 V AC (360 to 520 V) Line frequency: 47 to 63 Hz Integrated line voltage compensation

Power supply

Load types Control of semiconductor switching devices, contactors, relays

Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With half-wave control: Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With soft start: All types of resistive loads possible

• With half-wave control: Electrical heating elements with max. 15 times the inrush current in the 1st half-wave

• With soft start: All types of resistive loads possible

Load types

Control mode Control of digital outputs via higher-level controller Half-wave control with solid-state relay that switches at zero crossover

• POM, low-end: Half-wave control using triacs that switch at zero crossing

• POM, mid-range: Half-wave control using triacs that switch at zero crossing or soft start

• Half-wave control using triacs that switch at zero crossing or soft start

Control mode

Fuse Not required since digital outputs are short-circuit-proof • Short-circuit and overload protection of power outputs: 2 x 9 fuses in forward and reverse line

• Protection of the fan output: 1 fuse as short-circuit and overload protection

Short-circuit and overload protection of power outputs: • per POM, low-end: 16 fuses• per POM, mid-range: 12 fuses

Short-circuit and overload protection of power outputs: • per POM: 2 x 9 fuses in forward and reverse line

Fuse

Mechanical design Mechanical design Dimensions (W x H x D) Module size without DIN rail

• Basic unit: 45 x 106 x 120 mm• TM4: 22.5 x 102 x 120 mm• DM6/DCM: 22.5 x 92 x 120 mm

300 x 430 x 200 mm • CIM: 43 x 285 x 136 mm• POM: 36 x 285 x 281 mm• RACK for 12 POMs: 488 x 285 x 293 mm• RACK for 4 POMs: 204 x 285 x 293 mm• Rack with 3 fan modules and CIM: 502 x 347 x 309 mm

• CIM: 56 x 285 x 136 mm• POM busbar mounting: 104 x 340 x 250 mm• POM rear-wall mounting: 104 x 344 x 217 mm

Dimensions (W x H x D)

Fan – 1 output for external 230 V AC fan Fan module for 4 POMs each (option) Fan integrated FanEnvironmental conditions/standards Environmental conditions/standardsAmbient temperature (operation)

–25 to +60 °C 0 to +50 °C 0 to +55 °C 0 to +55 °C Ambient temperature (operation)

Transport/storage temperature –40 to +80 °C –40 to +70 °C –25 to +70 °C –25 to +70 °C Transport/storage temperatureRelative humidity Max. 95% at +25 °C Max. 95% at +25 °C Max. 95% at +25 °C Max. 95% at +25 °C Relative humidityType of protection IP20 IP65 IP20 IP20 Type of protectionCertifications CE, PROFIBUS, KC, EAC, C-Tick,

available soon: UL, CSACE, UL, PROFIBUS, KC, EAC, RCM CE, PROFINET, PROFIBUS, KC, EAC, RCM,

available soon: UL, CSACE, UL, CSA, PROFINET, PROFIBUS, KC, EAC, RCM Certifications

Subject to technical changes/improvements without prior notice. ¹⁾ You will find the current ordering data as well as sale and delivery

conditions on the Internet at siemens.com/industrymall

Overview of technical data

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Siemens AG Digital Factory P.O. Box 48 48 90026 Nürnberg Germany

Engineered with TIA Portal

Subject to change without prior notice 11/2015 Article No.: DFFA-B10103-00-7600 Dispo 46371 WS 11153.0 Printed in Germany © Siemens AG 2015

The information provided in this brochure contains me re ly general descriptions or characteristics of per-for m ance which in case of ac tual use do not always ap ply as described or which may change as a result of fur ther de ve lopment of the products. An obliga-tion to provide the respective characteristics shall only exist if ex pressly agreed in the terms of contract.

All product designations may be trademarks or prod-uct na mes of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Siemens provides automation and drive products with industrial security functions that support the secure operation of plants or machines. They are an important component in a holistic industrial security concept. With this in mind, our products undergo continuous development. We therefore recommend that you keep yourself informed with respect to our product updates and that you use only the latest versions. Please find further information on this subject at: http://support.automation.siemens.com You may also register for a product-specific newsletter at this address.

To ensure the secure operation of a plant or machine it is also necessary to take suitable preventive action (e.g. cell protection concept) and to integrate the automation and drive components into a state-of-the-art holistic industrial security concept for the entire plant or machine. Any third-party products that may be in use must also be taken into account. Please find further information at: www.siemens.com/industrialsecurity

SIPLUS HCS really turns up the heat

Precise temperature control Total integration Engineered with TIA Portal Simple visualization of

heater fields PROFINET / PROFIBUS

communication Rapid detection of faults

Find out more: siemens.com/siplus-hcs