SIPLUS - Siemens...SIPLUS HCS300I System Manual, 09/2011, A5E02494131A-01 9 Important notes 1 1.1...

Answers for industry.

SIPLUS

Heating Control

SIPLUS HCS300I

System Manual · 09/2011

�SIPLUS HCS300I�

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SIPLUS

Heating controller SIPLUS HCS300I

System Manual

09/2011 A5E02494131A-01

Important notes 1

System description 2

Module description 3

System communication 4

Heating controller application for extruders

5

Mounting and connection 6

Commissioning 7

Diagnostics and maintenance

8

Dimensional drawings 9

Technical data 10

Appendix A

List of abbreviations B

Legal information

Legal information Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE indicates that an unintended result or situation can occur if the relevant information is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products Note the following:

WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

Order number: A5E02494131A-01 Ⓟ 09/2011

Copyright © Siemens AG 2011. Technical data subject to change

SIPLUS HCS300I System Manual, 09/2011, A5E02494131A-01 5

Table of contents

1 Important notes.......................................................................................................................................... 9

1.1 About this documentation ..............................................................................................................9

1.2 General safety information...........................................................................................................10

2 System description .................................................................................................................................. 13

2.1 System structure ..........................................................................................................................13

2.2 System components at a glance..................................................................................................15

3 Module description................................................................................................................................... 17

3.1 Basic unit (GG2) ..........................................................................................................................17

3.2 Expansion modules......................................................................................................................18 3.2.1 Temperature module (TM4) .........................................................................................................18 3.2.2 Digital module (DM6) ...................................................................................................................22 3.2.3 Decoupling module (DCM)...........................................................................................................24

3.3 Current measuring module (IM) ...................................................................................................26

3.4 Current / voltage measuring module (UM)...................................................................................30

3.5 Addressing plug ...........................................................................................................................31

3.6 Optional accessories: Solid state relays ......................................................................................32

4 System communication............................................................................................................................ 33

4.1 Definitions ....................................................................................................................................33

4.2 Data transfer ................................................................................................................................34

4.3 Process image and diagnostics ...................................................................................................36 4.3.1 Cyclic data transfer ......................................................................................................................36 4.3.2 Process image output (PIQ).........................................................................................................37 4.3.3 Process input image (PII).............................................................................................................38 4.3.4 Diagnostics data and interrupts ...................................................................................................40 4.3.5 Slave diagnostics .........................................................................................................................41

4.4 Integration of SIPLUS HCS300I in DP master systems ..............................................................50 4.4.1 Preparation for data transfer ........................................................................................................50 4.4.2 Slave modes ................................................................................................................................50 4.4.3 Integration of SIPLUS HCS300I as a DPV1 slave.......................................................................50 4.4.4 Evaluating diagnostics data .........................................................................................................56 4.4.5 Parameterization over the PROFIBUS ........................................................................................57

5 Heating controller application for extruders.............................................................................................. 59

5.1 SIPLUS HCS300I heating controller for extruders.......................................................................59

6 Mounting and connection......................................................................................................................... 69

6.1 General mounting and wiring instructions....................................................................................69

Table of contents

SIPLUS HCS300I 6 System Manual, 09/2011, A5E02494131A-01

6.2 Mounting the system modules .................................................................................................... 71 6.2.1 Mounting the basic unit and expansion modules........................................................................ 71 6.2.2 Mounting the current measuring modules................................................................................... 72 6.2.3 Mounting current / voltage measuring modules.......................................................................... 74

6.3 Wiring the system modules ......................................................................................................... 75 6.3.1 Wiring the basic unit and expansion modules............................................................................. 75 6.3.2 Terminal assignment on the basic unit and expansion modules ................................................ 78 6.3.2.1 Terminal assignment on the basic unit ....................................................................................... 78 6.3.2.2 Terminal assignment on the temperature module ...................................................................... 80 6.3.2.3 Terminal assignment on the digital module ................................................................................ 82 6.3.2.4 Terminal assignment on the decoupling module ........................................................................ 84 6.3.3 Wiring on the current measuring module .................................................................................... 85 6.3.4 Wiring on the current / voltage measuring modules ................................................................... 86

6.4 Connection of the system interfaces........................................................................................... 89

6.5 Connection of the PROFIBUS DP .............................................................................................. 91

7 Commissioning ........................................................................................................................................ 93

7.1 General information..................................................................................................................... 93

7.2 Commissioning............................................................................................................................ 94

7.3 PROFIBUS DP address setting .................................................................................................. 95

8 Diagnostics and maintenance.................................................................................................................. 97

8.1 System messages....................................................................................................................... 97

8.2 Troubleshooting using the LEDs................................................................................................. 98

8.3 Replacing system components ................................................................................................. 100

9 Dimensional drawings............................................................................................................................ 103

9.1 Basic unit................................................................................................................................... 103

9.2 Expansion modules................................................................................................................... 104 9.2.1 Temperature module................................................................................................................. 104 9.2.2 Digital module and decoupling module ..................................................................................... 105

9.3 Current measuring modules...................................................................................................... 106 9.3.1 2.4 A to 25 A current measuring module .................................................................................. 106 9.3.2 10 A to 100 A current measuring module ................................................................................. 107 9.3.3 20 A to 200 A current measuring module ................................................................................. 108

9.4 Current / voltage measuring modules ....................................................................................... 109 9.4.1 2.4 A to 25 A current / voltage measuring module.................................................................... 109 9.4.2 10 A to 100 A current / voltage measuring module................................................................... 110 9.4.3 20 A to 200 A current / voltage measuring module................................................................... 111

10 Technical data ....................................................................................................................................... 113

10.1 General technical data .............................................................................................................. 113

10.2 Technical data of the basic unit ................................................................................................ 114

10.3 Technical data of the temperature module ............................................................................... 116

10.4 Technical data of the digital module ......................................................................................... 118

Table of contents


10.5 Technical data of the decoupling module ..................................................................................119

10.6 Technical data of the current measuring modules and the current / voltage measuring modules......................................................................................................................................120

A Appendix................................................................................................................................................ 123

A.1 Recycling and disposal ..............................................................................................................123

A.2 Online service & support............................................................................................................123

A.3 Training center ...........................................................................................................................124

B List of abbreviations............................................................................................................................... 125

Glossary ................................................................................................................................................ 127

Table of contents



Important notes 11.1 About this documentation

The SIPLUS HCS300I system manual begins with an introduction to the product family. It continues with further information about configuring, commissioning and maintaining the system. The application "Heating controller for extruders" demonstrates how the SIPLUS HCS300I heating control is used in the plastics automation industry.

Required background To use this documentation, you must have a basic knowledge of low voltage switchgear and controlgear, digital circuitry, and automation technology.

Applicability The system manual only applies to the components of the SIPLUS HCS300I heating controller presented in this document. It describes the technology of these products valid at the time of publication. SIEMENS reserves the right to include updated product information in case of technical modifications or the introduction of new system components.

Further documentation Refer also to the operating instructions for the individual system components.

Document identification number SIPLUS HCS300I module A5E02377948 Basic unit (GG2) A5E02377947 Temperature module (TM4) A5E02377941 Digital module (DM6) 631 6283-10 Decoupling module (DCM) 631 6530-30 Current measuring module (IM) 631 6595-30 Current / voltage measuring module (IM/UM)

Important notes 1.2 General safety information


1.2 General safety information

Reliability of products and components Extensive and complex measures are implemented during the development and production process to ensure maximum product and component reliability:

● Use of high-quality components

● Worst-case design of all circuits

● Systematic and computer-aided testing of all components

● Measures to prevent static electricity when handling MOS circuits

● Visual inspections at various stages of manufacture

● Careful computer-controlled final testing

● Statistical evaluation of all returned systems and components to enable the immediate initiation of suitable corrective measures

These measures are referred to in safety engineering as basic measures because they prevent or rectify the majority of possible faults.

Risks In all cases where the occurrence of failures can result in material damage or injury to persons, special measures must be taken to enhance the safety of the installation – and therefore also of the situation. Special plant-specific regulations that also have to be taken into consideration when designing the control system exist for such applications.

Regarding electronic control equipment with a safety function, the measures that have to be taken to prevent or rectify faults are based on the risks arising from the plant. In this respect, the basic measures listed above are no longer adequate once the hazard exceeds a certain potential. Additional measures must be implemented and approved for the controller in accordance with DIN VDE 0801.

Division into safe and non-safe areas Nearly all systems contain components that perform safety-related tasks (e.g. emergency stop pushbuttons, guards, two-hand control devices). To avoid having to apply safety-related criteria to the entire controller, it is customary to divide it into two areas − one that is critical to safety and one that is not critical to safety. No special safety demands are made in the area that is not safety-critical as an electronic fault would not have any effect on the safety of the system. However, in the safety-critical area, only controllers and circuits that comply with the relevant regulations may be used.



Important note Even if a maximum degree of design safety has been achieved when configuring an electronic control system, it is nevertheless imperative to comply with the instructions provided in the relevant operating instructions exactly; improper or incorrect handling could otherwise render precautions intended to prevent dangerous faults ineffective or even create additional hazards.


System description 22.1 System structure

SIPLUS HCS300I controls loads such as solid state relays (SSR) or fans. The modular system structure allows you to realize made-to-measure solutions for any control task. A large quantity of operating, service and diagnostics data is made available to permit optimal operation and maintenance of SIPLUS HCS300I. All of this data is supplied to a higher-level automation system via PROFIBUS DP.

Typical system structure

① Basic unit (GG2) ② Digital module (DM6) ③ Temperature module (TM4) ④ Current / voltage measuring module (IM/UM)

System description 2.1 System structure


Each SIPLUS HCS300I heating controller includes a basic unit (GG) that is responsible for central system functions:

● Connection of expansion modules

● Device diagnostics by means of the device LEDs

● Communication with the higher-level automation system via PROFIBUS DP

● Operation of up to four digital modules

● Operation of up to four temperature modules

The digital module (DM6) has six digital outputs and provides the following functionality:

● Control of contactors or solid state relays (SSR)

The temperature module is an additional expansion module of the SIPLUS HCS300I heating controller. It connects the temperature sensors to the system and has the following properties:

● Measurement of temperature values and transfer of the measurement data to the basic unit

System description 2.2 System components at a glance


2.2 System components at a glance

System modules System module MLFB No. Application Basic unit (GG2) 6BK1700-3BA20-0AA0 • Integration of system components

• Device diagnostics • Communication over PROFIBUS

DP

Digital modules (DM6): Standard digital module Digital module with solid state relay connector

6BK1700-4BA50-0AA0 6BK1700-2BA80-0AA0

Six additional binary outputs

Temperature module (TM4) 6BK1700-4BA60-0AA0 Temperature monitoring with temperature sensors

Decoupling module (DCM) 6BK1700-4BA40-0AA0 • Expansion of the system with a current / voltage measuring module (UM) or a current measuring module (IM) if the power consumption is too high

• Use in conjunction with the current / voltage measuring module (UM) in single-phase or ungrounded three-phase systems

Current measuring module (IM) 2.4 A to 25 A

6BK1700-3BA30-0AA0 Current measurement with through-hole technology

Current measuring module (IM) 10 A to 100 A


Current measuring module (IM) 20 A to 200 A


Current / voltage measuring module (UM) 2.4 A to 25 A

6BK1700-3BA60-0AA0 • Current measurement with through-hole technology

• Voltage measurement

Current / voltage measuring module (UM) 10 A to 100 A

6BK1700-3BA70-0AA0 • Current measurement • Voltage measurement

Current / voltage measuring module (UM) 20 A to 200 A

6BK1700-3BA80-0AA0 • Current measurement • Voltage measurement

System description 2.2 System components at a glance


Accessories Application Connecting cable: Length 0.025 m flat Length 0.1 m flat Length 0.3 m flat Length 0.5 m flat Length 0.5 m round Length 1.0 m round Length 2.5 m round

3UF7930-0AA00-0 3UF7931-0AA00-0 3UF7935-0AA00-0 3UF7932-0AA00-0 3UF7932-0BA00-0 3UF7937-0BA00-0 3UF7933-0BA00-0

• Connection of system components

via the system interfaces • Various cable lengths from 0.025 m

to 2.5 m can be used

DM-to-SSR connecting cable Type 1: Basic length 70 cm (connector 1) + 2.3 cm per additional connector Type 2: Basic length 84 cm (connector 1) + 2.3 cm per additional connector

6BK1700-2FA00-0AA0 6BK1700-2FA10-0AA0

Connection of the digital module to a solid state relay (SSR)

Addressing plug Note: The addressing plug is included in the scope of supply of the GG2.

3UF7910-0AA00-0 PROFIBUS DP address setting


Module description 33.1 Basic unit (GG2)

The basic unit (GG2) is the basic component of the SIPLUS HCS300I heating controller.

Functionality ● Three digital relay outputs for switching ohmic loads

● Communication with the higher-level automation system over PROFIBUS DP

● Local control of the system

● Four digital inputs for supplying external signals

LEDs ● Device LED: Operating state of the basic unit

● Bus LED: Status of the PROFIBUS

● Gen. Fault LED: Fault in the device feeder

Operator controls ● "Test" button:

– Storage of the PROFIBUS address when the addressing plug is inserted

Module description 3.2 Expansion modules


System interfaces ● System interface on the front of the enclosure:

– Connection to an expansion module or an addressing plug

Note SIPLUS HCS300I basic unit

The second system interface on the underside of the basic unit of the SIPLUS HCS300I heating controller has no function.

Power supply ● Power supply of the expansion modules via basic unit

Note

In the case of increased demands on the emitted interference of the system we recommend damping of the supply lines with ferrites.

3.2 Expansion modules

3.2.1 Temperature module (TM4) The function of the temperature module (TM4) in the SIPLUS HCS300I heating controller is to measure analog temperature values.



Functionality ● Up to four analog sensor measuring circuits in two-wire technology or two analog sensor

measuring circuits in four-wire technology, see also Section "Terminal assignment on the temperature module (Page 80)

NOTICE

If four-wire measurements are implemented, channels B and D are used as the power source and thus do not supply any valid measured data. In this case do not evaluate the two channels.

● Up to four temperature modules per system for measuring up to 16 analog temperature values

● The temperature values have a resolution of one decimal place

● Automatic calibration on powering up assures high measuring accuracy

NOTICE

Influence of the ambient temperature on measuring accuracy

A change in the ambient temperature can cause the measuring accuracy of the temperature module to deteriorate. The total measuring error that can occur due to a change in temperature is less than 0.5°C (typical) within the operating temperature range and measuring temperature range of the module.

The module must recalibrate itself in order to restrict this error to a minimum. Restart the temperature module so that it is automatically recalibrated.

● Different sensor types are supported for use in solid, liquid, or gaseous media:

– Resistance sensors:

◆ Pt100

◆ Pt1000

– Thermocouples:

◆ TC type J

◆ TC type K

◆ TC type L

● Integrated measuring principle with a conversion time of < 600 ms



● To calculate the correct temperature, in the case of thermocouple measurements, the temperature module requires the temperature at the clamping point (compensation temperature) to which the thermocouple is connected.

The following modes are available for determining the compensation temperature:

– No compensation

When the temperature module is used with a compensating box (0°C).

The temperature at the clamping point between the thermocouple and the compensating box is equalized in the compensating box and the temperature at the clamping point is not taken into account in the calculation.

– Internal compensation

When the temperature is measured directly at the temperature module.

The temperature at the clamping point for the temperature module is acquired via internal temperature sensors. Internal compensation is not recommended for measurements with stringent demands for measuring accuracy. When using internal compensation, sudden changes in ambient temperature and draughts must be avoided.

– External compensation (Pt100-4 cable)

When the temperature module is used with an external clamping point without its own compensation.

The clamping point temperature can be acquired using a Pt100 sensor in a 4-wire connection.

– Compensation via the higher-level automation system (compensation value)

When several temperature modules are used with an external clamping point without its own compensation.

The "Compensation value" setting supports the use of a temperature value transferred from the higher-level control. Using just one additional sensor you can then supply the compensation temperature to several temperature modules.

NOTICE

The SIPLUS HCS300I heating controller does not check the selected compensation method. If you parameterize an unsuitable compensation method, measuring errors or malfunctions can occur in the temperature module. However, the temperature module cannot be damaged as a result of incorrect parameterization.



● A process interrupt can be parameterized for reverse polarity detection for thermocouples in the specified measuring range. Reverse polarity is also reported if measuring temperatures are below the specified measuring range. Refer to the "Process interrupts" section in Chapter Slave diagnostics (Page 41).

Note

The standard parameter assignment "deactivated" enables you to switch off the temperature module. There is then no longer any communication to the downstream devices. An incorrect parameterization can also cause the temperature module to assume the "deactivated" state.

In the deactivated state the temperature module does not supply any valid temperature values. A deactivated temperature module does not necessarily result in a "Gen.Fault" being displayed on the basic unit or in a flashing bus LED. For this reason, check the parameterization in the event of malfunctions.

LEDs ● Operation LED: Operating state of the temperature module

System interfaces ● System interface on the front of the enclosure (left):

– Connection to the previous expansion module or the basic unit

● System interface on the front of the enclosure (right):

– Connection to the next expansion module, current measuring module or current / voltage measuring module

Measuring range

NOTICE Overrange and wire break can be reported as a "wire break" diagnostic interrupt, whereas underrange cannot be reported by a diagnostic interrupt.

NOTICE If compensation is set, reverse polarity detection is also active at the same time. In this case, depending on the compensation temperature, measured values less than 0°C can be reported as a reverse polarity immediately with substitute value 7FFF. The underrange is not applicable in this event.



Representation of the temperature value Temperature (°C)

Decimal Hexadecimal

Range

Depending on the sensor used

32767 7FFF Overflow

≥ 400.1 ≥ 4001 ≥ FA1 Overrange 0.0 ... 400,0 0 ... 4000 0 to FA0 Rated range

≤ -0.1 ≤ 65534 ≤ FFFE Underrange Depending on the sensor

used 32767 7FFF Underflow

3.2.2 Digital module (DM6) The digital module (DM6) expands the SIPLUS HCS300I heating controller with six additional digital outputs.

Functionality ● Six digital 24 V DC outputs in the form of "high-side" switches,

see also section "Terminal assignment on the digital module (Page 82)".

● Up to four digital modules can be connected to a basic unit

● Up to 24 digital output signals can be switched to loads of up to 500 mA

● Control of the digital outputs by means of a higher-level automation system that communicates with the SIPLUS HCS300I basic unit via the PROFIBUS

● Simple connection of solid state relays (SSR) (6BK1700-2BA80-0AA0).

Note

After switching on the system and immediately setting the digital outputs, the outputs may briefly switch back once to the value zero.



LEDs ● Operation LED: Operating state of the digital module




– Connection to the next expansion module, current measuring module or current / voltage measuring module

Power supply Comply with the following instructions when designing the power supply for the SIPLUS HCS300I heating controller and the load circuit:

NOTICE Safe isolation from the load circuit

The digital module forms a SELV / PELV system together with the basic unit. The load voltage supply for the digital module belongs to this SELV / PELV circuit.

Ensure safe isolation from the load circuit with the help of the input circuit of the relays or SSRs used.

NOTICE Power supply for the SIPLUS HCS300I and the load circuit

Comply with the following instructions in order to ensure a reliable power supply for the SIPLUS HCS300I module tier and the load circuit: • Remember that the 24 V DC voltage at the digital output drops by the same amount as

the voltage drop due to the current load on the 24 V DC load voltage supply lines. • The maximum permissible voltage difference between the SIPLUS HCS300I system

ground and the ground of the load circuit is 9V. If the voltage difference is any higher, the outputs can no longer be switched and the digital module is not destroyed.

• If you have two electrically isolated, floating voltage sources, connect the SIPLUS HCS300I heating controller to one voltage source and the load circuit to the other source.

• If, on the other hand, you use a single voltage source for both the SIPLUS HCS300I heating controller and the load circuit, you must comply with the following instructions: – Connect the return conductors of the loads direct to the power supply unit. – Only use the ground connection between the power supply unit and the load voltage

terminal on the digital module for equipotential bonding.



3.2.3 Decoupling module (DCM) If you use a current / voltage measuring module in an ungrounded or single-phase system, you must also use a decoupling module (DCM). You also need a decoupling module if the maximum current consumption of the system bus is reached and you want to operate a current measuring module or a current / voltage measuring module.

Functionality ● Electrical isolation of the current / voltage measuring module from the previous expansion

modules or a basic unit

LEDs ● Operation LED: Operating state of the decoupling module




– Connection to the current / voltage measuring module



Using the decoupling module If you use a current / voltage measuring module in a single-phase system or an ungrounded three-phase system, you must also use a decoupling module.

You should additionally take account of the maximum permissible number of modules per basic unit when designing your SIPLUS HCS300I heating controller:

● Four temperature modules

● Four digital modules

● One current measuring module or one current / voltage measuring module

If you are planning a mixed configuration with temperature modules, digital modules and a current / voltage measuring module, you must check whether you need a decoupling module before you start:

Number of TM4s * current factor + number of DM6s * current factor + number of UMs or IMs * current factor > 14

Module: Current factor Temperature module 2 Digital module 1 Current / voltage measuring module 4

Examples:

Number of temperature modules

Number of digital modules

Current / voltage measuring module

Calculation Decoupling module required

4 2 1 4*2+2*1+1*4=14 No 4 3 1 4*2+3*1+1*4=15 Yes 4 4 0 4*2+4*1=12 No

Module description 3.3 Current measuring module (IM)


3.3 Current measuring module (IM) Current measuring modules are used together with the basic unit to measure load currents. The current measuring module must be selected according to the expected maximum current of all connected loads.

2.4 A to 25 A current measuring module 10 A to 100 A current measuring module

20 A to 200 A current measuring module

Functionality ● Current measurement on a feeder,

see also section "Wiring on the current measuring module (Page 85)".

● Current ranges between 2.4 A and 200 A




Mounting options ● 2.4 A to 25 A and 10 A to 100 A current measuring modules:

– DIN rail

– Direct mounting on a mounting plate with push-in lugs

● 20 A to 200 A current measuring module:

– DIN rail

– Direct mounting on a mounting plate with screws

System interfaces ● System interface on the underside or front of the enclosure

Measuring range Definition of the current setting:

The current setting is the current that is expected during normal operation. If the measured current corresponds to the current setting, the current measuring module (IM) indicates 100%. The current setting must be within the permissible current range of the IM and can be set in 10 mA steps.

Note Units of the current setting: 10 mA

The current setting is parameterized in steps of 10 mA.

Ensure that the parameterized value is an integer multiple of 10 mA.

Values can be parameterized for the current setting in the following value ranges:

Module Min. value Max. value 2.4 A – 25 A 240 2500 10 A – 100 A 1000 10000 20 A – 200 A 2000 20000



Measured value display

The measured value is displayed as a relative current value (i.e. as a ratio of the measured current to the specified current setting) in percent.

To obtain the current in amperes, the displayed value must be multiplied by the selected current setting (in amperes).

Display of relative current value

Decimal Hexadecimal

Range

1000 (1041*) 3E8 (411*) 1000 % (1041 %*) Iin Maximum value of the current measuring module

100 - 1000 (1041*) 64 - 3E8 (411*) 100 %- 1000 % (1041 %*) Iin The measured current is higher than the current setting.

100 64 100 % Iin The measured current is exactly the same as the current setting.

0 - 100 0 - 64 0 % - 100 % Iin The measured current is lower than the current setting.

0 0 0 % Minimum value, no measurable current is flowing

* 2.4 A to 25 A current measuring module with current setting Iin = 2.4 A

Example 1 You want to measure a current that you expect to be approximately 8 A. You select a current measuring module with a measuring range of 2.4 - 25 A.

You expect the current under normal operating conditions to be around 8 A, so you select 8 A as the current setting. You parameterize the current setting by entering the value as a multiple of 10 mA units. This is "800" for this example.

If the expected value of 8 A is flowing, the HCS300I heating controller outputs the value 100: The measured current therefore represents 100% of the current setting that you specified.

If the measured current value deviates from the current setting, the actual percentage of the current setting that it represents will be displayed.



If a current of 24 A flows instead of the expected 8 A due to, for example, a fault in a heating zone, the measured value 300 will be displayed: The measured current is 300% of the current setting.

Note Display resolution

The resolution of the percentage display is 1%.

The maximum resolution of the measured value for current in amperes is obtained from the selected current setting value divided by 100.

In the above example, the resolution for the current is therefore 80 mA.

Example 2 If there is no expected value for measured current, and the current should simply be displayed in amperes, you can simplify conversion of the displayed value to the real current value by making an appropriate selection of the current setting:

If you are using a 10 - 100 A current measuring module and do not have particularly demanding requirements regarding the resolution of the current value, you can define the current setting as 100 A.

The minimum resolution in this case will be around 1 A. The current value of 100 A will be shown on the display as 100%. In this case, the display in percent corresponds to the measuring current in amperes and conversion is not necessary.

Module description 3.4 Current / voltage measuring module (UM)


3.4 Current / voltage measuring module (UM) The SIPLUS HCS300I heating controller allows a current / voltage measuring module to be used instead of a current measuring module. In addition to measuring the load currents, current / voltage measuring modules can also be used to measure phase voltages in a single or three-phase system.

2.4 A to 25 A current / voltage measuring module

10 A to 100 A current / voltage measuring module


Functionality ● Current measurement on a feeder,

see also section "Wiring on the current / voltage measuring modules (Page 86)".

● Current ranges between 2.4 A and 200 A

● Measurement of phase voltages up to 400 V (e.g. UL1) or phase-to-phase voltages up to 690 V (e.g. UL1UL2)

● Measurements in three-phase systems or single-phase AC systems


Module description 3.5 Addressing plug


Mounting options ● 2.4 A to 25 A and 10 A to 100 A current / voltage measuring modules:

– DIN rail

– Direct mounting on a mounting plate with push-in lugs

● 20 A to 200 A current / voltage measuring modules:

– DIN rail

– Direct mounting on a mounting plate with screws

System interfaces ● One system interface on the front of the enclosure for:

– Electrical power supply from a basic unit

– Connection to an upstream decoupling module

– Connection to a SIPLUS HCS300I module or a basic unit

Measuring range

Representation of the voltage value Voltage (V)

Decimal Hexadecimal

Range

400 400 190 Maximum value* 0 ... 400 0 ... 400 0 ... 190

0 0 0 Minimum value

* Approved for max. 400/690 V system

3.5 Addressing plug You can use the addressing plug to assign a PROFIBUS DP address to the basic unit via the system interface of the basic unit.

Module description 3.6 Optional accessories: Solid state relays


3.6 Optional accessories: Solid state relays The SIPLUS HCS300I heating controller allows you to control load switches such as solid state relays quickly and easily.

SIRIUS semiconductor switching devices SIRIUS semiconductor contactors and solid state relays can be purchased as optional accessories for use with SIPLUS HCS300I. SIRIUS semiconductor switching devices are the ideal solution for ohmic loads that need to be switched frequently. Since they have no mechanical moving parts, they offer silent, wear-free switching and a long service life. Their compact design additionally enables space saving installation in industrial control panels.

Further information on SIRIUS semiconductor switching devices can be found on the Internet at: SIRIUS semiconductor switching devices (http://www.siemens.com/solid-state-switching-devices).

http://www.siemens.com/solid-state-switching-devices�

http://www.siemens.com/solid-state-switching-devices�


System communication 44.1 Definitions

PROFIBUS DP PROFIBUS bus system with the DP protocol. DP stands for the German equivalent of distributed I/O. The main task of PROFIBUS DP is to manage the fast, cyclic data exchange between the central DP master and the I/O devices.

PROFIBUS DPV1 PROFIBUS DPV1 is an expansion of the DP protocol. It also supports the acyclic exchange of parameter, diagnostics, control and test data.

DP master A master with characteristics to EN 50 170, Volume 2, PROFIBUS with the DP protocol is referred to as the DP master.

Class 1 master A Class 1 master is an active node on the PROFIBUS DP. It is characteristically used for cyclic data exchange with other nodes. Typical Class 1 masters include PLCs with a PROFIBUS DP connection.

DPV1 slave A slave operated on the PROFIBUS with the PROFIBUS DP protocol that behaves in accordance with EN 50 170, Volume 2, PROFIBUS is referred to as the DPV1 slave.

GSD Device master data (GSD) contains DP slave descriptions in a standardized format. The use of device master data simplifies the configuration of the DP slave in a DP master system.

Write data Writing data means that data is transferred to the SIPLUS HCS300I heating controller.

Read data Reading data means that data is transferred from the SIPLUS HCS300I heating controller.

System communication 4.2 Data transfer


4.2 Data transfer

Structure of a communications network PROFIBUS DPV1 provides several different ways to organize the data transfer between the system components. A typical configuration is shown in the following diagram.

System communication 4.2 Data transfer


Communication principle The system components transfer data in different ways, depending on the selected master-slave mode:

System communication 4.3 Process image and diagnostics


4.3 Process image and diagnostics

4.3.1 Cyclic data transfer Cyclic data is exchanged between the PROFIBUS DP master and the PROFIBUS DP slave once in every DP cycle. The PROFIBUS DP master module sends the control data to the SIPLUS HCS300I heating controller. The SIPLUS HCS300I heating controller responds by sending the message data to the master module.

You access the cyclic data in the PLC software via the inputs (message data) and the outputs (control data).

The length of the cyclically transferred data is determined when the SIPLUS HCS300I heating controller is integrated in the DP master system by selecting modules that define the structure and length of the cyclic data.

Available expansion modules Cyclic data transfer from the PROFIBUS DP master to SIPLUS HCS300I:

Designation Length Assignment Temperature module 2 control data bytes Cyclic control – analog value for

compensation Digital module 1 control data byte Cyclic control – bits 0 to 5

You can parameterize substitute values for the digital module. The basic unit (GG2) transfers substitute values if the PROFIBUS DP master no longer sends any cyclic data. Substitute values are not switched in the event of communication errors with the expansion modules.

Cyclic data transfer from SIPLUS HCS300I to the PROFIBUS DP master:

Designation Length Assignment Temperature module 8 message data bytes (temperature

channel) Cyclic signaling – analog inputs A to D

UM module 6 message data words Cyclic signaling – analog inputs I1 to I3 and U1 to U3

IM module 3 message data words Cyclic signaling – analog inputs I1 to I3

You define which digital or analog information is contained in the cyclic data by means of the parameters in STEP 7.



4.3.2 Process image output (PIQ) The PIQ contains the control data for the individual modules. All addresses are specified as an offset relative to the base address 0.0. The actual addresses are obtained from the configuration of the overall system.

PIQ for basic unit, length 1 byte (8 bits) Q address PIQ Meaning Q 0.0 Relay output OUT1 Terminal 2 (common potential

Terminal 1) Q 0.1 Relay output OUT2 Terminal 3 (common potential

Terminal 1) Q 0.2 Relay output OUT3 Terminal 7 (common potential

Terminal 6) Q 0.3 reserved No function Q 0.4 reserved No function Q 0.5 reserved No function Q 0.6 reserved No function Q 0.7 reserved No function

PIQ for temperature module, length 1 byte (16 bits) Q address PIQ Meaning QW 0 Compensation value from automation

system; in 1/10°C, 0...4000 Analog value, only effective with the parameterization "Compensation value from AS"

AS: Automation system

PIQ for digital module, length 1 byte (8 bits) Q address PIQ Meaning Q 0.0 Digital output 1 Terminal DO1 Q 0.1 Digital output 2 Terminal DO2 Q 0.2 Digital output 3 Terminal DO3 Q 0.3 Digital output 4 Terminal DO4 Q 0.4 Digital output 5 Terminal DO5 Q 0.5 Digital output 6 Terminal DO6 Q 0.6 reserved No function Q 0.7 reserved No function



4.3.3 Process input image (PII) The PII contains the status information for the individual modules. All addresses are specified as an offset relative to the base address 0.0. The actual addresses are obtained from the configuration of the overall system.

PII for basic unit, length 1 byte (8 bits) I address PII Meaning I 0.0 Digital input IN1 Terminal 9 I 0.1 Digital input IN2 Terminal 10 I 0.2 Digital input IN3 Terminal 4 I 0.3 Digital input IN4 Terminal 5 I 0.4 0 reserved I 0.5 0 reserved I 0.6 0 reserved I 0.7 0 reserved

PII for temperature module, length 4 words (of 16 bits each)

PII I address

Case P1 Case P2 Case P3

Meaning

IW 0 Input A Input A Input A Analog value1) IW 2 Input B x x Analog value1) IW 4 Input C Input C Input C Analog value1) IW 6 Input D x Input D Analog value1)

x: Value not defined 1) For representation, see Section "Temperature module (TM4) (Page 18)"



The actual status display of the temperature module depends on the parameterization of the sensor type in combination with an appropriate type of compensation. There are three different cases:

Cases Sensor type Compensation type

"Pt100-2 cable" "Pt1000-2 cable"

"No compensation" Case P1

"TC-EL Typ J (Fe-CuNi)" "TC-EL Typ K (NiCr-Ni)" "TC-EL Typ L (Fe-CuNi)"

"No compensation" "Internal" "Compensation value" (from automation system)

Case P2 "Pt100-4 cable" "Pt1000-4 cable"

"No compensation"

Case P3 "TC-EL Typ J (Fe-CuNi)" "TC-EL Typ K (NiCr-Ni)" "TC-EL Typ L (Fe-CuNi)"

"Pt100-4 cable" (external)

PII for current measuring module, length 3 words (of 16 bits each) I address PII Meaning IW 0 Relative current value L1 Percentage value1) IW 2 Relative current value L2 Percentage value1) IW 4 Relative current value L3 Percentage value1)

1) For representation, see Section "Current measuring module (IM) (Page 26)"



PII for current / voltage measuring module, length 6 words (of 16 bits each) I address PII Meaning IW 0 Relative current value L1 Percentage value1) IW 2 Relative current value L2 Percentage value1) IW 4 Relative current value L3 Percentage value1) IW 6 Voltage L1 Analog value2) IW 8 Voltage L2 Analog value2) IW 10 Voltage L3 Analog value2)

1) For representation, see Section "Current measuring module (IM) (Page 26)" 2) For representation, see Section "Current / voltage measuring module (UM) (Page 30)"

4.3.4 Diagnostics data and interrupts The diagnostics data contains important information about the operating state of the SIPLUS HCS300I control to facilitate troubleshooting. In contrast to cyclic data, diagnostics data is only transferred by the system to the master module if anything changes.

There are several diagnostics options according to the PROFIBUS DP standard:

● Standard diagnostics

● Status messages

● Channel-specific diagnostics data

● Process and diagnostic DPV1 interrupts



4.3.5 Slave diagnostics When you diagnose a slave, the DP slave sends the following telegram:

The diagnostics telegram has a maximum length of 46 bytes.



Station status The station status provides information about the status of a DP slave.

● Station status 1:

Bit Description Cause / remedy 0 The DP master cannot address

the DP slave. Check the following: • Is the correct PROFIBUS

address set on the DP slave?

• Is the bus connector connected?

• Is voltage present on the DP slave?

• Is the RS485 repeater correctly configured?

1 The DP slave is not yet ready to exchange data.

The DP slave is still starting up. Wait until the startup is completed.

2 The configuration data transferred from the DP master to the DP slave does not match the DP slave configuration.

Check that the correct station type and the correct DP slave configuration have been entered in the configuring software.

3 External diagnostics data exists (group diagnostics indication).

Evaluate the identifier-related diagnostics data, the status messages and the channel-specific diagnostics data. Bit 3 is reset as soon as all faults have been rectified. The bit is set again if a new diagnostic message appears in the diagnostics data bytes.

4 The function you requested is not supported by the DP slave.

Check the configuration.

5 The DP master cannot interpret the response from the DP slave.

Check the bus configuration.

6 The DP slave type does not match the software configuration.

Specify the correct station type in the configuring software.

7 The DP slave was not parameterized by the DP master that is currently accessing it.

This bit is always 1 if you access the DP slave with another DP master. The "Master PROFIBUS address" diagnostic byte contains the PROFIBUS address of the DP master that assigned parameters to the DP slave.




Bit Description 0 The DP slave must be reparameterized. 1 A static diagnostic message is pending. The DP

slave will not work until the fault is rectified. 2 This bit is always set to "1" if a DP slave with this

PROFIBUS address exists. 3 Response monitoring is enabled for this DP

slave. 4 The DP slave has received a "FREEZE" control

command. This bit is updated only if another diagnostic message also changes.

5 The DP slave has received a "SYNC" control command. This bit is updated only if another diagnostic message also changes.

6 This bit is always set to "0". 7 The DP slave is deactivated and cannot be

processed at present.


Station status 3 is not used for slave diagnostics:

Bit Description 0 through 7 All the bits in the status message are set to "0".

Master PROFIBUS address The "Master PROFIBUS address" diagnostic byte contains the following information:

● Address of the DP master (Class 1 master) that assigned parameters to the DP slave

● Address of the DP master (Class 1 master) that has read and write access to the DP slave

The master PROFIBUS address is always contained in the third byte of the diagnostic message.



Manufacturer ID The manufacturer ID contains a code specifying the type of the DP slave:

Byte Value Manufacturer ID for: 4 81H SIPLUS HCS300I 5 74H SIPLUS HCS300I

Identifier-related diagnostic data You can find the identifier-related diagnostic data in bytes 6 to 8.



Status messages The status messages provide detailed information about the current state of the SIPLUS HCS300I heating control. In order to detect module failures you have to read out the diagnostic data cyclically and evaluate the status messages.

Byte 13 of the status message contains one of the following values, depending on the type of fault:

Value Fault type 0x01 Internal fault 0x02 Configuration error 0x04 Parameter error



Channel-specific diagnostics data The channel-specific diagnostics data provides further information over and above the identifier-related diagnostics data and helps pinpoint a hardware fault in the SIPLUS HCS300I heating controller.

If no diagnostics data exists, there is no block for channel-specific diagnostics data. If SIPLUS HCS300I has run a channel-specific diagnosis, on the other hand, there are either one or two such blocks.



Diagnostics interrupts Hardware faults and parameter errors are possible reasons for diagnostic interrupts. The SIMATIC S7 starts to execute diagnostic interrupt OB 82 as soon as SIPLUS HCS300I triggers an interrupt.



n Number of channel-specific diagnostic bytes

The start byte in the diagnostic interrupt block can be shifted between 3 and (3 * n) bytes, depending on the number of channel-specific diagnostic bytes.



Process interrupts Process interrupts are caused by process faults, process alarms, and process messages. The SIMATIC S7 starts to execute process interrupt OB 40 as soon as SIPLUS CCT triggers an interrupt.

n Number of channel-specific diagnostic bytes

The first byte in the process interrupt block can be shifted between 3 and (3 * n) bytes, depending on the number of channel-specific diagnostic bytes.

System communication 4.4 Integration of SIPLUS HCS300I in DP master systems


4.4 Integration of SIPLUS HCS300I in DP master systems

4.4.1 Preparation for data transfer

Preconditions for communication with a Class 1 master: ● Integration according to chapter Slave modes ()

● PROFIBUS DP address setting (see chapter PROFIBUS DP address setting (Page 95)).

4.4.2 Slave modes The following table provides an overview of the slave modes supported by the SIPLUS HCS300I heating controller on a Class 1 master:

Integration of SIPLUS HCS300I

DP master Vendor-independent, without DPV1 interrupts

DP master Vendor-independent, with DPV1 interrupts

S7 master

DPV1 slave via device master data

• Cyclic data exchange • Standard diagnostics • Acyclic reading and

writing of DPV1 data records

• Cyclic data exchange • Standard diagnostics • Process and diagnostic

interrupts • Acyclic reading and


• Cyclic data exchange • Standard diagnostics • Process and diagnostic

interrupts • Acyclic reading and


4.4.3 Integration of SIPLUS HCS300I as a DPV1 slave SIPLUS HCS300I can be integrated in your system as a DPV1 slave using a GSD file. You can find the required GSD files under:

GSD files (http://www.siemens.com/profibus-gsd)

The following GSD files are available for SIPLUS HCS300I:

● siem8174.gsg (German)

● siem8174.gse (English)

http://www.siemens.com/profibus-gsd�



You will be given a GSD file to help you configure the operation of SIPLUS HCS300I on a PROFIBUS DP master. The GSD file (the file containing the device master data) describes all the properties of a DP slave that must be known to the DP master during operation. SIPLUS HCS300I is registered with PROFIBUS International under ID 8174 and the GSD file has the name "siem8174.gsg".

NOTICE Using the full functionality of SIPLUS HCS300I

If you want to use the full functionality of SIPLUS HCS300I, your configuring tool must support GSD files Rev. 5 (STEP 7 V5.3 and higher).

Note Operation on a non-S7 master

To install the GSD file on a non-S7 DP master, follow the installation instructions described in the Operating instructions for the DP master.



Procedure To integrate the GSD file in SIMATIC S7 (STEP 7 V5.1 + SP2 and higher) and add SIPLUS HCS300I from the hardware catalog, carry out the following steps:

1. Launch SIMATIC STEP 7.

2. Open an existing project or create a new project.

3. Select "Options > Install New GSD Files" in HW Config.

4. Select the file called "siem8174.gsg" from the next dialog and confirm with "OK". The field device is listed in the hardware catalog in the "PROFIBUS DP" directory under "Additional field devices > General > SIPLUS HCS300I".

5. Add "SIPLUS HCS300I" to the PROFIBUS.

6. Select the expansion modules (TM4, DM6) or a current / voltage measuring module UM.



7. Add the desired modules.

Note Slot allocation without gaps

The slots must be filled without leaving gaps. On slot assignment, you must therefore ensure that there are no gaps from slot 2 onwards.

An HCS300I "Empty slot" (see column "Order number/Designation") can only be assigned to a different module following conversion to a DP "Empty slot" through deletion (see column "DP ID").

8. If a slot is unassigned you must assign it as an HCS300I "Empty slot" or you will not be

able to compile the project correctly.

9. Check the selected DP interrupt mode and the DPV1 interrupt enable in the properties of the DP slave.



10. Parameterize the modules:

Temperature module (TM4)

Digital module (DM6)



Current / voltage measuring module (UM)

11. After successfully parameterizing the modules you must reload the configuration into the system.



4.4.4 Evaluating diagnostics data

DP master with DPV1 interrupt support In a DP master system with DPV1 interrupt support, the diagnostics data is transferred and evaluated by means of diagnostic and process interrupts. These interrupts must be enabled in the PROFIBUS configuring tool for this purpose (diagnostic interrupts, process interrupts).

Using the configuring tool, you can define the DP interrupt mode in which the integration took place in the DP slave properties and specify whether interrupts are enabled. You do this in SIMATIC STEP 7 by selecting the properties of the DP slave in HW Config.

● Diagnostics sequence in STEP 7

– A hardware fault triggers a diagnostic interrupt (OB 82) in the CPU.

– A message from the process triggers a process interrupt (OB 40).

– If OB 82 or OB 40 has not been programmed, the CPU switches to "STOP" mode.

● Interrupts from a DPV1 slave, received with STEP 7:

– The interrupt is read directly in OB 82 or OB 40 with SFB 54 "RALRM".

– The data range addressed with SFB 54 by means of the "AINFO" parameter contains the interrupt information described in Slave diagnostics (Page 41). The first byte read corresponds there to byte 28.

Note

The SFB 54 "RALRM" interface is identical to the "RALRM" FB defined in the standard with the name "PROFIBUS Guideline, PROFIBUS Communication and Proxy FunctionBlocks according to IEC 61131-3".

For further information on SFB 54, refer to the STEP 7 Online Help system.



DP master without DPV1 interrupt support In a DP master system without DPV1 interrupt support, SIPLUS HCS300I diagnostics data can be evaluated using the status messages for the device-specific diagnostics and the channel-specific diagnostics as part of advanced diagnostics. See Section Slave diagnostics (Page 41).

Using the configuring tool, you can define the DP interrupt mode in which the integration took place in the DP slave properties.

The device-specific diagnostics data contains detailed information about faults, alarms, and messages recorded by the process via SIPLUS HCS300I while the channel-specific diagnostics data contains information about faults affecting the actual unit hardware.

● Diagnostics sequence in STEP 7 Each newly diagnosed hardware fault or message from the process triggers OB 82 in the CPU. If OB 82 has not been programmed, the CPU switches to "STOP" mode.

● Readout of the slave diagnostics data with STEP 7: You can determine which DP slave has supplied diagnostics data by evaluating the start information in OB 82 ("OB82_MDL_ADDR" variable). OB82_MDL_ADDR corresponds here to the diagnostics address of the slave that is configured in HW Config. The diagnostics data itself is read, for instance, in the cyclic part of the user program with SFC 13 "DPNRM_DG". The diagnostics data that is read with SFC 13 has the structure described in chapter Slave diagnostics (Page 41).

For further information on SFC 13, refer to the STEP 7 Online Help system.

4.4.5 Parameterization over the PROFIBUS

Parameter data during startup Parameter data is transferred to the unit on the PROFIBUS DP each time the SIPLUS HCS300I heating controller is started up.

Either standard parameters only or standard and device-specific parameters are transferred, depending on the master module used and the type of integration into the DP master system. The parameters are stored in the PLC or the DP master and automatically transferred to the DP slave when the system is started up.

You can set device-specific parameters with the configuring tool once the device master data has been loaded, e.g. with STEP 7 HW Config. You define the SIPLUS HCS300I parameters by setting the module properties and the device-specific parameters in the slave properties.


Heating controller application for extruders 55.1 SIPLUS HCS300I heating controller for extruders

SIPLUS HCS300I is a modular system with a wide range of potential applications.

In combination with the temperature control software TCP 3000, SIPLUS HCS300I can be used to implement a high-performance temperature control for extruder heaters.

Typical single-tier system configuration The main component of a single-tier system configuration is the basic unit, which is responsible for communication with the higher-level automation level as well as local control of the system components. The various modules can be used to tailor the SIPLUS HCS300I heating controller to the specific requirements of your application:

● The current / voltage measuring module measures the load currents of the heating or cooling zones and supplies these values to the basic unit, which makes the data available to the higher-level automation system.

● Temperature modules process the analog temperature values that are supplied by temperature sensors at various points in your system.

● Digital modules expand the system with additional digital outputs that switch the solid state relays or contactors (e.g. SIRIUS SC).

● In order to control SIPLUS HCS300I from the higher automation level, you need a suitable automation system such as a SIMATIC programmable controller (PLC).

● The TCP 3000 temperature control software that executes on a SIMATIC S7 (CPU 315 PN/DP and higher) performs the closed-loop control and visualization tasks.



Example: System with 8 temperature sensors, 18 digital outputs and current / voltage measuring



Example: System with 16 temperature sensors and 24 digital outputs without current / voltage measuring

Maximum single-tier system configuration You can expand the basic unit of the SIPLUS HCS300I heating controller with up to four temperature modules and four digital modules. In addition, you can connect to the basic unit either a current measuring module for measuring load currents or a current / voltage measuring module for measuring current and voltage. By installing a decoupling module, you can also connect a current or current / voltage measuring module if the maximum current consumption of the system bus has already been reached. Refer also to the installation guidelines in chapter Decoupling module (DCM) (Page 24).

The following module combinations can still be configured as a single-tier SIPLUS HCS300I system:

Current measuring module

Current / voltage measuring module

Temperature modules Digital modules Decoupling module

1 0 4 4 1 1 0 4 4 1 0 1 4 4 1 0 1 4 4 1 0 0 4 4 0 0 0 4 4 0



Example: System with 16 temperature sensors and 24 digital outputs and current / voltage measuring

Multitier system configuration If your application requires more than 16 analog inputs or 24 digital outputs, you can connect additional basic units to the higher-level automation system. Your SIPLUS HCS300I heating controller can then be expanded to 128 inputs or 256 outputs.



Example: System with 24 temperature sensors and 48 digital outputs and current / voltage measuring



TCP 3000 temperature control software A SIMATIC S7 and the WinCC flexible visualization system are necessary for operation of the TCP 3000 temperature control software. The minimum memory and performance requirements for this purpose are a CPU 315 PN / DP and an MP 177 / 377. Other S7 controllers (S7-300, 400 or WinAC RTX) or visualization devices (e.g. PC runtime) with a higher performance can also be used.

The TCP 3000 temperature control software supplies standard user pages that can be adapted and edited easily and customer-specifically using the visualization software WinCC flexible.

Functions:

● Various configuring, operating and service screens support easy and efficient working

● Graphical temperature presentation / trend curves

● Time switch

● Limits

● Controller settings / 2-point or 3-point controller

● Separate PID parameters for heating and cooling

● Self tuning of all controller parameters with synchronization of coupled zones

● Wire-break detection with parameterizable controller reaction

● Plausibility checking of actual value and control loop

● Adaptation of parameters for fast compensation of errors

● STEP 7 program for stand-alone execution

● Expandable up to 128 channels

● Configurable control response, to shut down the controller, for example, when the second tolerance limit is overshot

● Sampling times are separately configurable for each controller channel.

● Two separate tolerance bands (absolute or relative)

● Pulse width – actuating signal with minimum On time

● Heating channel control

● Two temperature setpoints

● Measuring and monitoring of the heating current



Example screens

Zone overview



Messages



Temperature curves



Heating current measurement

You can purchase the following licenses for the TCP 3000 temperature control software:

● Temperature Control TCP 3000 Initial License

– Application number: A4027462-A0443

● Temperature Control TCP 3000 Runtime License

– Application number: A4027462-A0444

Additional information is available under the following link: http://www.siemens.com/plastics

Select the extrusion application and follow the TCP3000 link.


Mounting and connection 66.1 General mounting and wiring instructions

NOTICE Comply with the maximum permissible torques

You should comply with the torques specified for each system component in the next chapter in order to guarantee problem-free operation of the system modules.

NOTICE Use different fixing lugs for screw mounting

Two different fixing lugs are provided for screw mounting for technical reasons: • Basic unit, digital module, temperature module, or decoupling module:

– Order no. 3RP1903 • Current measuring modules and current / voltage measuring modules, 45 mm and 55

mm wide: – Order no. 3RP1900-0B

NOTICE Note the different coding of the removable terminals

All removable terminals are mechanically coded and therefore only fit in one specific position!

NOTICE Do not exceed the maximum total cable length

The maximum cable length permissible per system between the system interfaces is 3 m. Longer cable connections can lead to system communication errors.

Use cables as short as possible to connect the system components, to avoid exceeding the maximum cable length per system.

Mounting and connection 6.1 General mounting and wiring instructions


NOTICE Isolate the load circuit safely

The digital module forms a SELV / PELV system together with the basic unit. The load voltage supply for the digital module belongs to this SELV / PELV circuit.

Ensure safe isolation from the load circuit with the help of the input circuit of the relays or solid state relays used.

NOTICE Lay the ground connection for the SIPLUS HCS300I modules correctly

You should lay the ground connection for the SIPLUS HCS300I modules as follows in order to avoid malfunctions: • Fasten a grounding bar underneath the SIPLUS HCS300I module tier. • The connection between the PE terminals on the SIPLUS HCS300I modules and the

grounding bar should always have the minimum possible impedance. • Connect the sensor shields to the grounding bar as close to the module as possible. • Connect the grounding bar to ground as close to the basic unit as possible.

NOTICE Condensation

If condensation forms on the modules this can result in module malfunctions or damage.

Therefore take appropriate measures to prevent condensation forming.

Mounting and connection 6.2 Mounting the system modules


6.2 Mounting the system modules

6.2.1 Mounting the basic unit and expansion modules You can either attach the basic unit and the expansion modules of the SIPLUS HCS300I heating controller to a DIN rail or fasten them to a mounting plate with screws.

Screw mounting on a mounting plate Basic unit Expansion module

1. Insert the fixing lugs into the mounting holes provided for this purpose on the rear of the basic unit at the top and bottom.

– Basic unit, digital module, temperature module, or decoupling module: Order no. 3RP1903

– Current measuring modules and current / voltage measuring modules, 45 mm and 55 mm wide: Order no. 3RP1900-0B

2. Make sure the lugs snap into the basic unit correctly.

3. Fasten the basic unit to a mounting plate with four screws.



6.2.2 Mounting the current measuring modules

2.4 A to 25 A and 10 A to 100 A current measuring modules

Note Fixing lugs for current measuring modules up to 100 A

Use fixing lugs with order no. 3RP1900-0B to screw-mount current measuring modules up to 100 A. These fixing lugs are only suitable for mounting current and current / voltage measuring modules!

If you want to use a 2.4 A to 25 A current measuring module, you will also need a 25 mm long spacer.

1. Insert the fixing lugs into the top and bottom of the current measuring module .

2. If you want to use a 2.4 A to 25 A current measuring module, you must insert a 25 mm long spacer between the top fixing lug and the mounting plate.

3. Fasten the current measuring module to the mounting plate with two screws.




1. Fasten the current measuring module to the mounting plate with four screws.



6.2.3 Mounting current / voltage measuring modules

2.4 A to 25 A and 10 A to 100 A current / voltage measuring modules

Note Fixing lugs for current / voltage measuring modules up to 100 A

Use fixing lugs with order no. 3RP1900-0B to screw-mount current / voltage measuring modules up to 100 A. These fixing lugs are only suitable for mounting current / voltage and current measuring modules!

If you want to use a 2.4 A to 25 A current / voltage measuring module, you will also need a 25 mm long spacer.

1. Insert the fixing lugs into the top and bottom of the current / voltage measuring module .

2. If you want to use a 2.4 A to 25 A current / voltage measuring module, you must insert a 25 mm long spacer between the top fixing lug and the mounting plate.

3. Fasten the current / voltage measuring module with two screws.

20 A to 200 A current / voltage measuring modules

1. Fasten the current / voltage measuring module to the mounting plate with four screws.

Mounting and connection 6.3 Wiring the system modules


6.3 Wiring the system modules

6.3.1 Wiring the basic unit and expansion modules

Removable terminals Connect the basic unit and the expansion modules by means of removable terminals that hold the connecting leads. These terminals allow you to replace the basic unit without having to disconnect and reconnect the wiring. The following conductor cross-sections, stripped lengths, and tightening torques are specified for the terminal wiring:

Removable terminals Screwdriver Tightening torque

PZ2 / Ø 5 mm - 6 mm

Torque: 7 lb/in to 10.3 lb/in 0.8 Nm to 1.2 Nm

Stripped length Conductor cross-section

Solid

2 x 0.5 mm2 to 2.5 mm2 / 1 x 0.5 mm2 to 4 mm2 2 x AWG 20 to 14 / 1 x AWG 20 to 12

Finely stranded

2 x 0.5 mm2 to 1.5 mm2 / 1 x 0.5 mm2 to 2.5 mm2 2 x AWG 20 to 16 / 1 x AWG 20 to 14

NOTICE Mechanical coding of the terminals

All the terminals used for the SIPLUS HCS300I system are mechanically coded and may only be used for their intended purpose.

Always connect the terminals to the connection positions provided, in order to prevent damage to the unit or the terminals.



Connection of the basic unit and expansion modules Basic unit Expansion modules

1. If you want to connect a temperature module, first connect a terminal on the bottom to connection position B.

2. Then connect a terminal to position A.

3. Connect the terminal that is provided for position D.

4. Connect the last terminal to position C.



Connection of a solid state relay (SSR) The digital module with an SSR connector (6BK 1700-2BA80-0AA0) has an additional slot to enable a solid state relay (SSR) to be connected easily. The appropriate connecting cable DM-to-SSR can be ordered as an accessory.

1. Insert the connecting cable for the solid state relay (SSR) into the slot provided for this purpose in the bottom of the digital module so that it snaps into place.

2. You can control up to six solid state relays. The connecting cable has a different cable length for each SSR. The shortest cable corresponds to output DO1 and the longest DO6:

See also section "Terminal assignment on the digital module (Page 82)" and section "System components at a glance (Page 15)" for further information.



6.3.2 Terminal assignment on the basic unit and expansion modules

6.3.2.1 Terminal assignment on the basic unit

Terminals on the top: Terminals on the bottom: 1 Common potential for relay outputs 1 and 2 A1 Supply voltage connection 1 2 Relay output OUT1 A2 Supply voltage connection 2 3 Relay output OUT2 A PROFIBUS DP connection A 4 Digital input IN3 B PROFIBUS DP connection B 5 Digital input IN4 Shield / PE X1,X2 Thermistor connection, not used

SPE/PE

6 Relay output OUT3 7 Relay output OUT3 8 24 V DC only for IN1 to IN4 9 Digital input IN1 10 Digital input IN2



NOTICE Correct connection of the PE terminal to the grounding bar

The connection between the PE terminal on the basic unit and the grounding bar should always have the minimum possible impedance in order to avoid module malfunctions.

Supply voltage for basic unit inputs You have three options for supplying the inputs:

● 24 V DC internal, 4 inputs can be used

● 24 V DC external, 3 inputs can be used

Input 3 is the reference potential, i.e. three inputs are available to you.

● 24 V DC external, 4 inputs can be used

24 V DC

All inputs operate reaction-free, i.e. the signal states on the neighboring inputs have no influencing effect.



6.3.2.2 Terminal assignment on the temperature module

C-PE CC+

D-PE DD+

SIPLUS CCT TM4

A+ A-PE

B+ B-PE B Terminals on the top: Terminals on the bottom: D+ Input D+, temperature sensor 1 A+ Input A+, temperature sensor 3 PE D Input PE D, ground connection for sensor

1 PE Input PE, ground connection for sensor 3

and for the system interface D- Input D-, temperature sensor 1 A- Input A-, temperature sensor 3 C+ Input C+, temperature sensor 2 B+ Input B+, temperature sensor 4 PE C Input PE C, ground connection for sensor

2 PE B Input PE B, ground connection for sensor

4 C- Input C-, temperature sensor 2 B- Input B-, temperature sensor 4

NOTICE Correct connection of the PE terminals to the grounding bar

The connection between the PE, PE B, PE C, and PE D terminals and the grounding bar should always have the minimum possible impedance in order to avoid module malfunctions.



NOTICE Shielding of the temperature sensor

If the connected temperature sensor is not adequately shielded, the temperature module will measure the temperature values incorrectly. • Ask the manufacturer of the temperature sensor for information about the envisaged

shielding measures. • Provide the specified shielding measures. • Connect the PE, PE B, PE C, and PE D separately from one another and wire them to

ground using cables as short as possible. • Connect the cable shield to ground using shield clamps.

4-wire system The figure shows the connection method for PT sensors in a 4-wire system.

D+B+

C+A+

D-B-

C-A-

PE DPE CPEPE B

① Attach cable shield to grounding rail or a functional grounding terminal

External compensation When the TM4 temperature module is used with an external clamping point without its own compensation, the clamping point temperature can be acquired by a Pt100 sensor in a 4-wire system. The Pt100 sensor is connected to terminals A and B in this case.



6.3.2.3 Terminal assignment on the digital module The digital module is available in two different versions:

● Standard digital module

● Digital module with solid state relay connector

CAUTION Power supply

The digital module must be connected to the same power supply as the basic unit.

NOTICE Correct connection of the PE terminal

The connection between the PE terminal on the digital module (DM6) and the grounding bar should always have the minimum possible impedance in order to avoid module malfunctions.



A2(-) PEA1(+)

DO1 DO3DO2

DO4 DO6DO5

SIPLUS CCT DM6

24V

Terminals on the top: DO1 Digital output 1 DO2 Digital output 2 DO3 Digital output 3 DO4 Digital output 4 DO5 Digital output 5 DO6 Digital output 6 Terminals on the bottom: A1(+) 24 V A2(-) Ground PE Shield connection



Connection of a solid state relay (SSR) The digital module with an SSR connector (6BK1700-2BA80-0AA0) has an additional slot on the underside to enable a solid state relay (SSR) to be connected easily.

The required connecting cable DM-to-SSR can be ordered as an accessory. See also section "Wiring the basic unit and expansion modules (Page 75)" and section "System components at a glance (Page 15)" for further information.

6.3.2.4 Terminal assignment on the decoupling module

Terminals on the bottom: PE Ground connection



6.3.3 Wiring on the current measuring module

NOTICE Assignment of the feed-through openings

Each feed-through opening must be loaded with no more than the specified maximum permissible current in order to guarantee problem-free operation of the current measuring modules.

Wire the feed-through openings so that the aggregate current of the conductors that are inserted through them does not exceed the maximum permissible current.

Select the most suitable current measuring module, depending on the expected aggregate current:

2.4 A to 25 A current measuring module



The current measuring modules supplied for the SIPLUS HCS300I system are designed with through-hole technology and the leads for the three phases are fed into the modules through the holes.



6.3.4 Wiring on the current / voltage measuring modules

Note Measurement of voltage or power-related variables

Connect the main circuit L1, L2, L3 of a current / voltage measuring module to the clamps (L1, L2, L3) of the removable terminal with a 3-core cable. Provide additional protection in the supply lines, e.g. using short-circuit proof cables or fuses.

NOTICE Assignment of the feed-through openings

Each feed-through opening must be loaded with no more than the specified maximum permissible current in order to guarantee problem-free operation of the current measuring modules.

Wire the feed-through openings so that the aggregate current of the conductors that are inserted through them does not exceed the maximum permissible current.



Select the most suitable current / voltage measuring module, depending on the expected aggregate current:

Current / voltage measuring module 2.4 A to 25 A

Current / voltage measuring module 10 A to 100 A


The current measuring modules supplied for the SIPLUS HCS300I system are designed with through-hole technology and the leads for the three phases are fed into the modules through the holes.



Connections for the voltage measurement System type Connections DCM Measuring points: Three-phase system, star point at ground potential

L1, L2, L3 Dependent on the type and number of system expansion modules

L1, L2, L3

Ungrounded three-phase system, star point not at ground potential

L1, L2, L3 DCM required L1, L2, L3

Single-phase system L1, N (at L2) DCM required L1+L21)

1) The actual voltage value is the sum of the line voltages L1 and L2 and must be calculated in the application.

Note Use of a decoupling module in grounded systems

If you operate several expansion modules in the system in addition to the current / voltage module, it may also be necessary to use a decoupling module in a grounded system.

Refer to the instructions for decoupling modules contained in chapter Decoupling module (DCM) (Page 24) when designing your SIPLUS HCS300I system.

NOTICE Correct connection of the phases

Comply with the following rules in order to avoid malfunctions or damage to the current / voltage module: • Measurements are only possible if you connect either one phase and its neutral or all

three phases L1, L2, L3. • Never connect conductors that carry voltages belonging to the same phase to several

terminals simultaneously. • You cannot measure different cophasal voltages with a current / voltage measuring

module.

Mounting and connection 6.4 Connection of the system interfaces


6.4 Connection of the system interfaces Each SIPLUS HCS300I component has at least one system interface to enable it to communicate with other system modules. The system interfaces are provided on the front and underside of the devices. You can insert the addressing plug into the basic unit directly; other SIPLUS HCS300I modules can be connected using cables of various lengths.

CAUTION Always connect the system components in a voltage-free state!

System interfaces ● System interfaces on the basic unit and expansion modules:

● System interfaces on the current measuring modules:

Mounting and connection 6.4 Connection of the system interfaces


● System interfaces on the current / voltage measuring modules:

Connection of the system interfaces

1. Insert the cable connector into the connector slot without skewing it.

2. The locking mechanisms for the connector slot must audibly snap onto the connector enclosure.

Mounting and connection 6.5 Connection of the PROFIBUS DP


6.5 Connection of the PROFIBUS DP The SIPLUS HCS300I system is integrated into a PROFIBUS DP network by means of the basic unit.

NOTICE Selection of the PROFIBUS DP connection

You can make the connection between the PROFIBUS DP and the basic unit either with the 9-pole sub D socket or with the A/B terminals.

You should only ever choose one of these connection options in order to avoid malfunctions or damage to the system.

Connection of the basic unit with the sub D socket

1. Connect the PROFIBUS DP cable with the 9-pole sub D connector to the 9-pole sub D socket on the basic unit.

2. Make sure the connector snaps into place in the socket.

Mounting and connection 6.5 Connection of the PROFIBUS DP



Commissioning 77.1 General information

WARNING

Voltage hazards

Contact with live components can result in serious injuries. Disconnect the system and all devices from the power supply before starting work.

NOTICE Condensation

If condensation forms on the modules this can result in module malfunctions or damage.

Therefore take appropriate measures to prevent condensation forming.

Prerequisites The following requirements must be met prior to commissioning:

● All the system components must be mounted and wired.

● All the devices that will be controlled by SIPLUS HCS300I must be switched off.

Notes on parameterization You parameterize the SIPLUS HCS300I heating controller with your automation system via PROFIBUS DP. To do this, you must connect the PROFIBUS DP cable to the PROFIBUS DP interface on the basic unit.

Commissioning 7.2 Commissioning


Possible commissioning scenarios There are two possible commissioning scenarios:

● SIPLUS HCS300I has the factory settings and has not yet been parameterized:

If it is connected to the PROFIBUS DP, the green "Bus" LED flashes when a DP master is connected.

● SIPLUS HCS300I is connected to the PROFIBUS DP, has a PROFIBUS DP address and has already been parameterized by the DP master:

– Green "Device" LED lit

– Green "Bus" LED flashes

7.2 Commissioning Refer also to the information in the previous chapter General information (Page 93).

Procedure 1. Switch on the power supply.

2. Check that the correct system operating state is indicated by the LEDs:

– "Device" LED: Continuous green light

– "Bus" LED: Continuous or flashing green light

3. If the LEDs on the basic unit flash in another color, diagnose the fault as described in chapter Troubleshooting using the LEDs (Page 98).

4. If you want to make the SIPLUS HCS300I heating controller available on the PROFIBUS DP, you must set the PROFIBUS DP address (see chapter PROFIBUS DP address setting (Page 95)).

5. Either reparameterize with your SIPLUS HCS300I automation system or check the existing parameters with SIMATIC STEP7 HW Config (see chapter Integration of SIPLUS HCS300I as a DPV1 slave (Page 50) ).

6. After successful parameterization you must restart the system.

Commissioning 7.3 PROFIBUS DP address setting


7.3 PROFIBUS DP address setting

Status of the "Test" button: In order to assign a PROFIBUS DP address to the system, you must activate the "Test" button on the basic unit. The "Test" button is activated if the addressing plug is connected.

Setting the PROFIBUS DP address with the addressing plug

1. Set the required address with the DIP switch on the addressing plug.

2. Switch off the the basic unit.

3. If the system interface of the basic unit is occupied by a connecting cable, remove this cable.

4. Connect the addressing plug to the system interface on the basic unit and switch on the basic unit. The "Device" LED is yellow.

5. Briefly press the "Test" button. The address you set is now stored.

6. Switch off the system.

7. Withdraw the addressing plug from the system interface and if applicable reconnect the other system components.

8. Switch the system on again.

Commissioning 7.3 PROFIBUS DP address setting



Diagnostics and maintenance 88.1 System messages Message Meaning How to remedy Acknowledgment Configuration error The configured unit

configuration does not match the actual configuration.

• Check whether all the configured components are available

• Check the actual configuration with "Configuration"

Set the configured unit configuration; reset

Hardware fault The hardware of the basic unit is defective.

Replace the basic unit. Rectify the problem

Module fault At least one system module is not ready.

• Connecting cable defective or incorrectly connected

• Module defective. Replace the module.

Rectify the problem; reset

Wrong parameter The parameter data is incorrect.

You can determine the name of the wrong parameter from the byte number in the system manual.

Correct the parameter; reset

Wrong parameter The parameter data transferred to the unit is incorrect.

Make sure the parameter data that is transferred to the unit has the correct contents.

-

Parameter changes not allowed in the current operating state

You attempted to change at least one parameter that cannot be changed in the current operating state.

Many parameters can only be changed if the motor feeder is switched off and not in "Remote" mode. The following parameters can always be changed:

-

Fault - Bus A fault has occurred during PROFIBUS DP communication.

Check the PROFIBUS connection.

Reset; wait for auto-reset

Fault - PLC/PCS The PLC that controls the feeder was or is in STOP mode.

Check the operating state of the PLC.

Reset; wait for auto-reset

Fault - Temporary components

The addressing plug is defective.

Replace the defective addressing plug.

-

Diagnostics and maintenance 8.2 Troubleshooting using the LEDs


Message Meaning How to remedy Acknowledgment Temperature module: out of range

The measuring input of the temperature module is out of range.

Check the temperature sensor.

-

Temperature module: sensor fault

A short-circuit or open circuit has occurred in the temperature sensor circuit.

Check the temperature sensor and the sensor cable.

-

8.2 Troubleshooting using the LEDs

LEDs

The SIPLUS HCS300I basic unit has three LEDs for indicating operating states:

● "Device" LED: Unit status

● "Bus" LED: Bus status

● "Gen. Fault" LED: Fault status

Diagnostics and maintenance 8.2 Troubleshooting using the LEDs


"Device" LED LED signal Description of operating state How to remedy Continuous green light Ready - Continuous yellow light Addressing plug detected, "Test" button

controls the addressing plug -

Continuous red light Basic unit defective Replace the basic unit Not lit Supply voltage too low Make sure the supply voltage is wired

and switched on

"Bus" LED LED signal Description of operating state How to remedy Continuous green light Communication with PLC/PCS - Flashing green light Baud rate detected - Not lit Bus not connected or bus fault Connect the bus or check the bus

parameters

"Gen. Fault" LED LED signal Description of operating state How to remedy Continuous red light Incorrect parameterization or

configuration error Rectify the fault in the unit feeder or reparameterize.

Not lit No fault -

LED "Ready" on temperature module, digital module and decoupling module Display Description of operating state How to remedy Steady light Ready - Flashing light1) No connection to the basic unit Establishing a connection to the basic

unit Not lit The device is out of service. -

1) Does not apply to decoupling module

Diagnostics and maintenance 8.3 Replacing system components


8.3 Replacing system components

Note Never disconnect the wiring from the removable terminals

You can replace SIPLUS HCS300I components by withdrawing the removable terminals from the components concerned together with the wiring, in other words the wiring does not need to be disconnected.

Replacing the basic unit

1. Switch off the main power for the unit feeder and the power supply for the basic unit.

2. Disconnect the cable from the system interface if necessary.

3. Withdraw the removable terminals without disconnecting the wiring.

4. Dismantle the basic unit.

5. Withdraw the removable terminals from the new basic unit.

6. Mount the new basic unit.

7. Reconnect the removable terminals together with the wiring.

8. Set the correct PROFIBUS DP address on the basic unit, see Section "PROFIBUS DP address setting (Page 95)".

9. Connect the cable to the system interface.

10. Switch on the power supply for the basic unit and the main power for the unit feeder again.



Replacing the expansion modules


2. Disconnect the cables from the system interfaces.

3. Withdraw the removable terminals without disconnecting the wiring.

4. Dismantle the expansion module.

5. Withdraw the removable terminals from the new basic expansion module.

6. Mount the new expansion module.

7. Reconnect the removable terminals to the module together with the wiring.

8. Connect the cables to the system interfaces.

9. Switch on the power supply for the basic unit, then the main power for the unit feeder.



Replacing the current measuring module or the current / voltage measuring module


2. Withdraw the connecting cable from the system interface.

3. If you are replacing a current / voltage measuring module, you must now withdraw the removable terminal.

4. Then remove the power supply lines from the feed-through openings.

5. Dismantle the old module.

6. If you are replacing a current / voltage measuring module, you must now withdraw the removable terminals from the new module.

7. Mount the new module.

8. Reinsert the power supply lines through the feed-through openings.

9. If you are replacing a current / voltage measuring module, you must now connect the removable terminal to the new module again.

10. Connect the cable to the system interface.

11. Switch on the power supply for the basic unit, then the main power for the unit feeder.


Dimensional drawings 99.1 Basic unit

Dimensional drawings 9.2 Expansion modules


9.2 Expansion modules

9.2.1 Temperature module

Dimensional drawings 9.2 Expansion modules


9.2.2 Digital module and decoupling module

Dimensional drawings 9.3 Current measuring modules


9.3 Current measuring modules

9.3.1 2.4 A to 25 A current measuring module



9.3.2 10 A to 100 A current measuring module



9.3.3 20 A to 200 A current measuring module

Dimensional drawings 9.4 Current / voltage measuring modules


9.4 Current / voltage measuring modules

9.4.1 2.4 A to 25 A current / voltage measuring module



9.4.2 10 A to 100 A current / voltage measuring module



9.4.3 20 A to 200 A current / voltage measuring module


Technical data 1010.1 General technical data

General specifications Degree of protection according to IEC 60529 IP20 Shock resistance (sine pulse) 15 g / 11 ms Mounting position Any Frequencies 50/60 Hz ±5%

Permissible ambient temperature range Operation: -25°C to +60°C Storage and transportation: -40°C to +80°C

Immunity to electromagnetic interference according to IEC 61131-2

Conducted interference, burst according to IEC 61000-4-4 • 2 kV (power ports) • 1 kV (signal ports)

Conducted interference, high-frequency according to IEC 61000-4-6

10 V

Conducted interference, surge according to IEC 61000-4-5 • 2 kV (line to ground) • 1 kV (line to line)

Electrostatic discharge, ESD according to IEC 61000-4-2 • 8 kV (air discharge) • 4 kV (contact discharge) Observe the ESD directive when installing. Expansion modules must be mounted left-aligned in relation to the basic unit or to an expansion module.

Field-related interference according to IEC 61000-4-3 10 V/m

Immunity to electromagnetic interference according to IEC 61131

Class SIPLUS HCS300I components are Class A products. They can cause signal interference in the vicinity of radio equipment. Take suitable protective measures if necessary.

Conducted and radiated interference emission DIN EN 55011/CISPR11 (corresponds to severity A)

Technical data 10.2 Technical data of the basic unit


10.2 Technical data of the basic unit

Enclosure Mounting Snap-mounted to 35 mm DIN rail or screw-mounted with

additional push-in lugs Display • "Device" LED

• "Bus" LED • "GEN. FAULT" LED

"Test" button • Functional test (system self-test) • Stores a PROFIBUS DP address

System interfaces • Connections on the device front for: – Expansion modules – Addressing plug

PROFIBUS DP interface • Interface types: RS 485 • Connection method:

– 9-pole sub D socket (12 Mbit) – Terminals (1.5 Mbit) – Same conductor cross-sections as control circuit

The PROFIBUS DP line is connected via a cable clamp connection or a 9-pole sub D socket.

Power supply Rated control supply voltage Us (acc. to DIN EN 61131-2) 24 V DC Operating range 0.85 x Us to 1.2 x Us Power consumption (including two expansion modules connected to the basic unit)

10 VA / 7 W

Rated insulation voltage Ui 300 V at pollution degree 3 Rated impulse withstand voltage Uimp 4 kV Mains buffering time 200 ms

Technical data 10.2 Technical data of the basic unit


Relay outputs Number Three monostable relay outputs Auxiliary contacts of the three relay outputs Potential-free NO contacts with parameterizable NC

behavior: • Two relay outputs connected to common potential • One relay output connected to separate potential, freely

assignable to control functions

Specified short-circuit protection for auxiliary contacts (relay outputs)

• Fuse links, Class gL/gG 6 A, quick-acting 10 A (IEC 60947-5-1)

• Miniature circuit-breaker 1.6 A, C characteristic (IEC 60947-5-1)

• Miniature circuit-breaker 6 A, C characteristic (Ik < 500 A)

Rated uninterrupted current 5 A, per common potential Rated switching capacity • DC 13:

– 2 A/24 V DC – 0.55 A/60 V DC – 0.25 A/125 V DC

Binary inputs Number Four inputs with the following properties:

• Supplied with power internally by the device electronics (24 V DC)

• Connected to common potential for recording process signals, freely assignable to control functions

Connections Tightening torque Torque: 7 lb/in to 10.3 lb/in

0.8 Nm to 1.2 Nm Conductor cross-sections • Solid:

– 2 x (0.5 mm2 to 2.5 mm2) – 1 x (0.5 mm2 to 4 mm2) – 2 x AWG 20 to 14 – 1 x AWG 20 to 12

• Finely stranded with end sleeve – 2 x (0.5 mm2 to 1.5 mm2) – 1 x (0.5 mm2 to 2.5 mm2) – 2 x AWG 20 to 16 – 1 x AWG 20 to 14

Technical data 10.3 Technical data of the temperature module


10.3 Technical data of the temperature module


additional push-in lugs LEDs "Ready" LED Connectors for temperature sensors Connections for four temperature sensors with a shield

connection

Interfaces Number 2 Connection options The temperature module has interfaces for the following

system modules: • Basic unit • Expansion module • Current measuring module or current / voltage

measuring module

Typical current consumption from system interface 20 mA

Technical data 10.3 Technical data of the temperature module


Sensor circuit Type of connection 2-wire or 4-wire connection Number of analog inputs • 2-wire connection: 4

• 4-wire connection: 2

Maximum electric strength 15 V Conversion time for 4 channels < 600 ms Measuring principle Integrating Noise suppression 50 Hz / 60 Hz Typical sensor circuit • Pt100: 210 µA

• Pt1000: 210 µA

Open-circuit detection Yes Measuring range • Pt100 / Pt1000: 0°C to +400°C

• TC type J, K, L: 0°C to +400°C

Measuring accuracy at an ambient temperature of 20°C max. ±1 °C Deviation at an ambient temperature of 20°C as a percentage of the measuring range

0.05 % per K

Offset due to temperature drift (typical) < 0.1°C / °C change in ambient temperature Measured value deviation due to temperature drift (typical) < 11.5 ppm / °C change in ambient temperature Measured value deviation for internal compensation temperature

± 3°C (typ.)

Isolation between channels Functional isolation, max. voltage difference ±1 V Galvanic isolation from the system interface Electrical isolation, isolating voltage 500 V DC




• Finely stranded with end sleeve: – 2 x (0.5 mm2 to 1.5 mm2) – 1 x (0.5 mm2 to 2.5 mm2) – 2 x AWG 20 to 16 – 1 x AWG 20 to 14

Technical data 10.4 Technical data of the digital module


10.4 Technical data of the digital module


additional push-in lugs LEDs "Ready" LED Number of digital outputs 6

System interfaces Number 2 Connection options The digital module has interfaces for the following system

modules: • Basic unit • Expansion module • Current measuring module or current / voltage

measuring module

Typical current consumption from system interface 10 mA

Output circuit Load voltage L+ (nominal value) 24 V DC Short-circuit protection Yes Minimum output current for "1" signal L+ (- 1 V) Maximum output current for "1" signal 500 mA Maximum switching frequency at ohmic load • For a digital module: typically 50 Hz

• For maximum configuration: min. 20 Hz

Aggregate current of the outputs 3 A Isolation of the outputs No Galvanic isolation from the system interface No

Technical data 10.5 Technical data of the decoupling module





• Finely stranded with end sleeve: – 2 x (0.5 mm2 to 1.5 mm2) – 1 x (0.5 mm2 to 2.5 mm2) – 2 x AWG 20 to 16 – 1 x AWG 20 to 14

10.5 Technical data of the decoupling module


additional push-in lugs Display "Ready" LED System interfaces The decoupling module has interfaces for:

• Left interface: – Expansion module

• Right interface: – Current measuring module or current / voltage

measuring module

Connections Tightening torque 0.8 to 1.2 Nm Conductor cross-sections • Solid:

– 1 x (0.5 mm2 to 4.0 mm2) – 2 x (0.5 mm2 to 2.5 mm2)

• Finely stranded with end sleeve: – 1 x (0.5 mm2 to 2.5 mm2) – 2 x (0.5 mm2 to 1.5 mm2)

Technical data 10.6 Technical data of the current measuring modules and the current / voltage measuring modules


10.6 Technical data of the current measuring modules and the current / voltage measuring modules

Enclosure Mounting (6BK1700-3BA30-0AA0 and 6BK1700-3BA40-0AA0 modules)

Snap-mounted to 35 mm DIN rail or screw-mounted with additional push-in lugs

Mounting (6BK1700-3BA50-0AA0 module) Snap-mounted to 35 mm DIN rail, screw-mounted on a mounting plate, or mounted directly on the contactor

System interfaces Connections for a basic unit, an expansion module, or a decoupling module



Main circuit Measuring range • 6BK1700-3BA30-0AA0 module: 2.4 A to 25 A

• 6BK1700-3BA40-0AA0 module: 10 A to 100 A • 6BK1700-3BA50-0AA0 module: 20 A to 200 A

Rated insulation voltage Ui at pollution degree 3 • 6BK1700-3BA30-0AA0 and 6BK1700-3BA40-0AA0 modules: 690 V

• 6BK1700-3BA50-0AA0 module: 1000 V

Rated operational voltage Uin 690 V Rated impulse withstand voltage Uimp • 6BK1700-3BA30-0AA0 and 6BK1700-3BA40-0AA0

modules: 6 kV • 6BK1700-3BA50-0AA0 module: 8 kV

Rated frequency 50/60 Hz Type of current Three-phase (grounded without DCM, otherwise with DCM)

Single-phase AC (with DCM) Short-circuit protection Additional short-circuit protection is required in the main

circuit Current measuring accuracy Within the measuring range ± 3% Typical voltage measuring range • Phase-to-phase / line-to-line voltage: 110 V to 690 V;

only the phase voltages are available to the system as measured values

• Phase voltage: 65 V to 400 V

Voltage measuring accuracy in the range from 230 V to 400 V

Typically ± 3%

Conversion time for 3 phases • IM : < 500 ms • UM: < 700 ms

Measuring principle Integrating Voltage measurement in ungrounded systems or in systems with integrated insulation measurement or insulation monitoring

The current / voltage measuring module can only be used in these systems in conjunction with a decoupling module.

Supply lines for voltage measurement Additional protection may need to be provided in the supply lines for voltage measurement.

Feed-through opening Diameter of the opening on the 6BK1700-3BA30-0AA0 module:

7.5 mm

Diameter of the opening on the 6BK1700-3BA40-0AA0 module:

14.0 mm

Diameter of the opening on the 6BK1700-3BA50-0AA0 module:

25.0 mm


Appendix AA.1 Recycling and disposal

The components of the SIPLUS HCS300I heating controller are ecologically compatible, and thus suitable for recycling. For environmentally sound recycling and disposal of your old devices please contact a certified disposal service company for electronic scrap.

A.2 Online service & support

Service & support for SIPLUS HCS300I If you require any further information about the products described in this system manual, please contact:

e-mail: HCS300I support (mailto:[email protected])

Phone: +49 (0) 89 9221-3999

Online service & support In addition to our documentation pool, you can take advantage of our complete online knowledge base on the Internet.

Service and support (http://www.automation.siemens.com/_en/portal/html/support/support.htm)

You will find the following information there:

● Our newsletter, providing the latest information on your products

● Relevant documentation for your application, which you can access via the search function in "Product Support"

● A worldwide forum in which users and experts exchange ideas and experiences

● Your local Industry Automation & Drive Technologies representative in our contact database

● Information on field service, repairs and spare parts. Much more is available on the "Services" pages

mailto:[email protected]�

http://www.automation.siemens.com/_en/portal/html/support/support.htm�

Appendix A.3 Training center


A.3 Training center We offer a range of courses to help get you started with the SIMATIC S7 automation system. Please contact your local training center or the central training center in

D-90327 Nuremberg, Germany

Phone: +49 (0) 911 895 3200

Internet: (http://www.siemens.com/sitrain)

http://www.siemens.com/sitrain�


List of abbreviations B

Abbreviation Meaning AWG American Wire Gauge Acycl. Acyclic CISPR Comité international spécial des perturbations

radioélectriques CPU Central Processing Unit DC Direct Current DCM Decoupling module DIN German Institute for Standardization DM6 Digital Module DP Distributed I/O DPV0 Distributed I/O Version 0 DPV1 Distributed I/O Version 1 DO Digital Output EN European standard FB Function Block FMS Fieldbus Message Specification Gen. General GG2 Basic unit GSD Device master file IEC International Electrotechnical Commission IP Ingress Protection IM Current measuring module LED Light Emitting Diode MOS Metal Oxide Semiconductor OB Organization Block PE Protective Earth PELV Protective Extra Low Voltage PCS Process Control System PI PROFIBUS International SELV Safety Extra Low Voltage Rev. Revision RS Recommended Standard SFB System Function Block SFC System function

List of abbreviations


Abbreviation Meaning PLC Programmable controller SSR Solid State Relay TM4 Temperature Module UM Current / voltage measuring module VDE Association for Electrical, Electronic and Information

Technologies (Germany) Cycl. Cyclic


Glossary

Addressing plug The addressing plug is required in order to assign a PROFIBUS DP address to the basic unit.

Basic unit (GG2) The basic unit is the basic component of the SIPLUS HCS300I heating controller. Your system configuration must therefore always include a basic unit when you use SIPLUS HCS300I.

Baud rate The baud rate is a measure of the data transfer rate, indicating the number of bits transferred per second (baud rate = bit rate). PROFIBUS DP supports baud rates between 9.6 kbaud and 12 Mbaud.

Bus Shared transmission path over which all nodes in a system are connected. A bus has two defined ends. In the case of PROFIBUS, the bus is a two-wire line (copper cable) or a fiber optic conductor.

Bus segment PROFIBUS DP consists of at least one bus segment. Each bus segment has at least two stations, one of which must be the DP master. Up to 32 stations can be connected to a bus segment.

Class 1 master PROFIBUS DP is based on a master-slave architecture. Telegrams are sent by the master to the addressed station (slave) and responded to by the slave.

Connecting cable Connecting cables are required to connect the basic unit to the other system modules. Various types and lengths are available. The total length of all the connecting cables in a system must not exceed 3 m.

Glossary


Current / voltage measuring module (UM) The SIPLUS HCS300I heating controller allows a current / voltage measuring module to be used instead of a current measuring module. In addition to measuring currents, current / voltage measuring modules can also be used to monitor voltages.

Current measuring module (IM) Current measuring modules are used together with the basic unit. The current measuring module must be selected according to the current to be monitored. The SIPLUS HCS300I current measuring modules cover current ranges between 10 A and 200 A.

Decoupling module (DCM) The decoupling module must be used in conjunction with a voltage measuring module in single-phase or ungrounded three-phase systems. The module is switched via the system interface upstream of a current / voltage measuring module.

Digital module (DM6) Digital modules allow the type and number of binary inputs and outputs on the basic unit to be increased if necessary. Up to four digital modules can be connected to one basic unit. The SIPLUS HCS300I can thus be expanded to a maximum of 24 binary outputs.

DP master A master that behaves in accordance with EN 50 170, Volume 2, PROFIBUS with the DP protocol. Cyclic message data is exchanged between the DP master and the DP slave once in every DP cycle. The DP master sends cyclic control data to SIPLUS HCS300I and receives cyclic message data from the system components in response.

DP slave and DP standard slave Slave operating on PROFIBUS with the PROFIBUS DP protocol. It is compliant with EN 50 170, Volume 2, PROFIBUS.

GSD file PROFIBUS DP is based on a master-slave architecture. Telegrams are sent by the master to the addressed station (slave) and responded to by the slave.

High-side switch A high-side switch switches a positive supply voltage that is higher than the load to be switched.

Glossary


PROFIBUS PROFIBUS (Process Field Bus) is a bus system that connects PROFIBUS compatible automation systems and field devices on the cell and field level. PROFIBUS uses the DP (= Distributed I/O), FMS (= Fieldbus Message Specification), PA (= Process Automation), and TF (= Technological Functions) protocols.

The PROFIBUS standard is defined in the European process and fieldbus standard EN 50 170, Volume 2, PROFIBUS, which specifies the functional, electrical, and mechanical properties of a bit-serial fieldbus system.

PROFIBUS DP PROFIBUS bus system with the DP (distributed I/O) protocol. The main task of PROFIBUS DP is to manage the fast, cyclic data exchange between the central DP units and the I/O devices.

PROFIBUS DP Interface In the SIPLUS HCS300I heating control, the basic unit has an integrated PROFIBUS DP interface that is connected to the PROFIBUS by means of the sub D socket or a cable clamp connection. SIPLUS HCS300I uses the PROFIBUS DP interface to communicate with the higher-level automation system.

PROFIBUS DPV1 Extension of the DP protocol. In addition to the DP functions, the DPV1 protocol allows parameterization, diagnostics, control, and test data to be exchanged acyclically.

PROFIBUS International installation guidelines The PROFIBUS DP/FMS installation guidelines published by PROFIBUS International must be observed in connection with PROFIBUS networks. These guidelines contain important information about cable routing and the commissioning of PROFIBUS networks.

Programmable controller (PLC) Controller whose functionality is stored in the control equipment as a software program. The PLC comprises a CPU, memory, input/output modules and an internal bus system. The I/Os and the programming language are based on the specific control tasks.

SIMATIC Designates the products belonging to a Siemens AG industrial automation system.

Slave PROFIBUS DP is based on a master-slave architecture. Telegrams are sent by the master to the addressed slave and responded to by this slave with its message data.

Glossary


Station Device that can send, receive, or amplify data on the bus.

STEP 7 Engineering system. Contains programming software for creating user programs for SIMATIC S7 controllers.

System interface cover Cover to protect unused system interfaces from pollution.

Temperature module (TM4) The temperature module allows analog temperature monitoring.

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Subject to change without prior noticeA5E02494131A© Siemens AG 2011

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SIPLUS - Siemens...SIPLUS HCS300I System Manual, 09/2011, A5E02494131A-01 9 Important notes 1 1.1...

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