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Siemens SIPLUS HCS3200 Operating Instructions Manual
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Siemens SIPLUS HCS3200 Operating Instructions Manual

Siemens SIPLUS HCS3200 Operating Instructions Manual

Heating control systems
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Summary of Contents for Siemens SIPLUS HCS3200

  • Page 3 ___________________ SIPLUS HCS3200 Introduction ___________________ Safety notes ___________________ Description ___________________ Heating Control Systems Application planning ___________________ Mounting Heating control system ___________________ SIPLUS HCS3200 Connection ___________________ Commissioning ___________________ Functions Operating Instructions ___________________ Communication ___________________ Error handling ___________________ Service and maintenance ___________________...
  • Page 4 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 5: Table Of Contents

    RS232 interface ........................34 Commissioning ............................. 35 Requirements .......................... 35 7.1.1 Hardware requirements ......................35 7.1.2 Integrating the GSD file......................35 7.1.3 Configuring the device-specific parameters................36 7.1.4 Setting the bus address ......................37 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 6 Dimension drawings ....................... 65 Appendix .............................. 67 Certificates and approvals ..................... 67 Order numbers for spare parts/accessories ................68 A.2.1 Ordering data ......................... 68 Service & Support ........................69 A.3.1 Application example ....................... 70 Index ..............................71 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 7: Introduction

    ● Knowledge of working with the PROFIBUS DP fieldbus is also necessary. History The following earlier release versions of these operating instructions have been published: Edition Note 07/2014 First edition Registered trademarks SIPLUS ® is a registered trademark of Siemens AG. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 8 Introduction 1.1 Introduction SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 9: Safety Notes

    The supply system to which the heating control system is connected must have a disconnecting means. The device must be switched off and secured against switching on again, before connecting to the line voltage. Otherwise, there is a risk of electric shock. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 10 Repairs WARNING No user-serviceable parts May cause death or serious injury Incorrectly performed repairs may result in substantial damage to equipment or endanger the user. Return the device to Siemens for repair. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 11: Security

    IT security IT security guidelines Siemens offers IT security mechanisms for its automation and drive product portfolio in order to support the safe operation of the plant/machine. We recommend that you inform yourself regularly on the IT security developments regarding your products. For information on this topic, refer to: http://support.automation.siemens.com.
  • Page 12 Safety notes 2.2 IT security SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 13: Description

    Internal temperature monitoring through NTC thermistor • Voltage monitoring • Line voltage compensation • PROFIBUS DP address setting with rotary switch (internally • accessible) Station status LED indicators (internally accessible) • Serial interface for firmware updates (internally accessible) • SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 14: Structure

    Lower fuse block: for fuses F111 (left) to F119 (right) along the incoming lines for heating ele- ments 1 to 9. ⑪ Upper fuse block: for fuses F101 (left) to F109 (right) along the outgoing lines for heating ele- ments 1 to 9. Figure 3-1 HCS3200 structure SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 15: System Configuration

    3.4 System configuration System configuration System components The SIPLUS HCS3200 heating control system is a distributed I/O device. It communicates via the PROFIBUS DP fieldbus with the SIMATIC S7 controller. A complete system includes the following components: ● HCS3200 heating controller ●...
  • Page 16 Description 3.4 System configuration SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 17: Application Planning

    3. Make a visual check of the device and the components for transport damage. Keep the packaging material in case you have to return the device. Scope of delivery ● HCS3200 device ● Mounting hardware ● Compact Operating Instructions SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 18: Requirements Regarding The Mounting Location

    Application planning 4.3 Requirements regarding the mounting location Requirements regarding the mounting location Ambient conditions SIPLUS HCS3200 may only be installed indoors. The main ambient requirements are described below: mounting position vertical Ambient temperature °C 0 … 50 during operating •...
  • Page 19 2.0 kV unsymmetrical with Ri = 12 Ω; evaluation criterion B Without a lightning protector, the following interference immunity is achieved: 0.5 kV symm. with Ri = 2 Ω; evaluation criterion B 0.5 kV unsymmetrical with Ri = 12 Ω; evaluation criterion B SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 20 Application planning 4.3 Requirements regarding the mounting location SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 21: Mounting

    • When two heating controllers are mounted one above the other, you must ensure that the heat emitted from the lower device is routed past the upper device. Remove surface protection Remove the surface protection on the front and rear of the device before installation. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 22: Mounting The Device

    ● Permitted mounting position: The device may only be operated in the vertical position. The exact positions of the fixing points and drill holes are shown in the dimension drawing (see section Dimension drawings (Page 65)). SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 23: Final Work

    Mounting 5.3 Final work Final work The cage clamps of the fuse holder may have loosened during transport. We recommend that you tighten the cage clamps before commissioning with a torque of 2.1 Nm. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 24 Mounting 5.3 Final work SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 25: Connection

    ● The incoming supply is disconnected at the mounting location of the device and secured against being switched on again. ● The cables to be connected are not live. ● The incoming supply / cabling requirements have been met (see Chapter Requirements regarding the mounting location (Page 18)). SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 26: Block Diagram

    The figure below shows the main connections between the HCS3200 heating controller and the main supply and heating elements. The power outputs are internally secured by two fuses per power output. It is essential to connect an external disconnecting means. Figure 6-1 Block diagram of HCS3200 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 27: Connection Element Locations

    Mains connection Connection of heating elements PROFIBUS DP / 24 V DC supply voltage PROFIBUS DP / 24 V DC supply voltage Figure 6-2 Connector element locations - Underside of device SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 28: X1 (Mains Connection / Grounding)

    Must be selected according to the connecting cable used. IP65 degree of protection must be maintained here. 1x PE expansion Article number: 09 14 000 9912 The Harting article number is specified for all parts. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 29 This connector is used for protective conductor connection for the device. The protective conductor must be connected to the connector according to the instructions of the manufacturer. Note: In North America this connection is referred to as the "ground terminal". SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 30: X2 (Heating Element Connection

    You can connect up to 9 heating elements/loads at connection socket X2. NOTICE The connected loads (heat emitters) must not exceed the total power output of the device of 25200 W. X2 pin assignment Figure 6-3 X2 pin assignment SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 31 DANGER Risk of electric shock / fire Will cause death or serious injury Voltages to ground of 230 V AC may be present at X2. The connection cables must have double or reinforced insulation. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 32: X3/X4 (Profibus Dp / 24 V Dc)

    If the bus connector is located at the start or the end of a bus segment, the terminating resistor must be connected. The bus terminating resistors are already integrated into the Siemens bus terminators (6GK1 905-0DA10). Make sure that stations with an activated terminating resistor are always supplied with power during startup and operation.
  • Page 33 Siemens: article number 6GK1905-0CB00 (straight outlet) or 6GK1905-0CD00 (angled outlet) Bus terminator Siemens 6GK1 905-0DA10 or compatible You can obtain detailed information regarding the electrical and mechanical properties of the connection plug from the manufacturer of the plug. SIPLUS HCS3200...

  • Page 34: Rs232 Interface

    9-pin sub D male connector. Please note that you must only use shielded connector casings and cables. A large surface area of both sides of the cable shield must be in contact with the connector casing. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 35: Commissioning

    STEP 7 V5.x or in STEP 7 V11 and higher (TIA Portal) in accordance with the online help for STEP 7. If a non-Siemens DP master is used, install the GSD file as described in the manufacturer's instructions.

  • Page 36: Configuring The Device-Specific Parameters

    Commissioning 7.1 Requirements 7.1.3 Configuring the device-specific parameters Note For the heating control system variant 6BK1 932-0AA00-0AA0, the device-specific parameters do not have any effects, since an external fan cannot be connected. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 37: Setting The Bus Address

    Set the bus address using the rotary switches. Location of the rotary switch for setting the bus address ① Tens digit of PROFIBUS DP address ② Ones digit of PROFIBUS DP address SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 38: Commissioning

    2. Switch on the line voltage. The device is in operation. Note When power up is not completed without errors, the current operating state or error is indicated by the appropriate LED display (see section Status and fault display with LEDs (Page 49)). SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 39: Functions

    Depending on the specified setpoint, the power outputs are controlled with an equal number of positive and negative half-waves (reference value: 200 half-waves). To avoid excessively high inrush currents, the power outputs are switched on time-delayed. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 40: Power Output Diagnostics

    For a 0 % setpoint, the fault is not detected and also cannot be indicated. You will find information about the causes of faults and possible rectification measures in the Fault reporting through diagnostics data section. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 41: Line Supply Voltage Monitoring

    NOTICE Excessive voltages can damage the device It is the responsibility of the user to ensure compliance with the maximum voltage limits. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 42: Line Voltage Compensation

    (e.g. due to disturbance over an extended period), a frequency fault will be reported to the user (see section Diagnostics data). The heating is not switched off and the previous frequency value measured is retained. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 43: Temperature Monitoring

    If the fan is not functioning correctly, a fault is reported to the user (see section Diagnostics data (Page 47)). The fault does not cause the heating to be switched off. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 44 Functions 8.6 Temperature monitoring SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 45: Communication

    Refer to section Temperature monitoring (Page 43) Factor for line voltage compensation in % Refer to section Line voltage com- pensation (Page 42) Voltage measured value Lxy Refer to section Line supply volt- age monitoring (Page 41) SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 46: Cyclic Output Data

    (Page 39) Power output 2 setpoint Power output 3 setpoint Power output 4 setpoint Power output 5 setpoint Power output 6 setpoint Power output 7 setpoint Power output 8 setpoint Power output 9 setpoint SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 47: Diagnostics Data

    (error code 1 ... 4) Error information for power output 7 (error code 1 ... 4) Error information for power output 8 (error code 1 ... 4) Error information for power output 9 (error code 1 ... 4) SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 48 In the case of the following messages, the diagnosis is "Fault", i.e. a fault exists that must be rectified: ● Temperature trip threshold reached ● Line voltage outside the measuring range ● All power output faults (error code 1 ... 4) All other signals are transmitted as status signals. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 49: Error Handling

    Internal fault; device is not ready for operation times If the fault still occurs after the 24 V power supply has been switched off and on again, the device is defective and must be replaced. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 50: Fault Reporting Through Diagnostics Data

    • data Switch off the machine, rectify the fault (e.g. cooling • malfunction), restart Internal fan Possible causes / corrective action Fan defective Check temperature if fault is reported. Corrective action: Replace fans promptly. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 51: Service And Maintenance

    Check regularly that the cooling ducts on the rear of the device are free from coarse soiling. If dirt is visible, clean the cooling channels with a vacuum cleaner. Internal fan Check regularly that the internal fan is functional. Remove dust deposits with a cleaning brush and vacuum cleaner. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 52: Firmware Update

    In the event of a fault or if an update is necessary, you can load the firmware by means of the "HCSSetup.exe" program. You can download the "HCSSetup.exe" program from the Siemens Service&Support (http://www.siemens.com/automation/service&support) website. Note The HCS3200 is delivered as standard with the current firmware version and is ready to switch on.
  • Page 53 10.Switch on the supply voltage again 11.Restart the HCS3200 by switching the supply voltage off and on again. Note If the voltage supply or the serial connection is interrupted before the end of loading, you can repeat the process. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 54: Fuse Replacement

    • Before working on the heating control system or the connected components, ensure the system is disconnected. NOTICE Use only the prescribed fuse types (see section Ordering data (Page 68)). If you operate the device with unapproved fuses, the device could be destroyed. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 55 ● Upper fuse block: for fuses F101 to F109 along the incoming lines for heating elements 1 to 9. ● Lower fuse block: for fuses F111 to F119 along the incoming lines for heating elements 1 to 9. Figure 11-1 HCS3200 Position of the fuses SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 56 3. Check for ruptured or defective fuses (refer to fault information in the section Diagnostics data (Page 47) 4. Replace defective fuses 5. Check corresponding heating elements 6. Close the enclosure door 7. Connect the line voltage 8. Reactivate the device SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 57: Fan Replacement

    1. Switch off the line voltage and secure against switching on again 2. Switch off the 24 V DC power supply of the HCS3200 3. Open the enclosure door Tool You will need a 2.5 mm slot screwdriver. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 58 Terminal open The internal fan of the HCS3200 is fixed without screws. Rotate the fan unit in the clockwise direction as far as the stop and then remove it. Fan released Fan fixed in place SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 59 Insert the fan leads into the 3 insulation displacement ② terminals . Lock the leads in place using the screw- driver as a lever. Note: There is no need to strip the leads beforehand. Fan installed and connected SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 60: Replacing The Device

    Since the HCS heating controller components only contain low levels of harmful substances, they are suitable for recycling. Contact a certified electronic scrap disposal company in order to ensure the environmentally-friendly recycling and disposal of your used device. SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 61: Technical Data

    Type of voltage of supply voltage Supply voltage for AC rated value Supply voltage frequency 1 rated value • 2 rated value • Relative symmetrical tolerance of the supply voltage frequency Conditional short-circuit current rated value SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 62 Type of display as status display by LED LED green = status indicator, LED red = fault indicator Supply voltage type of voltage Supply voltage for electronics Relative symmetrical tolerance of input voltage Current consumption without electronics maximum 0.25 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 63 15g / 11 ms / 3 shocks / axis Vibration resistance during storage in accordance with 5 ... 9 Hz / 3.5 mm, 9 ... 500 Hz / IEC 60068-2-6 Protection class IP IP65 Depth Height Width SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 64 • 660 … 1080 during storage • Relative humidity at 25 °C during operating maximum • at 50 °C during operating maximum • Installation altitude at a height over sea level maxi- 2000 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 65: Dimension Drawings

    Technical data 12.2 Dimension drawings 12.2 Dimension drawings Figure 12-1 SIPLUS HCS3200 dimension drawing SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 66 Technical data 12.2 Dimension drawings SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

  • Page 67: Appendix

    You can check which of the following approvals have been granted for your product by the markings on the type plate. EC directives SIPLUS HCS3200 products conform to the requirements and safety objectives of the EC Directives listed below. Low-voltage directive SIPLUS HCS3200 products meet the requirement of the EC Directive: 2006/95/EC "Electrical Safety".

  • Page 68: Order Numbers For Spare Parts/Accessories

    Ordering data Single part Order number HCS3200 device (UL variant) 6BK1932-0AA00-0AA0 Spare fuse for heat emitter connection (F101-F109, Manufacturer: Siemens, Order No.: 3NW6005-1 F111-F119) Manufacturer: Cooper Bussmann (www.cooperindustries.com), Cylindrical fuse Class CC 10x38 15A Order No.: C10G16 Internal fan 6BK1932-6AA00-0AA0...

  • Page 69: Service & Support

    ● Your local contact for IA/DT on site. ● Information about on-site service, repairs, and spare parts. Much more can be found under "Our service offer". Heater controller homepage For general information about the Siemens AG heater controllers, visit Homepage (http://www.automation.siemens.com/mcms/topics/en/siplus/industrial-heating- control/Pages/default.aspx). Online catalog and ordering system The online catalog and the online ordering system can also be found on the Industry Mall Homepage (http://www.siemens.com/industrymall).

  • Page 70: Application Example

    An example application for S7 and SIMOTION is available as a guide and basis for your own applications. This application example explains the mode of operation of the heater control. You can download the application example from the Siemens Service&Support website . SIPLUS HCS3200...

  • Page 71: Index

    Gaiter clamp, 59 Connection elements, 27 Installing, 59 Location, 27 Fault, 50 Connectors Firmware, 13, 52 Location, 27 download, 52 Control Update, Heating elements, 39 Firmware update, 13, 34, 49 Controller, 15 Frequency fault, 42 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...
  • Page 72 Fuse types, 54 Mounting bracket, 22 fuses vertical, 22 Checking, 56 Mounting bracket, 22 Fuses, 14 Location, 55 Non-Siemens DP master, 35 Green LED, 38, 49 GSD file, 35 download, 35 Installing, 35 OB82, 47 Operating state, 38 Ordering data, 68...
  • Page 73 System configuration, 15 System initialization, 49 System startup, 49 Target group, 7 Technical Support, 69 Temperature measured value, 43 Temperature monitoring, 13, 43 Temperature threshold, 43 Terminating resistor, 32 TN system, 41 Unpacking, 17 SIPLUS HCS3200 Operating Instructions, 07/2014, A5E31278506C/002...

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