SIPLUS HCS – I/O systems for industrial heating processes

SIPLUS HCS delivers pinpointed heat

Heat plays a role in many industrial production processes. To keep the temperature very precise and reliable is critical for a high product quality. With SIPLUS HCS heating control systems your heating elements are always at the right temperature. The intelligent heating family reduces the total costs for commissioning, operation and maintenance by up to 70 percent compared with a heating solution comprising individual components. Thanks to integrated diagnostics and reproducibility, you benefit from an improved heating process - and ultimately from an increase in product quality.

Heat under control - SIPLUS HCS – I/O systems for industrial heating applications

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I/O systems for industrial heating processes 

Siemens offers different options to control electrical heating elements. In addition to the modules of the ET 200 there are optimized I/O systems for controlling a wide variety of heating elements: SIPLUS HCS. With them, a heating process can be easily integrated into the automation.

SIPLUS HCS3200 - The compact solution 

For controlling heating elements up to 10 A at 400 V, in IP65 degree of protection. Thanks to the compact, sealed enclosure and the high IP65 degree of protection, SIPLUS HCS3200 can be used in distributed configurations in the vicinity of the heating elements, and thus helps reduce wiring. In a linear configuration, up to nine heating elements as well as an external fan can be controlled per device. SIPLUS HCS3200 can be used wherever electrical heating elements with medium power ratings (up to 4000 W) require switching in an industrial environment. It is a distributed I/O unit that communicates via the PROFIBUS DP fieldbus with a higher-level control system such as SIMATIC S7 / SIMOTION. SIPLUS HCS3200 is suitable for all common heating elements, such as quartz heaters, cartridge heaters, ceramic heaters, and infrared heaters up to 15x starting current.

SIPLUS HCS4200 - The flexible solution

 

For controlling heating elements up to 20 A at voltages of 45 V, 70 V, 110 V and in 230/277 V or 400/480 V networks. Exceptionally space-saving and cost-optimized heating solution with different output and I/O modules as well as racks.

 

The modular, compact and particularly space-saving IO system HCS4200 can be adapted flexibly to the respective industrial heating application.

 

HCS4200 consists of:

  • A Central Interface Module (CIM) for PROFINET or PROFIBUS communication
  • Up to 24 Power Output Modules (POM) per CIM einem oder zwei Racks (Racks gibt es in 2 Versionen, eins für maximal 12 POMs und eins für maximal 4 POMs)
  • One or two racks (racks are available in two versions, one for a maximum of 12 POMs and one for a maximum of 4 POMs)
  • Optional: One I/O module per CIM, either for temperature measurement, DI/DQ or current and voltage measurement (main voltage compensation)
  • Optional: Fan modules, one module for a maximum of 4 POMs

Up to 16 heating elements can be controlled per POM, meaning a maximum of 192 heating elements per rack and a maximum of 384 heating elements per bus node. If more heating elements are required, additional racks can be used.

 

View installation video

 

Peripheral Modules

An peripheral module (PM) for additional functions can be plugged into each Central Interface Module (CIM).
From left to right

  • PM4000 DI/DO: 8 digital outputs and 8 digital inputs or outputs
  • PM4000 U/I: Current and voltage measurement
  • PM4000 temperature: 4 inputs for temperature sensors, 4 analog inputs

SIPLUS HCS4300 - The high-performance solution

For controlling heating elements up to 16 A in 400/480 V networks, for a maximum of 7.68 kW per output.

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

 

 

HCS4300 consists of:

  • A Central Interface Module (CIM) for PROFINET or PROFIBUS communication, main voltage compensation integrated
  • Up to 24 Power Output Modules (POM) per CIM, POM: Fan integrated, 9 power outputs per POM, forward and return lines of each heating element are individually fused, load output via 3-pin plugs
  • If necessary, Extension modules (EM), one EM after each 8th POM
  • Optional: One peripheral module per CIM: For temperature measurement, DI/DQ, or current and voltage measurement (main voltage compensation)

Up to 9 heating elements can be controlled per POM, which means a maximum of 216 heating elements per CIM. If more heating elements are required, additional CIMs can be used.

 

Watch mounting video

Watch scaling video

Peripheral Modules

An peripheral module (PM) for additional functions can be plugged into each Central Interface Module (CIM).
From left to right

  • PM4000 DI/DO: 8 digital outputs and 8 digital inputs or outputs
  • PM4000 U/I: Current and voltage measurement
  • PM4000 temperature: 4 inputs for temperature sensors, 4 analog inputs
System overview

SIPLUS HCS at a glance

SIPLUS HCS is the intelligent answer to sensitive thermal requirements in the industry. With these heating control systems, you can easily integrate your heating processes into your industrial automation – and control electrical heating elements such as infrared, quartz, and flash heaters exactly as needed.

The perfect solution for any application

Depending on the requirements of the heating process – for example, the output power of the heating elements, diagnostic depth, and the degree of protection – you can choose from three different heating control systems: the compact SIPLUS HCS3200, the flexible SIPLUS HC4200, or the powerful SIPLUS HCS4300. You determine the capacity. Our heating systems can be modularly expanded and flexibly adapted to meet specific requirements. Our systems can also be combined, to ensure that you always have the right solution.

Find your products using the TIA Selection Tool
Use the TIA Selection Tool to quickly and easily select, configure, and order your SIPLUS HCS products.

Go to the TIA Selection Tool

Industrial heating processes can be easily integrated into the automation with the I/O system HCS and TIA Portal

With SIPLUS HCS temperatures can be precisely controlled. The system save a lot of space in the control cabinet and can be wired without a lot of work.

HCS system characteristics – integrated added value

Precisely control temperature with SIPLUS HCS

Mr. Automation shows you how easily industrial heating processes can be integrated - with the engineering framework TIA Portal and the SIPLUS HCS block library.

A wide range of intelligent diagnostic options include of course.

Applications

One system – many applications

These days, there’s hardly any industrially manufactured product that doesn’t undergo thermal treatment during the production process. SIPLUS HCS is the ideal solution for many thermal applications. Experience for yourself the versatility of SIPLUS HCS.

For product quality when molding plastics

For thermoforming, the heating control system must ensure that the same forming temperature is maintained at all times. SIPLUS HCS also controls high-speed flash heaters with percentage accuracy. This ensures an economical forming process and shorter production times. The integrated diagnostic functions guarantee maximum availability of the thermoforming machines.

For maximum brilliance and color consistency

When drying paint, heating systems must maintain the target temperature reliably and precisely while controlling the heaters. SIPLUS HCS enables maximum brilliance and color consistency as well as high energy efficiency. The diagnostic functions detect faults immediately – for example, a defective heater is precisely located. Thanks to Totally Integrated Automation (TIA), plant operators can decide whether the adjacent heater can compensate for the defect or whether the drying process is at risk.

For maximum-precision welding points in thermal joining

Plastic components are joined in a process similar to riveting. Heated temperature-controlled mandrels have to compress the so-called domes (similar to a rivet) thermoplastically as precisely as possible. Thanks to channel-specific feedback from their diagnostics modules, SIPLUS HCS ensure maximum precision during thermal riveting and enable exact temperature monitoring for optimal results.

For maximum through put and high quality

PET bottles have become an essential part of our everyday lives. Their wide range of uses and the high production capacity come with strict quality requirements in terms of material properties and visual quality. SIPLUS HCS ensure maximum productivity and quality in PET blow molding. In addition, the quick and easy detection and locating of faults reduces response times to a minimum.

Cooking without a loss of nutrients

Foods cooked with infrared radiation retain their nutritional value. The oil-free processing can also help reduce production costs and improve environmental conditions. With SIPLUS HCS, the radiation intensity of the infrared heaters can be controlled with the highest precision – in conformity with the strict specifications of the food and beverage industry.

References

Precision in practice

The intelligent SIPLUS HCS have been responsible for the highest precision in thermal processes for more than 30 years. Discover for yourself how SIPLUS HCS brings electrical heating elements to the right temperature worldwide.
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