Engineered with TIA Portal

Heat under control

SIPLUS HCS – I/O systems for
industrial heating applications

siemens.com/hcs
SIPLUS HCS – pinpointed heating
For precise temperature control

From automobile painting and plastics molding to

manufacturing PET bottles: reliable, pinpoint control
and precise maintenance of temperatures are Fuses
absolutely crucial to quality in many manufacturing
processes and must be ensured at all times. SIPLUS
HCS, the industrial heating control systems from
Siemens for electrical heating elements, have been Switching
reliably providing this service for more than 25 years. elements
And they’re getting smarter all the time.

Diagnostics

Pinpointed heat Modular and compact

Almost all products require exact tem- No matter how many heating ele-
peratures during the manufacturing ments are to be controlled, and how
process, precisely focused in terms of high the required output power rating:
time and space. The SIPLUS HCS I/O SIPLUS HCS is open to modular expan-
system controls electrical heating sion, and is so versatile it can be
elements, such as infrared, quartz, adapted to suit specific requirements.
and flash heaters, exactly to suit
individual requirements. Simple integration
With SIPLUS HCS, heating processes
Intelligent efficiency are easy to integrate into Siemens’
Heat needs power – and the less, the industrial automation. Thanks to
better, because energy is expensive, Totally Integrated Automation, all
and both national and international automation components work
standards are becoming increasingly together perfectly. This means
stringent. This is where SIPLUS HCS consistent data management, global
helps with smart savings – through standards, and standardized interfaces
programmable heating programs, pro- for hardware and software.
portioning of the output power rat-
ings, and optimization of production
times.

2
SIPLUS HCS – all integrated
All-in-one

SIPLUS HCS heating control systems already

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

Intelligence

Less overhead Efficient engineering Heating element cables

Since all the most important compo- A key benefit is the incorporation of individually fused
nents are integrated, cabling work is SIPLUS HCS heating controllers into The cables of every single heating
reduced by up to 70% in the control the Totally Integrated Automation element are fuse-protected with
cabinet, and there are time savings of Portal (TIA Portal): this means that all SIPLUS HCS. This makes it easy to
up to 20% with on-site commissioning automation components fall back on replace fuses by simply removing
compared to conventional solutions a shared database, a standardized the relevant plug-in fuse module.
with individual components. operating concept and centralized
services. You benefit from reduced Highly versatile
Reduced footprint engineering overhead and faster You can tailor the system’s capacity
All-in-one also reduces the space commissioning. to your requirement. You can also
requirements in the control cabinet by combine different systems. As far as
up to 80%, enabling much more com- Intelligent routine the control mode is concerned, you
pact machines. Integrated control routines reduce have a choice between half-wave, soft
current peaks in the network supply starting and phase angle control.
Intelligent diagnostics because the heating elements are
Pending faults are detected, localized, switched on with a time delay. Net-
and reported within a single process work voltage compensation enables
cycle. This minimizes downtimes variations in the input voltage to be
and optimizes plant productivity. equalized, thus ensuring the required
output power.

3
SIPLUS HCS
The “hotspots” of the family

From designing, commissioning, operation

and maintenance, SIPLUS HCS not only
saves time, costs, and resources by up
to 70 percent compared with a heating
solution comprising individual components.
SIPLUS HCS also improves the heating pro-
cess itself – for less downtimes and better
product quality.

All in one
Integration of all components and functions
for controlling electrical heating
elements in a modular system.
Less overhead
Up to 70% less wiring in the control
cabinet. Up to 20% shorter
commissioning on site
Reduced footprint
Up to 80 percent space savings in the
control cabinet.
Intelligent diagnostics
Intelligent diagnostic functions detect and
localize errors in the load circuit
immediately with  the support of the
extensive TIA system diagnostics.
Easy integration of the heating process
Comprehensive block library and
project example for simple integration of
the heating process into the automation
system.
Efficient engineering
Engineering with TIA Portal ensures
maximum integration of all components
with a shared database
Integrated load management Space savings of up to 80 percent in the
control cabinet, as well as the reduction
Load is distributed evenly across the
in cabling work …
network as far as specified setpoint values
allow.

4
 The perfect solution for any
application
There is a choice of three different
heating control systems depending
on the requirements of the heating
process such as the output power of
the heating elements, diagnostic depth
and the degree of protection.

SIPLUS HCS3200 –
the compact solution
• For controlling 400 V heating
elements
• Can be used as a distributed solution
with IP65 protection near the heating
elements
• Ideal for the linear configuration
of heater fields in the
manufacture of PET bottles

SIPLUS HCS4200 –
the flexible solution
• For controlling 45 V, 70 V,
110 V, 230 / 277 V, 400 / 480 V
heating elements
• Exceptionally space-saving and
cost-optimized heating solution
with different output modules,
I/O modules and racks

SIPLUS HCS4300 –
the powerful solution
• For controlling 230/277 V,
400/480 V heating elements
up to 60 A
• Up to 92 kW per power output module
• Highest level of production reliability
thanks to detailed, intelligent
… together with …minimize total costs
diagnostics
“Totally Integrated Automation” … by up to 70 percent.

5
SIPLUS HCS3200
Super-compact

IP65 type of protection enables use near

the heating elements,  significantly
reducing the time and effort required for
cabling.

Special application
PET blow molding

Functionality
• For controlling 400 V heating elements
• Compact design with IP65 type of
protection
• 9 power outputs up to a
maximum of 4 kW per output
• Up to 25 kW output power per device
• External fan up to 500 W can be connected
• Can be used in ambient
temperatures up to 50 °C
• Two integrated and automatically
monitored fuses per power output,
for user-friendly fault diagnostics
and increased process reliability
• Diagnostics via PROFIBUS DP
without affecting the heating
process

PROFINET

SIMATIC HMI SIMATIC

TP1200 Comfort S7-1200

PROFIBUS

SIPLUS
HCS3200

Heater
fields

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SIPLUS HCS4200
Extremely flexible

Ideal for space-saving installation

in the control cabinet – with up to
384 power outputs per PROFINET
node and up to 20 A per output.

Special applications
Drying paints and coatings, thermo-
forming – for example, car door
interiors, refrigerator door interiors
and suitcases, welding plastics and
baking of food.

Functionality
• For energy-efficient control of heating
elements with various voltages: 45 V,
70 V, 110 V, 230 / 277 V, 400 / 480 V
• Up to 48 kW output power per
power output module (POM)
• Max. 16 power outputs per POM
• Max. 24 POMs per PROFINET node
• Quick installation and flexible
expansion thanks to variety of
POMs and rack sizes
• Installation of racks directly on
rear panel of control cabinet
• Intelligent and detailed diagnosis of
SIMATIC IPC 477D heating elements even connected
SIMATIC S7-1500
in parallel
• Convenient commissioning with the
PRONETA diagnostics tool
• PROFINET / PROFIBUS communication
PROFINET • I/O modules for additional functions
SINAMICS S120
ET 200SP ET 200SP with CU320-2

Heater
fields

7
SIPLUS HCS4300
High performance up to 60 A

Offers maximum output power and

production reliability thanks to its detailed
diagnostics. Enables detection of internal
faults in the load circuit, tripped fuses and
defective heating element cables.
Monitoring includes parameters such as
network voltage and internal temperature.

Special applications
Manufacturing PET bottles, treating carbon
materials and thermoforming
of plastics

Functionality
• For controlling 230 / 277 V, 400 / 480 V heat-
ing elements
• Up to 92 kW output power per power
output module (POM) at 480 V
• Max. 60 A per output
• Max. 9 power outputs per POM
• Max. 24 POMs per
PROFINET / PROFIBUS node
• Quick mounting on busbar or
onto rear control cabinet panel
• Integrated network voltage
compensation
• Supply and return circuit of every heating
Heater field
element protected by individual fuses
• Convenient commissioning with the SIMATIC SIMATIC HMI
S7-1500 TP1500 Comfort
PRONETA diagnostics tool
• I/O modules for additional functions
SIPLUS HCS4300

SCALANCE
X200-4P IRT
PROFINET

PROFINET

SIMATIC SIMATIC SIMATIC

ET200SP SIMOTION D ET200SP ET200SP

SINAMICS G120

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Totally Integrated Automation
Efficient starting. Enhanced productivity.

Die
TheIOI/OSysteme
systemsSIPLUS
are an HCS sindpart
integral integraler
of Bestandteil von Totally
Integrated Automation
Totally Integrated (TIA), der
Automation indust­
(TIA), riellen industrial
Siemens’ Automatisierung
automation.
von Siemens. Die offene ­
S ystemarchitektur steht für das effiziente
The open system architecture stands for the efficient interaction
Zusammenwirken aller Automatisierungskomponenten.
of all automation components.

Engineered with TIA Portal

A decisive benefit is the incorporation of the SIPLUS HCS
heating control system into the TIA Portal: this means that
all automation components thus fall back on a shared data-
base, a standardized operating concept and centralized ser-
vices. You benefit from reduced engineering overhead and
faster commissioning.

Configuration control
With the configuration control, stations can be easily
modified or extended without engineering effort.

PRONETA
The PRONETA configuration and diagnostics tool simplifies
commissioning and configuration in PROFINET networks.
The topology of a network is read automatically. SIPLUS
HCS can be parameterized, controlled and tested easily with
the aid of PRONETA. It enables a wiring test during installa-
tion – with clearly arranged documentation of test results.

SIPLUS HCS program library:

Easy integration of heating processes
Using the SIPLUS HCS program library and a detailed project
example, heating processes can be easily integrated
into the automation system. Individual program blocks only
need to be adapted to the respective application.

9
Technical specifications at a glance

HCS3200 – The compact solution HCS4200 – The flexible solution

Article No. 6BK1932 ¹⁾ 6BK1942 ¹⁾
Max. output power  10 A  20 A
per output

Load voltage 400 V 45 V, 70 V, 110 V, 230/277 V, 400/480 V

Number of outputs per POM 9 max. 16

Max. output power 25,2 kW 27,7 kW at 277 V, 48 kW at 480 V

per device/POM

No. of max. possible 9 384

power outputs

Bus topology PROFIBUS DP PROFINET, PROFIBUS DP

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

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

Electrical data

Line supply 4-pin connector at the bottom 3-pin connector on the front

Power supply 400 V AC 45 / 70 / 110 / 230 / 277 / 400 / 480 V AC

Line frequency: 47 to 63 Hz Line frequency: 47 to 63 Hz
Integrated line voltage compensation Optional line voltage compensation with PM U/I

Load types Ohmic loads Ohmic loads

Wiring of the heaters Phase-Phase Phase-Phase, Phase-Neutral, Economy Circuit (wye connec-
tion)

Control mode Half-wave control with solid-state relay Half-wave control, soft start or phase angle control
that switches at zero crossing

Mechanical design

Dimensions (W x H x D) 300 x 430 x 200 mm • CIM: 43 x 285 x 136 mm, POM: 36 x 285 x 281 mm
• CIM Compact incl. Rack + Fan for 2 POM: 104 x 339 x 296 mm
• Rack for 12 POM: 488 x 285 x 293 mm
• Rack for 4 POM: 204 x 285 x 293 mm
• Fan module for 4 POM: 142 x 94 x 274 mm

Fans 1 output for external 230 V AC fan Fan module for 4 POMs each (optional)

Environmental conditions/standards

Ambient temperature 0 to +50 °C 0 to +55 °C

(operation)

Type of protection IP65 IP20

Certifications CE, cULus, KC, EAC, C-Tick, PROFIBUS CE, cULus, KC, EAC, RCM, PROFINET, PROFIBUS

1) You can find up-to-date ordering data as well as our terms of sale and delivery on the Internet at siemens.com/industrymall

10
 References

HCS4300 – The powerful solution

6BK1943 ¹⁾
Geiss AG – more precise thermoforming machines thanks to an industrial solution
60  A from Siemens

230 / 277 V, 400 / 480 V

max. 9

53 kW at 277 V, 92 kW at 480 V

216

PROFINET, PROFIBUS DP

Implicit voltage diagnostics for detecting internal and

external faults, e.g. wire break, tripped fuse, defective
Dieffenbacher GmbH - fastest tape laying system in the world achieves high product
heating elements, current diagnosis quality through consolidation
PM for temperature measurement, DI/DO, current and
voltage measurement

Rear busbar or 3-pin terminal

230 / 277 / 400 / 480 V AC

Line frequency: 47 to 63 Hz
Integrated line voltage compensation

Ohmic loads

Phase-to-phase, phase/neutral, closed delta

Half-wave control, soft start or phase angle control

Metrik Sondermaschinenbau e. K. – efficient use of space and maximum precision

in plastics welding

• CIM: 56 x 285 x 136 mm

• POM busbar mounting: 104 x 340 x 250 mm
• POM rear-panel mounting: 104 x 344 x 217 mm

Fan integrated

0 to +55 °C

IP20

CE, cULus, KC, EAC, RCM, PROFINET, PROFIBUS

Vesper GmbH & Co. KG - hot solution for cool automotive interiors:
laminating-edge-folding system without sliders

11
Turn up the heat:
SIPLUS HCS

• All in one
• Less overhead
• Reduced footprint
• Intelligent diagnostics
• Easy integration of the heating process
• Efficient engineering
• Integrated load management

Find out more:

siemens.com/hcs

Published by
Siemens AG 2020

Digital Factory
P.O. Box 48 48
90026 Nuremberg, Germany

For the U.S. published by

Siemens Industry Inc.

100 Technology Drive

Alpharetta, GA 30005
United States

Article No.: DFFA-B10103-03-7600

Printed in Germany
Dispo 46371
75624 WS 03200.2

Subject to changes and errors. The information given

in this document only contains general descriptions
and/or performance features which may not always
specifically reflect those described, or which may un-
dergo modification in the course of further develop-
ment of the products. The requested performance
features are binding only when they are expressly
agreed upon in the concluded contract.

Siemens provides automation and drive products with

industrial security functions that support the secure
operation of plants or machines. They are an
important component in a holistic industrial security
concept. With this in mind, our products undergo
continuous development. We therefore recommend
that you keep yourself informed with respect to our
product updates. You can find more information at:
http://support.automation.siemens.com where you
can also register for a product-specific newsletter.

For the secure operation of a plant/machine, it is also

necessary to take suitable protective measures (e.g.
cell protection concept), and to integrate the auto-
mation and drives components into a holistic, state-
of-the-art industrial security concept for the entire
plant/machine. Products used from other manufac-
turers should also be taken into account here.
For more information, go to:
www.siemens.com/industrialsecurity

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