Industrial heating processes extremely precise and efficient

Transcription

1 Industrial heating processes extremely precise and efficient Heating Control Systems for controlling electrical heating elements SIPLUS HCS Answers for industry.

2 SIPLUS HCS the answer to sensitive thermal requirements in industry In manufacturing processes where temperature is a critical parameter, even deviations of just a few degrees can cause major quality problems. To maintain precision and minimize the rejection rate, highly accurate, reliable and individual control of electrical heating elements is essential. Therefore, users worldwide and in numerous industries - from automotive to food & beverage rely on SIPLUS HCS Heating Control Systems. This has been the intelligent answer to sensitive thermal requirements in industry for more than 20 years. Heating processes: extremely precise and straight to the point Almost all industrially manufactured products are treated thermally. Even small deviations in the thermal process can result in enormous impairment of product quality. In order to increase the quality and quantity of a thermally treated product, it is important to be able to accurately focus the required energy with regard to time and space. SIPLUS HCS guarantees extremely precise control of the ohmic loads, such as infrared heating elements. Heating processes: extremely efficient Energy efficiency is also becoming more and more important in mechanical and plant engineering. On the one hand, because energy is a major cost factor and on the other hand, because increasingly stringent national and international standards and regulations must be met. By using intelligent SIPLUS heating controls, you can save heating energy compared to conventional solutions. The optimized design of the controller reduces the power dissipation. A range of variable heating programs allows fine dosing of the output power and optimization of the production times. Tailor-made solutions thanks to modular and compact design Our heating control systems always ensure the right temperature at the right place. The high-performance, compact systems thus make a significant contribution to optimal product quality. No matter how many heating elements need to be controlled or how much output power is required, the extremely versatile SIPLUS HCS can be expanded modularly. This provides maximum flexibility to meet the specific requirements. Significantly lower overheads from planning to operation The SIPLUS HCS heating control systems reduce the time, cost and resources needed for configuration, commissioning, operation and maintenance. This is ensured by: Simple integration into existing automation systems such as SIMATIC and SIMOTION Minimal wiring and user-friendly engineering Intelligent diagnostic functions for rapid detection of faults Service-friendly design with ready-to-use function and data blocks Reduced volume in the control cabinet with up to 50% space savings 2

3 Increased productivity, less wastage With the precision SIPLUS HCS heating control systems you not only improve your energy balance, but also benefit from savings in materials and reduced waste: Minimization of material waste thanks to early detection of faults Precise control of the heating elements increases product quality and reduces production rejects From standard to customized Even though the standard products from our SIPLUS HCS product series cover a wide range of applications, sometimes the requirements are just too special. Therefore, we offer customer-specific solutions. This involves defining all of the required equipment characteristics in close cooperation with the customer. Part of Totally Integrated Automation SIPLUS HCS is part of Totally Integrated Automation, our open system architecture for company-wide automation. This results in a host of benefits: Easy to combine with any PROFIBUS DP master Can be realized as open or closed-loop control design with SIMATIC or SIMOTION User-friendly configuration Fast commissioning Fast and powerful diagnostics Worldwide support and service to the Siemens standard 3

4 SIPLUS HCS Heating Control Systems for all areas of application These days, there is hardly an industrially manufactured product that does not at some stage undergo thermal treatment. As a partner to industry, Siemens therefore offers a comprehensive range of heating control systems. The SIPLUS HCS systems provide extremely precise control for thermal processes in many sectors and branches of industry. The perfect solution for a wide variety of applications: Food & beverage industry Whether taste, color, consistency or concentration of ingredients in the food & beverage industry, SIPLUS HCS significantly contributes to perfect product characteristics such as when roasting nuts, drying foodstuffs or pre-baking prepared meals. SIPLUS HCS also optimizes plant efficiency in food packaging, whether in the manufacture of PET bottles, the production of chocolate trays or wrapping of foodstuffs. Photovoltaic industry In the photovoltaic industry, SIPLUS HCS ensures the optimum temperature profile. This levers maximum efficiency for solar cells, such as used in substrate drying or preheating in diffusion and sputtering processes. Automotive industry Especially in the automotive industry, a variety of materials undergo thermal processes that require extremely precise control to ensure the best possible end product, as in the drying of paints, welding of fuel tanks or heating of plastic strips, for example. Plastics industry The process and product temperature in the plastics industry, e.g. in thermoforming, blow molding or extrusion, are an important, even crucial factor influencing the quality of the final product. SIPLUS HCS can create the right conditions to help companies achieve a high level of quality in their production lines. 4

5 SIPLUS HCS Highlights at a glance The perfect solution for a wide variety of requirements: Four different heating control systems are available to choose from depending on your requirements, for example regarding the output power of the heating elements, diagnostics depth and type of protection. SIPLUS HCS300I the small one Variable output power with indirect control of electrical heating elements, e.g. via solid-state contactors Convenient control using temperature controller software and integrated temperature inputs SIPLUS HCS3200 the compact solution Can be used as a distributed solution with IP65 protection nearby the heating elements Ideal for the linear configuration of heat emitter arrays SIPLUS HCS716I the choice for flexibility Cost-effective, space-saving solution with a variety of power output modules Integrated diagnostics for detection of internal and external faults SIPLUS HCS724I the powerful solution Almost unlimited number of power outputs Highest level of production reliability thanks to comprehensive, detailed and integrated diagnostics High energy efficiency with reduced costs Fast, precise and efficient control of industrial heating systems Up to 50% space savings in the control cabinet compared to conventional solutions Significantly increased plant availability through detailed and intelligent diagnostics and localization of possible faults Considerable reduction of engineering and wiring overhead compared to conventional solutions Up to 15% less power loss due to finely-tuned output electronics Low costs for modernizing existing plants and increasing their efficiency Easy integration into existing automation systems, e.g. SIMATIC and SIMOTION 5

6 SIPLUS HCS300I the small one SIMATIC HMI SIMATIC S7-300 with TCP 3000 PROFIBUS SIPLUS HCS300I SIRIUS SSR SIMATIC I/O SIMATIC IPC 477C Band heaters e.g. from extruders Application example: System with 8 temperature sensors, 12 digital outputs, current/voltage detection The small SIPLUS HCS300I controls electrical heating elements using solid-state relays or contactors. Together with the user-friendly TCP 3000 temperature controller software, it is the ideal solution for controlling heat processes. Main areas of application Extrusion, injection molding Functionality Variety of power classes can be controlled: Current detection: A Voltage detection: V SIRIUS solid-state contactors: A Simple configuration and commissioning via STEP 7 Communication to higher-level automation system via PROFIBUS DP Modules and design Available modules: Basic device (GG) for communication with the higherlevel programmable controller Digital module (DM): 6 short-circuit proof outputs per DM for switching the solid state contactors (SSR) Temperature module (TM): 2 or 4 measuring inputs per TM, depending on wire connection Current detection module (IM) and current/voltage detection module (UM) for current detection using through-hole technology Decoupling module (DCM) Max. 4 digital modules and 4 temperature modules can be connected per basic device Power supply 24 V DC Interfaces PROFIBUS DP slave with 12 Mbit/s of solid-state contactors on digital module via terminals or plugs Temperature controller software TCP 3000 The temperature controller software TCP 3000 enables convenient and economical operator control and monitoring of heating processes in production. TCP 3000 provides standard user pages which are easy to customize using the WinCC visualization software. 6

7 SIPLUS HCS3200 the compact solution PROFINET SIMATIC HMI TP1200 Comfort SIMATIC S PROFIBUS SIPLUS HCS3200 Heater field Application example with SIMATIC and SIPLUS HCS3200 The compact SIPLUS HCS3200 with high IP65 protection rating can be used nearby the heating elements. This enables you to significantly reduce the amount of cabling required. Main areas of application PET blow molding, plastics processing, food & beverage, automotive Functionality Compact design with IP65 type of protection 9 power outputs up to max. 4 kw per output Can be used in ambient temperatures of up to 50 C option for external fan up to 500 W Simple configuration and commissioning using sample program provided for SIMATIC and SIMOTION Two automatically monitored integrated fuses per power output for easy fault diagnostics and enhanced process safety Voltage diagnostics via PROFIBUS DP without affecting the heating process Interfaces of the heating elements, external 230 V AC fan and line voltage via HAN plug of PROFIBUS DP via HAN-Brid plug Power outputs Max. 9 power outputs 2 x 9 power output fuses in easy-to-replace fuse holders Output power Max. 4 kw per power output (at T u = 50 C) Max. 25 kw per device All connections located on easy-to-access underside of the SIPLUS HCS3200 7

8 SIPLUS HCS716I the choice for flexibility SIMOTION D with SIMATIC MP377 PROFIBUS DP SINAMICS S120 with servomotors SIPLUS HCS716I Application example with SIMOTION, SINAMICS and SIPLUS HCS716I Heater field The SIPLUS HCS716I offers an unrivaled price-performance ratio and its flexibility results in substantial space savings. Main areas of application Thermoforming, drying ovens, packaging machines Functionality Enormously compact, yet particularly flexible due to: 3 different power output modules - from 650 W to 2.3 kw per power output Variety of racks with 4 or 12 slots and different mounting options Extremely space-saving: Up to 176 kw switching capacity on only 0.2 m² Up to 192 power outputs on only 0.2 m² Simple parameterization of heating elements by group formation Easy configuration and commissioning using supplied function and data block Integrated, automatically monitored backup for each power output enables convenient troubleshooting and improved process safety Explicit voltage diagnostics via PROFIBUS DP Simple connection to PROFIBUS I/O via GSD file Interfaces of the heating elements via two front panel 8-pin connectors PROFIBUS DP slave with 12 Mbit/s Serial port for firmware update of power supply via 3-pin connector or terminal Design 19" standard rack with up to 12 plug-in power output modules (LA) Mounting via swing frame or mounting frame direct on the carrier plate in the control cabinet Power outputs Max. 192 power outputs per rack Max. 4 racks per PROFIBUS master Output power Max. 2.3 kw per power output Max. 176 kw per rack 3 different power output modules 8

9 SIPLUS HCS724I the powerful solution PROFIBUS DP SIMATIC S7-300 (e.g. with CPU 317-2DP) SIPLUS HCS724I SIMATIC MP277 Tunnel drying oven Application example with SIMATIC S7 and SIPLUS HCS724I (ZA724I with 1 LA724I HP and 1 LA724I) The powerful SIPLUS HCS724I offers an almost unlimited number of outputs with high output power. Three power output modules enable tailored system expansion. Main areas of application Thermoforming, tunnel drying ovens, blow molding Functionality Direct control of heating elements up to 2.3 kw at 230 V or 4 kw at 400 V Indirect control of heating elements: depending on the connected solid-state contactors Extremely space-saving: Up to 512 kw switching capacity on only 0.4 m² Up to 384 power outputs on only 0.4 m² Even distribution over all connected loads Line voltage compensation and power calculation via NE724 (optional) Simple parameterization of heating elements by group formation Integrated front-panel power output fuses easy replacement High-performance diagnostic function Explicit voltage and current diagnostics via PROFIBUS DP Simple connection to PROFIBUS I/O via GSD file Interfaces of heating elements via front-panel connectors PROFIBUS DP slave with 12 Mbit/s Serial port for firmware update Design 3 different power output modules Each central interface (ZA) can control up to 16 power modules (LA) Multiple central interfaces can be operated in a network on a PROFIBUS master Safe and fast incoming supply using busbar system Small footprint: m² per ZA/LA Power outputs Max. 384 power outputs per central interface Copper busbars for fast installation of incoming supply 9

10 SIPLUS HCS - Technical specifications Order No. 6BK1700* 1) HCS300I HCS3200 Maximum output power per output Basic device: 3 relay outputs each with 5 A DM6: 6 outputs each with 0.5 A 4 kw Max. output power per device 25.2 kw Max. number of power outputs Max. number of temperature inputs Per DM6: 6 digital outputs Per basic device 4 DM6 Per TM4: 4 temperature inputs Per basic device 4 TM4 Bus topology PROFIBUS DP (max. 12 Mbit/s) PROFIBUS DP (max. 12 Mbit/s) Diagnostics Possible via current or current/voltage detection modules (evaluation in higher-level controller) 9 Implicit voltage diagnostics via PROFIBUS DP for detecting internal and external faults, e.g. wire break, tripped fuse, defective heating elements Mechanical design Dimensions (H x W x D) Module size without DIN rail Basic device: 106 x 45 x 120 mm TM4: 102 x 22.5 x 120 mm DM6/DCM: 92 x 22.5 x 120 mm 430 mm x 300 mm x 200 mm Fan 1 fan output: External 230 V AC fan with optional connection of max. 500 W Electrical specifications Rack/ Central interface/ Power line/ Power supply Power supply 24 V DC (20.4 V to 28.8 V) Connection via terminals Power line via 4-pin HAN plug Rated voltage 400 V AC (360 V to 440 V) Line frequency: 47 Hz to 63 Hz Line voltage compensation Load types Control mode (percentage accuracy) Fuse Control of semiconductor switching devices, contactors, relays Control of digital outputs via high-level PLC Not required because digital outputs short-circuit proof Electrical heating elements with max. 15 times cold current in the 1st half-wave Half-wave control solid-state relay that switches at zero crossover Short-circuit and overload protection of power outputs: 2 x 9 fuses 16 A in forward and reverse line HCS3200 with fan output: 1 fuse 4 A as short-circuit and overload protection Easy to replace fuses in closed fuse holders Environmental conditions/standards Ambient temperature (operation) 25 C to +60 C 0 C to +50 C Transport / storage temperature 40 C to +80 C 40 C to +70 C Relative humidity Max. 95% at +25 C Max. 95% at +25 C Certifications CE, PROFIBUS, KCC, GOST R, culus, C-Tick CE, PROFIBUS, KCC, GOST R, curus, C-Tick 10 Subject to technical changes/improvements. 1) Current order data as well as terms and conditions of sale and delivery can be found in the IC 10 catalog and on the Internet at siemens.de/industrymall

11 Max. output power per output HCS716I LA716: 16 power outputs; max kw (230 V) LA716I: 16 power outputs; max kw (230 V) LA716I HP: 8 power outputs; max. 2.3 kw (230 V) HCS724I LA724I: 24 power outputs; 230 V in Y mode; max kw LA724I HP: 12 power outputs max. 2.3 kw (230 V in Y mode); max. 4 kw (400 V in Δ mode) LA724I SSR: 24 control outputs to external solid-state relays 24 inputs for easy diagnostics Max. number of power outputs 192 (per rack) as 1 PROFIBUS slave 384 (per central interface) as 1 PROFIBUS slave Max. number of temperature inputs Bus topology PROFIBUS DP (max. 12 Mbit/s) PROFIBUS DP (max. 12 Mbit/s) Diagnostics Mechanical design Dimensions (H x W x D) Explicit voltage diagnostics via PROFIBUS DP for detecting internal and external faults, e.g. wire break, tripped fuse Dimensions swing frame: 266 x 483 x 350 mm Dimensions mounting frame with flange: 310 x 520 x 328 mm Dimensions mounting frame without flange: 4 slots: 310 x 226 x 290 mm 12 slots: 310 x 520 x 290 mm LA716: Double Eurocard format Explicit voltage and current diagnostics via PROFIBUS DP; voltage diagnostics for detecting internal and external faults, e.g. wire break, tripped fuse; current diagnostics for error detection with parallel operation of heating elements ZA724I: 480 x 50 x 210 mm LA724I / LA724I HP / LA724I SSR: 480 x 50 x 210 mm Fan Fan subassembly with 3 fans (optional) Fan module for 2 modules (optional) Electrical specifications Rack/ Central interface/ Power line/ Power supply Load types Control mode (percentage accuracy) Fuse Environmental conditions/standards Power supply via 2-pin terminal strip Rated voltage 230 V AC (187 V to 264 V); Line frequency: 47 Hz to 63 Hz Electrical heating elements with max. 15 times cold current in the 1st half-wave Full-wave control with triacs that switch at zero crossover Short-circuit and overload protection of power outputs: LA716: 16 fuses 5 A LA716I: 16 fuses 5 A LA716I HP: 8 fuses 10 A Fuses in open fuse holders Ambient temperature (operation) 0 C to +55 C 0 C to +55 C Transport / storage temperature 40 C to +70 C 40 C to +70 C Relative humidity Max. 95% at +25 C Max. 95% at +25 C Power supply via front-panel busbar system, rated voltage 230 V AC (187 V to 264 V); Line frequency: 47 Hz to 63 Hz Line voltage compensation and power calculation via NE 724 (optional) Electrical heating elements with max. 15 times cold current in the 1st half-wave Half or full-wave control with triacs that switch at zero crossover Phase fuses: LA724I: 3 fuses 32 A LA724I HP: 3 fuses 40 A Short-circuit and overload protection of power outputs: LA724I: 24 fuses 5 A LA724I HP: 12 fuses 16 A Certifications CE, PROFIBUS, KCC, GOST R CE, PROFIBUS, KCC, GOST R 11

12 Additional information: about the SIPLUS HCS heating control systems is available on the Internet at siemens.com/siplus-hcs about SIRIUS solid-state switching devices is available on the Internet at siemens.com/sirius-switching Technical Assistance Tel.: +49 (911) Siemens AG Industry Sector Control Components and Systems Engineering P.O. Box FÜRTH GERMANY Subject to change without prior notice 09/2012 Order No.: E80001-A202-P320-X-7600 Dispo WÜ/43206 MI.CE.SP.XXXX WS Printed in Germany Siemens AG 2012 The information provided in this brochure contains me re ly general descriptions or characteristics of per for m ance which in case of ac tual use do not always ap ply as described or which may change as a result of fur ther de ve lopment of the products. An obligation to provide the respective characteristics shall only exist if ex pressly agreed in the terms of contract. All product designations may be trademarks or product na mes of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.