SIPLUS HCS724I
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SIPLUS
Heater controller
SIPLUS HCS724I
Operating Instructions
09/2011
J31069-D0430-U001-A5-7618
Introduction
1
Safety Instructions
2
Description of the
components
3
Mounting
4
Connection
5
Start-up
6
Functions
7
Alarm, error and system
messages
8
Maintenance and service
9
Technical specifications
10
Order numbers
11
Appendix
A
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
J31069-D0430-U001-A5-7618
Ⓟ 09/2011
Copyright © Siemens AG 2008.
Technical data subject to change
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 3
Table of contents
1 Introduction................................................................................................................................................ 7
2 Safety Instructions ..................................................................................................................................... 9
3 Description of the components ................................................................................................................ 11
3.1 HCS724I overview .......................................................................................................................11
3.1.1 Field of application .......................................................................................................................11
3.1.2 Installation....................................................................................................................................12
3.1.3 System components ....................................................................................................................14
3.2 ZA 724 central interface module..................................................................................................17
3.2.1 ZA 724 features ...........................................................................................................................17
3.2.2 ZA 724 layout...............................................................................................................................18
3.2.3 ZA 724 connectors.......................................................................................................................20
3.3 LA 724I power output module......................................................................................................21
3.3.1 LA 724I features...........................................................................................................................21
3.3.2 LA 724l design .............................................................................................................................22
3.3.3 LA 724I connectors ......................................................................................................................23
3.3.4 Performance profile of the LA 724I ..............................................................................................24
3.4 LA 724I HP power output module................................................................................................26
3.4.1 LA 724I HP features.....................................................................................................................26
3.4.2 LA 724I HP design .......................................................................................................................27
3.4.3 LA 724I HP connectors ................................................................................................................28
3.4.4 Performance profile of the LA 724I HP ........................................................................................29
3.4.4.1 Star connection ............................................................................................................................29
3.4.4.2 Delta connection ..........................................................................................................................31
3.5 LA 724I SSR load switching unit..................................................................................................32
3.5.1 LA 724I SSR features ..................................................................................................................32
3.5.2 LA 724I SSR layout......................................................................................................................33
3.5.3 LA 724I SSR connectors..............................................................................................................34
3.6 NE 724 line-voltage sensing submodule .....................................................................................35
3.6.1 Features of the NE 724................................................................................................................35
3.6.2 NE 724 layout...............................................................................................................................36
3.6.3 NE 724 connectors ......................................................................................................................36
3.7 LM 724 fan module ......................................................................................................................37
3.8 SM 724I current measuring module.............................................................................................38
4 Mounting.................................................................................................................................................. 39
4.1 Requirements for the mounting location......................................................................................39
4.2 Setting the bus address ...............................................................................................................40
4.3 Installation of components on the mounting panel ......................................................................41
4.4 Installing the optional fan module ................................................................................................43
Table of contents
SIPLUS HCS724I
4 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
5 Connection .............................................................................................................................................. 47
5.1 Connecting the PROFIBUS DP field bus .................................................................................... 47
5.2 Connecting the parallel bus......................................................................................................... 48
5.3 Connecting the power supply to the ZA 724............................................................................... 51
5.4 Connecting heat emitters ............................................................................................................ 52
5.4.1 LA 724I/LA 724I HP .................................................................................................................... 52
5.4.2 LA 724I SSR ............................................................................................................................... 58
5.4.3 Connecting the NE 724............................................................................................................... 63
6 Start-up.................................................................................................................................................... 65
6.1 Hardware requirements............................................................................................................... 65
6.2 Software requirements................................................................................................................ 65
6.3 Incorporating the GSD file........................................................................................................... 67
6.4 Procedure for (standard) commissioning.................................................................................... 68
7 Functions................................................................................................................................................. 69
7.1 Initialization (start-up).................................................................................................................. 69
7.2 Operating the HCS724I............................................................................................................... 71
7.2.1 Manipulated value calculation..................................................................................................... 72
7.2.2 Mains compensation ................................................................................................................... 75
7.2.3 Operation of the power output modules/load switching units ..................................................... 77
7.3 Monitoring functions of the HCS724I .......................................................................................... 79
7.3.1 Cyclic monitoring of the outputs of the LA 724I xx...................................................................... 80
7.3.2 Monitoring of the outputs of the LA 724I xx by means of a "job" ................................................ 85
7.3.3 Controller outputs of the LA 724I xx............................................................................................ 85
7.3.4 Temperature at the power outputs.............................................................................................. 86
7.3.5 24 V on the load controllers ........................................................................................................ 86
7.3.6 Communication ........................................................................................................................... 87
7.4 Data exchange between an S7-DP master and ZA 724............................................................. 88
7.4.1 STEP 7 project provided ............................................................................................................. 88
7.4.2 Software structure....................................................................................................................... 90
7.4.3 Data blocks ................................................................................................................................. 92
7.4.3.1 DB_HS_INIT................................................................................................................................ 92
7.4.3.2 DB_HS_KANAL........................................................................................................................... 94
7.4.3.3 DB_HS_FELD ............................................................................................................................. 95
7.4.3.4 DB_HS_DIAG.............................................................................................................................. 96
7.4.3.5 DB_HS_IBS................................................................................................................................. 98
7.4.4 Functions and function blocks..................................................................................................... 99
7.4.4.1 FC_HS_INIT ................................................................................................................................ 99
7.4.4.2 FC_HS_AUFTRAG.................................................................................................................... 101
7.4.4.3 FC_HS_NE................................................................................................................................ 103
7.4.4.4 FC_HS_BETRIEBSART............................................................................................................ 104
7.4.4.5 FC_HS_RESET......................................................................................................................... 104
7.4.4.6 FB_HS_ZYKL ............................................................................................................................ 105
7.4.5 Generation of data blocks ......................................................................................................... 107
7.4.5.1 Prerequisites ............................................................................................................................. 107
7.4.5.2 Function..................................................................................................................................... 107
Table of contents
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 5
7.4.5.3 Description of the input fields.....................................................................................................108
7.5 Data exchange between a non-S7-DP master and ZA 724 ......................................................113
7.5.1 PROFIBUS DP interface............................................................................................................113
7.5.2 Datagram data ...........................................................................................................................114
7.5.3 Datagram sequence...................................................................................................................115
7.5.4 Cyclic data..................................................................................................................................116
7.5.5 Requests (datagram data) .........................................................................................................117
7.5.6 Request 01: Read module information ......................................................................................118
7.5.7 Request 02: Download configuration parameters......................................................................119
7.5.8 Request 03: Execution of tests ..................................................................................................120
7.5.9 Requests 04, 05 and 06: Transfer of channel setpoint values ..................................................120
7.5.10 Job 07: Field allocation ..............................................................................................................121
7.5.11 Job 08: Field factor for production mode ...................................................................................122
7.5.12 Job 09: Field factor for standby mode .......................................................................................122
7.5.13 Request 10: Channel diagnostics ..............................................................................................123
7.5.14 Request 11: Field diagnostics....................................................................................................124
7.5.15 Request 20: General diagnosis..................................................................................................124
7.5.16 Request 21: Channel diagnostics ..............................................................................................125
7.5.17 Request 22: Channel warning....................................................................................................126
7.5.18 Request 23: Initiate diagnostics cycle........................................................................................126
7.5.19 Request 30: Read the actual manipulated variable of the channel ...........................................127
7.5.20 Job 31: Read out current actual channel values........................................................................127
7.5.21 Request 32: Read actual temperature values ...........................................................................128
7.5.22 Request 40: Reset .....................................................................................................................128
8 Alarm, error and system messages ....................................................................................................... 129
8.1 Diagnostics with LED display.....................................................................................................129
8.1.1 LED indications on the ZA 724 ..................................................................................................129
8.1.2 LED indications on the LA 724I/LA 724I HP..............................................................................131
8.1.3 LED indications on the LA 724I SSR .........................................................................................132
8.2 Error messages in the S7 environment .....................................................................................133
8.3 Error messages in the non-S7 environment ..............................................................................136
8.4 Troubleshooting .........................................................................................................................138
9 Maintenance and service....................................................................................................................... 141
9.1 Loading the firmware for the HCS724I ......................................................................................141
10 Technical specifications......................................................................................................................... 143
10.1 Technical data ZA 724...............................................................................................................143
10.2 Technical data for NE 724 .........................................................................................................143
10.3 Technical data of the LA 724I ....................................................................................................144
10.4 Technical data of the LA 724I HP ..............................................................................................146
10.5 Technical data of the LA 724I SSR............................................................................................148
10.6 Technical data of the LM 724.....................................................................................................149
10.7 Technical data of the SM 724I ...................................................................................................149
10.8 Ambient conditions for all HCS724I components ......................................................................150
Table of contents
SIPLUS HCS724I
6 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
11 Order numbers....................................................................................................................................... 153
11.1 Components of the HCS724I .................................................................................................... 153
11.2 Accessories............................................................................................................................... 153
A Appendix................................................................................................................................................ 155
A.1 Recycling and disposal ............................................................................................................. 155
A.2 Service & Support ..................................................................................................................... 155
Index...................................................................................................................................................... 157
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 7
Introduction 1
Contents of this documentation
This document explains the functions of the SIPLUS HCS724I heater controller and its
intended use.
Further documentation
The following manuals describe how you operate the HCS724I with the PROFIBUS DB field
bus and how you can design your user program with the
STEP 7
programming software:
● Manual for PROFIBUS networks
● Manual entitled
Programming with STEP 7
V5.x
You will also need the manual for the DP master used.
Introduction
SIPLUS HCS724I
8 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 9
Safety Instructions 2
WARNING
Before working on the heater controller or the connected components, ensure the system is
disconnected.
WARNING
In the switching cabinet, voltages of > 60 V occur. Suitable safety precautions must
therefore be taken before commissioning and maintenance work.
The use of a residual current protective device as the sole protection against indirect
touching is forbidden.
Do not touch the metal housing of the modules with bare fingers. Danger of burning due
to hot surfaces!
Fuse replacement
WARNING
Before changing a fuse, you must isolate the load circuit from the supply.
CAUTION
Use only the prescribed fuse types. If you use the LA 724I/LA 724I HP with fuses that are
not permissible, the device could be destroyed.
Safety Instructions
SIPLUS HCS724I
10 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 11
Description of the components 3
3.1 HCS724I overview
3.1.1 Field of application
The HCS724I heater controller is used for controlling heat emitters used in industry. One
preferred use of the HCS724I is to control heat emitters in the areas of thermoforming and
blow molding. It is also used for paint dryers in the automotive industry, for plastics welding
and for extrusion.
In principle, the HCS724I can be used wherever resistive loads have to be switched and
monitored.
Description of the components
3.1 HCS724I overview
SIPLUS HCS724I
12 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.1.2 Installation
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The main component of the product is the central interface module (ZA 724), which enables
the unit to be expanded by a maximum of 16 power output modules/load switching units
(LA 724I xx). For different power classes, there are three types of power output
modules/load switching units available:
● The LA 724I for controlling 24 channels with a power output of 1150 W per channel
● The LA 724I HP for controlling 12 channels with a power output of 2300 W (230 V) / 4000
W (400 V) per channel
● The LA 724I SSR with 24 channels for switching solid state relays (SSR; external circuit-
breakers) with a power output per channel of up to 20 kW at 230 V/36 KW at 400 V
Description of the components
3.1 HCS724I overview
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 13
As a DP slave, the ZA 724 communicates with the higher-level controller (DP master) via the
PROFIBUS DP field bus.
Note
Several HCS724I units acting together can be operated from one DP master, whereby the
channels are counted serially.
The size of the HCS724I group greatly depends on the resources available in the DP master.
The control information generated by the ZA 724 is transferred via a parallel bus between
the components, and the respective status of the power output modules is reported back to
the ZA 724 in the same way. As an option, a line-voltage sensing submodule (NE 724) can
be integrated in order to carry out line-voltage compensation.
The individual components are built into a metal housing and are mounted on a support plate
in the switching cabinet.
Customized solutions without a metal housing are possible on request.
Description of the components
3.1 HCS724I overview
SIPLUS HCS724I
14 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.1.3 System components
A complete system includes the following components:
● A higher-level controller acting as the PROFIBUS DP master, e.g. SIMATIC S7 (with e.g.
CPU 315-2 DP or CPU 414-2 DP)
● A ZA 724 central interface module acting as a PROFIBUS DP slave with integrated µP
system for controlling the LA 724I xx power output modules/load switching units
● 1 to 16 LA 724I xx power output modules/load switching units
● NE 724 line-voltage sensing submodule (optional)
● SM 724I current measuring module (optional)
● Operator panel (optional)
Description of the components
3.1 HCS724I overview
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 15
● Heat emitter field/heat emitter
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Figure 3-2 Example of how the components of the heater controller interact with each other
Description of the components
3.1 HCS724I overview
SIPLUS HCS724I
16 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Interconnecting HCS724I units
Several HCS724I units, each with one ZA 724 central interface module and with a maximum
of sixteen LA 724I power output modules can be connected to a PROFIBUS DP master.
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Figure 3-3 Example of operation of an interconnected group of HCS724I devices
Description of the components
3.2 ZA 724 central interface module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 17
3.2 ZA 724 central interface module
3.2.1 ZA 724 features
The ZA 724 central interface module has the following features:
● Module installed in a metal housing
● Possibility of connecting a maximum of 16 power output modules/load switching units,
whereby the LA 724I, LA 724I HP and LA 724I SSR devices can be connected in any
combination
● Communication with the higher-level system via the PROFIBUS DP interface
● PROFIBUS DP addresses ranging from 00 to 99 can be set with rotary switches
● Bus transfer rates of up to 12 Mbaud
● Optional: expansion with the NE 724 line-voltage sensing submodule for integrated
compensation of fluctuations in the line voltage and for power calculation purposes
● Automatic detection of the line frequency
● Control of up to 384 channels in half-wave and full-wave mode
● Uniform load distribution over all channels and over all the HCS724I devices operated
together
● Operation of the outputs without direct component
● Monitoring of all power outputs and all connected load switching units
● Parameterization of channel control and diagnostics
Description of the components
3.2 ZA 724 central interface module
SIPLUS HCS724I
18 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.2.2 ZA 724 layout
Front view of the ZA 724
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The picture above is a front view of the central interface module.
Description of the components
3.2 ZA 724 central interface module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 19
The central interface module contains the following components:
● LED indicators showing the station status
● PROFIBUS DP slave interface (electrically isolated by optocouplers)
● 2 rotary switches for setting the PROFIBUS DP address (see "Setting the bus address")
(Page 40)
● RS 232 serial interface (non-floating) for firmware updates
● Parallel bus interface to the power output modules/load switching units
● Terminals for mains connection
● Internal voltage supply to the power output modules/load switching units
● Floating voltage supply for the PROFIBUS DP slave interface
Voltage supply
The input AC voltage of 230 V (min. 187 V, max. 264 V) is transformed with an integrated
transformer to an AC voltage of 24 V. A controlled DC voltage of 5 V is then generated from
this for the module logic.
When the voltage supply is switched on, an automatic reset signal for the µP system is
generated. As a result, the power output modules and also the processor are reset to a
defined operating state.
For the PROFIBUS DP, there is a floating voltage supply which is obtained from the
controlled 5 V voltage.
Mains supply synchronization
In order to ensure synchronization of the power output modules/load switching units with the
connected mains supply, the system is synchronized with Phase L1.
Description of the components
3.2 ZA 724 central interface module
SIPLUS HCS724I
20 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.2.3 ZA 724 connectors
The ZA 724 has five plug-in connections (see table below) and one slot for the optional line-
voltage sensing submodule NE 724 (see also Figure 3-4 Front view of the ZA 724
(Page 18)).
Table 3- 1 Plug-in connectors of the ZA 724
Labeling Function
Connection of the LA 724 to the parallel bus
Power output modules 1
to 8:
right-hand-side connector (1st row)
724 bus
Power output modules 9
to 16:
left-hand-side connector (2nd row)
PROFIBUS DP Connection of higher-level system via PROFIBUS DP
RS 232 Sub-D connector for connection to PC
L1x Terminal for connection of phase L1
N Terminal for connection of the neutral conductor
Connection of the protective conductor via a conductor rail
Description of the components
3.3 LA 724I power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 21
3.3 LA 724I power output module
3.3.1 LA 724I features
The LA 724I power output module has the following features:
● Module integrated in a metal housing
● 24 power channels with a maximum of 1150 W switching power per output at 230 V AC,
grouping of 8 outputs per phase
Due to the different physical properties of heat emitters, restrictions can be imposed on their
permissible switching capacity depending on the type of heat emitter.
Short-wave halogen or infrared emitters ("flash emitters") have a high starting current due to
their relatively low cold resistance. The starting current can be several times the rated
current, especially during the first half waves.
Overloading of the internal fuses of the LA 724I can occur depending on the number of
switching operations as well as the duration of switching operations and pause times.
NOTICE
Restriction of the switching power
If flash emitters with an output of more than 750 W at 230 V are used, switching operations
can result in extremely high currents and the triggering of the channel fuses.
We therefore recommend that you have these emitters gauged by Siemens AG.
● 5 A fuse, accessible from outside, for each power channel
● Internal protection for each phase with 32 A
Note
The total current per phase must not exceed 32 A.
● Connection of the phases via conductor rails
● Connection of the heat emitters via front connectors
Note
The mating connectors for connection of the heat emitters are not included in the scope
of supply. You have to order these separately.
● No settings have to be made on the module
● Diagnostics feature for detecting internal and external faults
● Diagnostics feature for detecting an emitter failure where emitters are connected in
parallel; this is done by means of current measurement
● Two-stage temperature monitoring by NTC thermistors (alarm stage, shutdown stage)
● LED indicators for channel faults and temperature monitoring
Description of the components
3.3 LA 724I power output module
SIPLUS HCS724I
22 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.3.2 LA 724l design
Front view of the LA 724I
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Figure 3-5 Front view of the LA 724I
Description of the components
3.3 LA 724I power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 23
Suppressor circuit
The bidirectional triode thyristor (Triac) and the optical bidirectional triode thyristor (Opto
Triac) are protected against overvoltages of the electric mains supply by Transil diodes. In
addition, the bidirectional triode thyristor is protected against short-circuit and overload by a
fuse.
Voltage isolation
The control circuit works with safety extra-low voltage (SELV) and is safely isolated from the
line and load-current circuits in accordance with EN 50178.
Temperature monitoring
For monitoring the heat-sink temperature, there is an NTC thermistor on the heat sink.
At 92 °C ±3 °C, this temperature-dependent resistor sends a signal to the S7 CPU via the ZA
724.
When a second switching threshold at 100 °C ±3 °C is reached, the power outputs of the
module are switched off.
3.3.3 LA 724I connectors
The power output module has the following plug-in connections:
Table 3- 2 Plug-in connectors of the LA 724I
Labeling Function
724 bus Connection of the subsequent power output module (right-hand socket) and the
preceding power output module or central interface module (left-hand socket) to
the parallel bus
L1s Connection of heat emitters 1 to 8 to phase L1
L2s Connection of heat emitters 9 to 16 to phase L2
L3s Connection of heat emitters 17 to 24 to phase L3
N Connection of the neutral conductor via a conductor rail
L1 Connection of phase L1 via a conductor rail
L2 Connection of phase L2 via a conductor rail
L3 Connection of phase L3 via a conductor rail
Connection of the protective conductor via a conductor rail
Description of the components
3.3 LA 724I power output module
SIPLUS HCS724I
24 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.3.4 Performance profile of the LA 724I
The following illustration shows the performance profile of the LA 724I.
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Evaluation example 1
Requirements:
● Ambient temperature TU = 40 °C
● Operation without fan module
● 24 emitters (channels)
● Ongoing production at 100 % simultaneity
(all emitters working at 100 % setpoint)
What is the maximum permissible emitter output?
We can derive the following from the illustration above:
At TU = 40 °C, the switching power of the LA 724I is PL ≈ 14.5 kW.
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Description of the components
3.3 LA 724I power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 25
Evaluation example 2
Requirements:
● Ambient temperature TU = 55 °C
● Operation without fan module
● 24 emitters (channels)
● Production : Standby = 4 : 1
● 85 % simultaneity (e.g. all emitters working at 85 % setpoint)
Are 500 W emitters permissible?
We can derive the following from the illustration above:
At TU = 55 °C, the switching power of the LA 724I is PL ≈ 8.5 kW.
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Result: 500 W emitters are permissible.
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
26 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.4 LA 724I HP power output module
3.4.1 LA 724I HP features
The LA 724I HP power output module has the following features:
● Module integrated in a metal housing
● 12 power channels with a maximum of 2300 W of switching power at 230 V AC or 4000
W of switching power at 400 V AC per output, groups of 4 outputs per phase
Due to various physical properties of heat emitters, restrictions can be imposed on their
switching power, depending on the type of emitter.
Short-wave halogen or infrared emitters, so-called flash emitters, have a high switch-on
current due to their relatively low cold resistance. This switch-on current can be a multiple of
the rated current especially during the initial half-waves.
● 16 A fuse for each power channel, accessible from the outside
● Internal protection for each phase with 40 A
Note
The total current per phase must not exceed 40 A.
● Connection of the phases via conductor rails
● Connection of the heat emitters via front connectors
Note
The mating connectors for connection of the heat emitters are not included in the scope
of supply. You have to order these separately.
● No settings have to be made on the module
● Diagnostics feature for detecting internal and external faults
● Diagnostics feature for detecting an emitter failure where emitters are connected in
parallel; this is done by means of current measurement
● Two-stage temperature monitoring by NTC thermistors (alarm stage, shutdown stage)
● LED indicators for channel faults and temperature monitoring
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 27
3.4.2 LA 724I HP design
Front view of the LA 724I HP
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Figure 3-7 Front view of the LA 724I HP
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
28 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Suppressor circuit
The bidirectional triode thyristor (Triac) and the optical bidirectional triode thyristor (Opto
Triac) are protected against overvoltages of the electric mains supply by Transil diodes. In
addition, the bidirectional triode thyristor is protected against short-circuit and overload by a
fuse.
Voltage isolation
The control circuit works with safety extra-low voltage (SELV) and is safely isolated from the
line and load-current circuits in accordance with EN 50178.
Temperature monitoring
For monitoring the heat-sink temperature, there is an NTC thermistor on the heat sink.
At 92 °C ±3 °C, this temperature-dependent resistor sends a signal to the S7 CPU via the ZA
724.
When a second switching threshold at 100 °C ±3 °C is reached, the power outputs of the
module are switched off.
3.4.3 LA 724I HP connectors
The power output module has the following plug-in connections:
Table 3- 3 Plug-in connectors of the LA 724I HP
Labeling Function
724 bus Connection of the subsequent power output module (right-hand socket) and the
preceding power output module or central interface module (left-hand socket) to the
parallel bus
L1s Connection of heat emitters 1 to 4 to phase L1
L2s Connection of heat emitters 5 to 8 to phase L2
L3s Connection of heat emitters 9 to 12 to phase L3
N Connection of the neutral conductor via a conductor rail
L1 Connection of phase L1 via a conductor rail
L2 Connection of phase L2 via a conductor rail
L3 Connection of phase L3 via a conductor rail
Connection of the protective conductor via a conductor rail
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 29
3.4.4 Performance profile of the LA 724I HP
Note
If you use the LA 724IHP in combination with a fan module, you extend its range of
applications and increase the reliability of the power output, even if there are high ambient
temperatures.
We therefore recommend that you always operate the LA 724I together with the LM 724 fan
module.
3.4.4.1 Star connection
Performance profile of the star connection
The following illustration shows the performance profile of the LA 724I HP with a star
connection.
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Figure 3-8 Performance profile of the LA 724I HP with star connection
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
30 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Evaluation example of star connection
Requirements:
● Ambient temperature TU = 40 °C
● Operation without fan module
● Star connection
● Production : Standby = 4 : 1
● 100 % simultaneity (e.g. all emitters working at 100 % setpoint)
Can five 250 W emitters be connected in parallel?
From the performance profile with star connection we can see:
At TU = 40 °C, the switching power of the LA 724I HP is PL ≈ 13 kW.
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Result: Parallel connection of five 250 W emitters is permissible.
Description of the components
3.4 LA 724I HP power output module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 31
3.4.4.2 Delta connection
Performance profile of the delta connection
The following illustration shows the performance profile of the LA 724I HP with a delta
connection.
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Figure 3-9 Performance profile of the LA 724I HP with delta connection
Evaluation example
Requirements:
● Ambient temperature TU = 50 °C
● Operation with fan module
● Delta connection
● Ongoing production at 100 % simultaneity
(all emitters working at 100 % setpoint)
What is the maximum permissible emitter output?
From the performance profile we can see:
At TU = 50 °C, the switching power of the LA 724I HP with fan module is PL ≈ 30.4 kW.
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Result: The emitter power output must not exceed 2.54 kW.
Description of the components
3.5 LA 724I SSR load switching unit
SIPLUS HCS724I
32 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.5 LA 724I SSR load switching unit
3.5.1 LA 724I SSR features
The LA 724I SSR load switching unit has the following features:
● Module integrated in a metal housing
● 24 power channels with a digital control signal of 24 V per output for switching external
solid state relays (SSR).
Maximum 20 kW switching power at 230 V or 36 kW at 400 V per output.
Grouping of 8 outputs per phase
● Protection for each channel is to be provided externally.
Note
The total current per phase must not exceed 400 A.
● Connection of the SSRs via front connectors
● Optional:
– Connection for feedback from emitters for diagnostic purposes; voltage measurement
for the detection of external faults
– Connection of the phases via conductor rails
● Optional:
Connection of the current-measuring module for diagnostic purposes;
current measurement for detection of external faults and for monitoring of power output in
the case of emitters connected in parallel
Note
The mating connectors for the connections of the SSR, the SM 724I, the 24 V supply and
the voltage monitoring unit are not included in the scope of supply. You have to order
these separately.
● No settings have to be made on the module
● Monitoring of the 24 V supply voltage
● LED indicators for channel faults and faults in the 24 V supply voltage
Description of the components
3.5 LA 724I SSR load switching unit
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 33
3.5.2 LA 724I SSR layout
Front view of the LA 724I SSR
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Description of the components
3.5 LA 724I SSR load switching unit
SIPLUS HCS724I
34 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Voltage isolation
The control circuit works with safety extra-low voltage (SELV) and is safely isolated from the
line and load-current circuits in accordance with EN 50178.
24 V monitoring
The connected 24 V supply is monitored for failure.
In the event of failure, the outputs to the SSR are deactivated.
3.5.3 LA 724I SSR connectors
The load switching module has the following plug-in connections:
Table 3- 4 Plug-in connectors of the LA 724I SSR
Labeling Function
724 bus Connection of the subsequent power output module (right-hand socket) and the
preceding power output module or central interface module (left-hand socket) to the
parallel bus
+/– 24 V– 24 V supply voltage for the solid state relays
SSR L1 Connection of SSR 1 to 8 to phase L1
SSR L2 Connection of SSR 9 to 16 to phase L2
SSR L3 Connection of SSR 17 to 24 to phase L3
Current Sense Connection for the current measuring module
L1d Voltage monitoring of SSR 1 to 8 for phase L1
L2d Voltage monitoring of SSR 9 to 16 for phase L2
L3d Voltage monitoring of SSR 17 to 24 for phase L3
N Connection of the neutral conductor via a conductor rail
L1 Connection of phase L1 via a conductor rail
L2 Connection of phase L2 via a conductor rail
L3 Connection of phase L3 via a conductor rail
Connection of the protective conductor via a conductor rail
Description of the components
3.6 NE 724 line-voltage sensing submodule
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 35
3.6 NE 724 line-voltage sensing submodule
3.6.1 Features of the NE 724
The line-voltage sensing submodule is a separate module and, as an option, can be inserted
in the ZA 724 if line-voltage fluctuations are to be compensated. The module is plugged into
the slot of the ZA 724 from the front. The slot is located in the busbar area. If the NE 724 is
not used, the opening is closed up with the busbar cover. If the line-voltage sensing
submodule is used, the cover is used for shock-hazard protection.
Note
Central interface modules are supplied from the factory without line-voltage sensing. If you
want to detect the line voltage and compensate for fluctuations, you have to order the
NE 724 module separately and install it yourself (see "Connecting the NE 724" (Page 63)).
Product features
The NE 724 line-voltage sensing submodule has the following features:
● Measures the voltage at phases L1, L2 and L3
● Connection of phases L1, L2, L3 and the neutral conductor via Teflon-coated cable
● Electrical isolation by means of a transformer
● Bus interface to the ZA 724
● Evaluation of the line voltage and calculatino of correction factors
Function
Compensation of line-voltage fluctuations
To compensate line-voltage fluctuation, you have to plug in an NE 724 line-voltage sensing
submodule into a ZA 724 within a network of several HCS724I units. The module calculates
correction factors and transfers the results to the DP master. The DP master then distributes
the data to all slaves.
Voltage measuring for enhanced diagnostics
An NE 724 is required for each ZA 724 in order to measure voltage values for enhanced
diagnostics (see "Monitoring functions of the HCS724I" (Page 79)). The determined voltage
value is used for detecting faults in emitters connected in parallel.
Description of the components
3.6 NE 724 line-voltage sensing submodule
SIPLUS HCS724I
36 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.6.2 NE 724 layout
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Figure 3-11 Structure of the NE 724
The illustration above shows the structure of the printed circuit board of the line-voltage
sensing submodule. The line-voltage sensing submodule contains the following components:
● Three voltage adapters and filter units on the 230 V side
● Three transformers for electrical isolation and voltage adaptation
● Three precision rectifiers with downstream filter
● A 4-channel A/D converter
● A -5V voltage supply for the converter
● A plug-in connector for connecting to the ZA 724
The module is approximately 180 mm long and approximately 80 mm wide.
3.6.3 NE 724 connectors
The line-voltage sensing submodule has the following plug-in connections:
Table 3- 5 Plug-in connectors of the NE 724
Labeling Function
N Connection of the neutral conductor
L1 Connection of phase L1
L2 Connection of phase L2
L3 Connection of phase L3
none Plug-in connection to the ZA 724
Description of the components
3.7 LM 724 fan module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 37
3.7 LM 724 fan module
The LM 724 fan module has the following features:
● Standard fan in an IP00 housing
● Is suspended under 2 modules of the HCS724I (see "Installing the optional fan module"
(Page 43))
● Use is optional, depending on the switching power needed (see "Performance profile of
the LA 724I" (Page 24) and "Performance profile of the LA 724I HP" (Page 29))
Figure 3-12 LM 724 fan module
Description of the components
3.8 SM 724I current measuring module
SIPLUS HCS724I
38 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
3.8 SM 724I current measuring module
The SM 724I current measuring module is needed if an LA 724I SSR is to be used to carry
out a diagnosis by means of current measurement. This diagnosis is recommended if
emitters connected in parallel are used in order to detect failure of an individual emitter.
The SM 724I is to be mounted in the switching cabinet:
● directly on a suitably stable mounting surface (recommended)
● on a rail
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Figure 3-13 SM 724I current measuring module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 39
Mounting 4
4.1 Requirements for the mounting location
The HS HCS724I heater controller is designed for stationary installation in a switching
cabinet.
Note
The components of the HCS724I are designed with degree of protection IP00. The
necessary shock-hazard protection must be provided by the switching cabinet in which
the HCS724I is installed.
When the unit is installed, the EMC directives are to be complied with.
The HCS724I is not suitable for connection to the public low-voltage grid but is to be
supplied from a separate medium-voltage transformer (industrial power network).
WARNING
In the switching cabinet, voltages of > 60 V occur. Suitable safety precautions must
therefore be taken before commissioning and maintenance work.
The use of a residual current protective device as the sole protection against indirect
touching is forbidden.
Do not touch the metal housing of the modules with bare fingers. Danger of burning due
to hot surfaces!
Requirements for the switching cabinet
In order to reliably prevent hazards for the operating personnel, the switching cabinet must
satisfy the following requirements:
● Closed cabinet
● Grounded cabinet
● It must be ensured that interface connections and ribbon cables at the devices are not
touched by live cables which only have a single layer of insulation and pass through the
switching cabinet.
Mounting
4.2 Setting the bus address
SIPLUS HCS724I
40 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
4.2 Setting the bus address
Communication of the heater controller with the master (e.g. S7 CPU) takes place via the
PROFIBUS DP field bus and requires that the bus address (slave address) be set on the
central interface module. The ZA 724 has two rotary switches for this purpose. These
switches can be used to set the address somewhere in the range of 00 to 99.
Steps
1. Use rotary switch S2 to set the units position of the PROFIBUS DP address.
2. Use rotary switch S3 to set the tens position of the PROFIBUS DP address.
The rotary switches are in such a position that they are accessible from above through the
fan openings of the housing of the central interface module.
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Figure 4-1 Setting the bus address
Mounting
4.3 Installation of components on the mounting panel
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 41
4.3 Installation of components on the mounting panel
The central interface module and the power output modules/load switching units of the
HCS724I are built into metal housings. These housings are mounted on a support plate in
the switching cabinet.
Steps
1. Disconnect the switching cabinet from the voltage supply.
2. Mark out the support plate according to the following hole diagram and then drill the
holes.
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Figure 4-2 Hole diagram for the components of the HCS724I
3. Screw the housing onto the fastening lugs on the support plate.
Use M6 screws.
Note
If two tiers are placed one above the other for two-tier installation of the HCS724I, the upper
tier will be additionally heated by the warm air coming from the lower tier.
For greater switching capacities and for operation with optional fan modules, you should
place an air guidance plate between the two tiers if necessary.
The two tiers of an HCS724I can also be placed next to each other. This prevents them from
causing each other's temperature to increase.
Mounting
4.3 Installation of components on the mounting panel
SIPLUS HCS724I
42 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Clearances for installation
When the HCS724I is being installed in a switching cabinet, the minimum distances from
cabinet walls, cable ducts etc. as shown in the following illustration are to be adhered to.
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Figure 4-3 Clearances for installing an HCS724I
Mounting
4.4 Installing the optional fan module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 43
4.4 Installing the optional fan module
Depending on the switching capacity needed (see "Performance profile of the LA 724I"
(Page 24) and "Performance profile of the LA 742i HP" (Page 29)), the LA 724I / LA 724I HP
must be retrofitted with the optional fan module.
Principles of installation
The fan module is suspended under two LA 724I xx modules or under the ZA 724 interface
module and under one LA 724I load switching unit.
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Figure 4-4 Installation of the optional fan module
Mounting
4.4 Installing the optional fan module
SIPLUS HCS724I
44 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Steps
1. Loosen the clamping plate at the front of the fan module (unscrew 2 oval-head screws but
not completely, and then push towards the rear).
2. First, hitch the catches of the fan module into the perforated metal plates of the modules
at the rear.
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3. Then, hitch the clamping plate into the front perforated metal plates of the modules.
Fasten the clamping plate in place with two M3 x 8 oval-head screws.
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Mounting
4.4 Installing the optional fan module
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 45
4. Reconnect all the protective conductors.
The protective conductor must have a cross-section of 0.75 mm2 and be pushed onto the
Faston plug-in tab with a lockable 6.3 x 0.8 Faston plug-in connector. It must be ensured that
the connection cannot become loose.
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5. Connect the power supply for the fan.
230 V AC is needed to operate the fan.
WARNING
Before you connect the fan, the mains lead must be disconnected from the supply.
- Connect the mains lead (0.75 mm2) to the connector supplied.
- Plug the connector into the bushing terminal on the front of the
fan module.
- Secure the connector with 2 screws.
Note
Secure the power leads to the fan in such a way that cable protection according to EN
60204, Part 1, or EN 50178 is ensured.
CAUTION
When the fan module is operating, do not reach through the perforated metal plate at the
bottom and touch the fan wheel!
Mounting
4.4 Installing the optional fan module
SIPLUS HCS724I
46 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 47
Connection 5
5.1 Connecting the PROFIBUS DP field bus
For communication between the central interface module and the higher-level controller
(master), the two components must be connected to each other by means of the PROFIBUS
DP field bus.
Steps
1. Plug the bus cable connector into the 9-pin Sub-D socket "PROFIBUS DP"
2. Secure the connector to the socket.
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Connection
5.2 Connecting the parallel bus
SIPLUS HCS724I
48 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
5.2 Connecting the parallel bus
The power output modules/load switching units are connected to the central interface
module by a parallel bus, which is looped through by means of a flat ribbon cable.
Each ZA 724 has 2 bus lines, to each of which a maximum of eight LA 724I xx load
operating units can be connected.
Steps
1. Press the connector of the flat ribbon cable into the right-hand "724 bus" socket of the
cental interface module until it engages.
2. Press the connector of the flat ribbon cable into the left-hand "724 bus" socket of the first
power output module/load switching unit until the connector engages.
Only if use is made of several power output modules/load switching units per central
interface module:
3. Press the connector of another flat ribbon cable into the right-hand "724 bus" socket
of the power output module/load switching unit last connected until the connector engages.
4. Press the connector of the flat ribbon cable into the left-hand "724 bus" socket
of the next power output module/load switching unit until the connector engages.
To connect additional power output modules/load switching units, repeat steps 3 and 4 (see
illustration "Connecting the parallel bus").
If power output modules/load switching units are arranged in two tiers:
5. Press the connector of the flat ribbon cable for the 2nd tier into the left-hand "724 bus"
socket
of the central interface module until the connector engages.
6. Press the connector of the flat ribbon cable into the left-hand "724 bus" socket of the first
power output module of the second tier
until the connector engages.
To connect additional power output modules/load switching units, repeat steps 3 and 4 (see
illustration "Installation options").
Note
The flat ribbon cables for connecting a 2nd tier have to be ordered separately.
For order numbers, see "Order numbers > Accessories" (Page 153).
Connection
5.2 Connecting the parallel bus
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 49
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Connection
5.2 Connecting the parallel bus
SIPLUS HCS724I
50 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
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Figure 5-3 Installation options
Connection
5.3 Connecting the power supply to the ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 51
5.3 Connecting the power supply to the ZA 724
The module is supplied with operating voltage by means of a power unit integrated on the
central interface module.
Steps
1. Connect the protective conductor to the "PE" conductor rail.
2. Strip the insulation from the end of the mains supply lead.
3. Connect phase L1 to the screw-type terminal marked "L1x".
The HCS724I is not suitable for connection to the public low-voltage grid but is to be
supplied from a separate medium-voltage transformer (industrial power network).
Note
L1x must have the same phase as the L1 conductor rail.
4. Connect the neutral conductor to the screw-type terminal marked "N".
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Figure 5-4 Position of the mains supply terminals on the ZA 724
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
52 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
5.4 Connecting heat emitters
5.4.1 LA 724I/LA 724I HP
The heat emitters are connected to the socket connectors on the front of the power output
modules by means of three 8-pin plug connectors with screw-type terminals. The three-
phase power system is connected via five conductor rails (three phases + one neutral
conductor + one PE)
WARNING
Only plug connectors for the heat emitters into the socket connectors or withdraw them
after disconnecting them from the supply. Before you connect the three-phase power
system to the conductor rails, disconnect the mains leads from the supply.
Any messages received from the DP master (e.g. station failure of the HCS724I or
interruption of DP communication) must be evaluated by the user, who must then react
accordingly to ensure the safety of the system (e.g. check heat emitters and, if necessary,
switch off individual heat emitters).
Note
The cables leading to and coming from the heat emitters are to be laid outside the control
cabinet in one cable conduit.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 53
Steps
1. Connect the protective conductor to the "PE" conductor rail.
2. Remove the insulation from the end of the heat emitter cables and firmly attach the
cables in the screw-type terminals of the 8-pin plug connector.
3. Plug the plug connectors of heat emitters 1 to 8 into the socket connectors L1s.
4. Plug the plug connectors of heat emitters 9 to 16 into the socket connectors L2s.
5. Plug the plug connectors of heat emitters 17 to 24 into the socket connectors L3s.
6. Connect the neutral conductor to the "N" conductor rail.
7. Connect phase L1 to the "L1" conductor rail.
8. Connect phase L2 to the "L2" conductor rail.
9. Connect phase L3 to the "L3" conductor rail.
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/V
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/V
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Figure 5-5 Front view of the LA 724I/LA 724I HP with the sockets for connecting heat emitters
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
54 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Table 5- 1 Assignment of the heat emitters to the pins of the sockets
Channel number
Socket connector Pin
LA 724I LA 724I HP
1 1
2 2
1
3 3
4 4
3
5 5
6 6
5
7 7
L1s
8 8
7
1 9
2 10
9
.
.
.
7 15
L2s
8 16
15
1 17
2 18
17
.
.
.
7 23
L3s
8 24
23
DANGER
After the conductor rails have been connected, the covers of the conductor rails must be
fitted again to provide protection against electric shock. After the operating voltage has
been switched on in the control cabinet, the conductor rails carry line voltage (230 V AC). It
is permitted to carry out wiring or maintenance work only after the system has been
disconnected from the supply.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 55
Star connection
The following illustration shows the connection of the heat emitters to the LA 724I/LA 724I
HP in a star connection (Y circuit).
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Figure 5-6 Star connection of heat emitters to LA 724I/LA 724I HP
Note
Unrestricted mixed operation of emitters for 230 V and 400 V is not possible in a network of
HCS724I devices. Please contact Technical Support
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
56 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Delta connection
The following illustration shows the connection of the heat emitters to the LA 724I HP in a
delta connection (∆ circuit).
71V\VWHP
9
9
3(
1
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Figure 5-7 Delta connection of heat emitters to LA 724I HP
Note
Secure the return leads from the heat emitters in such a way that cable protection according
to EN 60204, Part 1, or EN 50178 is ensured. The plant builder is responsible for correct
protection of the system.
Note
Unrestricted mixed operation of emitters for 230 V and 400 V is not possible in a network of
HCS724I devices. Please contact Technical Support.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 57
Multiple power supply
The HCS724I is to be supplied with power via several paths (incoming supply) if supply via a
single path would result in the maximum phase current on the conductor rail being
exceeded. The following diagram shows an example of supply via two paths.
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Figure 5-8 Example of supplying a HCS724I via two paths
Note
During configuration, it must be ensured that the maximum current of 120 A per conductor
rail is not exceeded.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
58 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
5.4.2 LA 724I SSR
The solid state relays are connected to the plug connectors on the front of the load switching
units by means of three 8-pin socket connectors. The three-phase power system is
connected via four conductor rails (three phases + one neutral conductor)
WARNING
Only plug socket connectors for the solid state relays onto the plug connectors or withdraw
them from the connectors after disconnecting them from the supply. Before you connect the
three-phase power system to the conductor rails, disconnect the mains leads from the
supply.
Any messages received from the DP master (e.g. station failure of the HCS724I or
interruption of DP communication) must be evaluated by the user, who must then react
accordingly to ensure the safety of the system (e.g. check heat emitters and, if necessary,
switch off individual heat emitters).
Steps
1. Connect the protective conductor to the "PE" conductor rail.
2. Remove the insulation from the end of the cables of the solid state relays and firmly
attach the cables in the screw-type terminals of the 8-pin orange-colored socket
connectors.
3. Plug the socket connectors of SSR 1 to 8 onto the plug connectors SSR L1.
4. Plug the socket connectors of SSR 9 to 16 onto the plug connectors SSR L2.
5. Plug the socket connectors of SSR 17 to 24 onto the plug connectors SSR L3.
6. Securely connect the 24 V supply to the 2-pin socket connector and plug the socket
connector into the "24V-" plug connnector.
Caution: Ensure correct polarity!
Note
Only diagnosis by means of voltage measurement or only diagnosis by means of current
measurement is possible - not both at the same time.
For diagnosis by voltage measurement, you must also carry out the following steps:
7. Connect the neutral condutor to the "N" conductor rail.
8. Connect phase L1 to the "L1" conductor rail.
9. Connect phase L2 to the "L2" conductor rail.
10. Connect phase L3 to the "L3" conductor rail.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 59
11. Connect the cables from the output of the SSR to the 8-pin green plug connectors.
Note
The feedback signals from the SSRs for voltage measurement must be sent along the same
channel as switching signals.
12. Plug the plug connector of SSRs 1 to 8 into the socket connector L1d.
13. Plug the plug connector of SSRs 9 to 16 into the socket connector L2d.
14. Plug the plug connector of SSRs 17 to 24 into the socket connector L3d.
For diagnosis by current measurement, you must also carry out the following steps:
7. Connect the cables from the current measuring module to the 6pin orange-colored
socket connector.
8. Plug the socket connector of the measuring cable onto the "Current Sense" plug
connector.
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Figure 5-9 Front view of the LA 724I SSR with the sockets for SSR connection
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
60 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Table 5- 2 Assignment of the SSRs to the pins of the plug/socket connectors
Pin/socket connector Pin SSR (channel)
SSR L1 and L1d 1
2
:
8
1
2
:
8
SSR L2 and L2d 1
2
:
8
9
10
:
16
SSR L3 and L3d 1
2
:
8
17
18
:
24
Table 5- 3 Assignment of the current measuring module to the pins of the plug connector
Plug connector Pin Terminal on current measuring
module
Current Sense 1
2
3
4
5
6
1
2
8
9
15
16
Table 5- 4 Assignment of the 24 V power supply to the pins of the plug connector
Plug connector Pin Signal
1 +24 V 24V–
2 0 V
DANGER
After the conductor rails have been connected, the covers of the conductor rails must be
fitted again to provide protection against electric shock. After the operating voltage has
been switched on in the control cabinet, the conductor rails carry line voltage (230 V AC).
It is permitted to carry out wiring or maintenance work only after the system has been
disconnected from the supply.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 61
Star connection
The following illustration shows the connection of the heat emitters to the LA 724I SSR in a
star connection (Y circuit).
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665
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/
/
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665/
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665/
665/
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9
9
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665
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Figure 5-10 Star connection of the heat emitters to LA 724I SSR (example with voltage signal
feedback for diagnostic purposes)
Note
Unrestricted mixed operation of emitters for 230 V and 400 V is not possible in a network of
HCS724I devices. Please contact Technical Support.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
62 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Delta connection
The following illustration shows the connection of the heat emitters to the LA 724I SSR in a
delta connection (∆ circuit).
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665
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/
/
/
/G
665/
9
665/
665/
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9
9
9
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665
665
665
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60L
9
Figure 5-11 Delta connection of the heat emitters to LA 724I SSR (example with current signal
feedback for diagnostic purposes)
Note
Secure the return leads from the heat emitters in such a way that cable protection according
to EN 60204, Part 1, or EN 50178 is ensured. The plant builder is responsible for correct
protection of the system.
Note
Unrestricted mixed operation of emitters for 230 V and 400 V is not possible in a network of
HCS724I devices. Please contact Technical Support.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 63
5.4.3 Connecting the NE 724
The NE 724 submodule is plugged into the slot of the ZA 724 from the front and pressed into
the plug-in connector. The cables of the submodule are connected to the neighboring LA
724I xx with the 3 phases and the neutral conductor.
Steps
1. Remove the conductor-rail cover of the ZA 724 and LA 724I xx.
2. Push the NE 724 submodule, together with the plug-in connector, into the slot of the ZA
724.
Make sure that the printed circuit board is resting in the grooves of the guide bolts (see
illustration below).
3. Carefully push the submodule inwards until the plug-in connector engages.
Connection
5.4 Connecting heat emitters
SIPLUS HCS724I
64 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
4. Connect the cable of the NE 724 submodule to the conductor-rail terminals of the
neighboring LA 724I xx (see illustration below).
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Figure 5-12 Position and connection of the NE 724
5. Re-attach the conductor-rail cover to the ZA 724 and LA 724I xx.
Note
The conductor-rail covers only engage in the front plate if the conductor rails and the NE
724 have been connected correctly.
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 65
Start-up 6
6.1 Hardware requirements
Controller
The controller needed is for example
● a SIMATIC S7 CPU 3xx or CPU 4xx with integrated PROFIBUS DP interface
● or a DP standard master
Heater controller
A heater controller includes the following components:
● 1 ZA 724 central interface module
● 1 to 16 LA 724I xx power output modules/load switching units
● NE 724 line-voltage sensing submodule (optional)
● SM 724I current measuring module (optional)
6.2 Software requirements
CD contents
Figure 6-1 CD contents
Directory \Firmware
contains the Flash loaders and the current firmware
Start-up
6.2 Software requirements
SIPLUS HCS724I
66 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Directory \Gsd
contains the language-specific GSD files for the HCS724I for installation in the planning tool
of the DP master.
SIEM80FF.gsg / SIEM80FF.gsd German
SIEM80FF.gse English
SIEM80FF.gsf French
SIEM80FF.gsi Italian
SIEM80FF.gss Spanish
Directory \Manual
contains the description in this document in electronic form.
Directory \S7
Archive with the current
STEP 7
program (for transferring projects to the SIMATIC Manager)
Directory \S7ConfigTool
Configuration tool for generating the data blocks used in the STEP7 program
Start-up
6.3 Incorporating the GSD file
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 67
6.3 Incorporating the GSD file
For purposes of heater control, there is a GSD file entitled SIEM80FF.GSD in which the
configuration of the DP slave is stored.
This file is needed to carry out PROFIBUS configuration. It is included in the scope of supply
of
STEP 7
.
The following table describes how you incorporate the GSD file in
STEP 7
if this GSD is not
yet available in the version of your planning software.
Table 6- 1 Incorporating the GSD file in your planning software
Step
STEP 7
, as of V5.0,
ServicePack 3
1 Start
STEP 7
and then select the menu command Tools > Install New GSD file in
HW Config.
2 From the next dialog box, select the GSD file you want to install and confirm with OK.
Result: The heater controller appears in the hardware catalog of the PROFIBUS DP
folder. (other field devices - general)
3 Configure the heater controller using
STEP 7
(refer to the online help in
STEP 7
).
If a DP master is used which is not an S7 DP master, install the GSD file as described in the
instructions for the DP master.
Features of the DP slave
● 32 bytes for output data, consistent
● 32 bytes for input data, consistent
● 64 bytes for diagnostic data (not yet used)
● Baud rates up to 12 Mbaud
● Supported standard: PROFIBUS DP
Start-up
6.4 Procedure for (standard) commissioning
SIPLUS HCS724I
68 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
6.4 Procedure for (standard) commissioning
Steps
1. Use rotary switches S2 and S3 on the central interface module to set the PROFIBUS
address (see "Setting the bus address" (Page 40))
2. Mount the components in the control cabinet (see "Mounting components on the support
plate" (Page 41) and "Installing the optional fan module" (Page 43)).
3. Connect the parallel bus (see "Connecting the parallel bus" (Page 48))
4. Install the NE 724 line-voltage sensing submodule (optional) and connect it (see
"Connecting the NE 724" (Page 63))
5. Connect the supply voltage (see "Connecting the supply voltage to the ZA 724"
(Page 51))
6. Connect the PROFIBUS DP (see "Connecting the PROFIBUS DP fieldbus" (Page 47))
7. Connect the heat emitters (see "Connecting the LA 724I / LA 724I HP" (Page 52) and
"Connecting the LA 724I SSR" (Page 58))
8.
– If the system is used with an S7 master:
Load the S7 project provided as an example and adapt it to the application.
For a description of the S7 interface, see "Functions > Data exchange between an S7
DP master and the ZA 724" (Page 88)
– If the system is used with a master that is not an S7 master:
Create your user program for operating the HCS724I.
For a description of the DP interface, see "Functions > Data exchange between a non-
S7 DP master and the ZA 724" (Page 113)
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 69
Functions 7
7.1 Initialization (start-up)
Start-up behavior
● For approximately 1 second, the firmware checks whether a request for a firmware
update has been sent via the serial interface. If yes, it changes over to the Flash loading
procedure.
● The firmware then checks the system. In the event of a problem (e.g. serious fault: Flash
not loaded), the system comes to a standstill during starting.
● During the initialization phase, data exchange is started between the DP master and the
ZA 724 (see "DB_HS_INIT" (Page 92) and "FC_HS_INIT" (Page 99)):
– Information on the status of the HCS724I
– Transfer of the configuration data to the HCS724I
– Carrying out start-up tests
Note
An exact description of the jobs or the contents for initialization is given in
"Functions > Data exchange between an S7 DP master and the ZA 724" (Page 88)
and "Functions > Data exchange between a non-S7 DP master and the ZA 724"
(Page 113).
Start-up tests
During the initialization phase, the line frequency and the rotating field can be tested in the
HCS724I. The tests are activated in one of the initialization message frames and carried out
on the HCS724I.
The result has to be checked in the DP master by the user. A description of the data needed
for the test is given in "Data exchange between an S7 DP master and the ZA 724" (Page 88)
and "Data exchange between a non-S7 DP master and the ZA 724" (Page 113).
Line-frequency test
This test must be performed during starting. The result of the test is the frequency which is
found (50/60 Hz).
If the frequency could not be determined, the value 255 is returned. Despite this, however,
the HCS724I starts up with the settings for 50 Hz. This can result in diagnostics errors.
Functions
7.1 Initialization (start-up)
SIPLUS HCS724I
70 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Rotating-field test
This test can be carried out during starting and for purposes of support during
commissioning.
At higher switching capacities, multiple power-infeed is necessary and therefore the LA
724I xx devices can be selected with whose channels the rotating field is to be tested.
For testing of the rotating field, the first channel of a phase must be wired on the power
output module, namely channels 1, 9 and 17. The test is carried out with the channels
switched off. During the test, the channels must be pulsed for the duration of a full wave only
in the case of the LA 724I SSR with connected SM 724I current measuring module.
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 71
7.2 Operating the HCS724I
Introduction
After successful initialization, the HCS724I heater controller must be switched to "heating
mode" with the corresponding control bits. The ZA 724 modules cyclically check the data for
changes and also monitor the power output modules/load switching units. The heat emitters
are operated with the current controller values.
Operating cycle
During operation, the following procedures are carried out cyclically:
● The temperature of the LA 724I/LA 724I HP power output modules is monitored
● The 24 V supply voltage of the LA 724I SSR load switching unit is monitored
● Data is exchanged with the DP master
● The power outputs are controlled and monitored.
Connected to the PROFIBUS DP, the ZA 724 central interface modules behave like DP
slaves.
Data exchange between the DP master and the HCS724I takes place in the form of cyclical
PROFIBUS DP data transfer. Output data are data which are transferred from the DP master
to the HCS724I and input data are the data which are sent from the HCS724I to the DP
master.
These data signals are each divided into two areas.
"Real" cyclical data are contained in the first 4 bytes: selection of operating mode by the DP
master, group signaling of defects by the HCS724I and exchange of correction data for line-
voltage compensation.
In the remaining 28 bytes, message frames are transferred between the DP master and the
HCS724I. In this way, the HCS724I is parameterized by the DP master and, in addition,
detailed diagnostic information and information regarding the commissioning of the HCS724I
is transferred to the DP master. The diagnostic mechanism via PROFIBUS DP is not used.
Note
An exact description of the data contents is given in "Functions > Data exchange between an
S7 DP master and the ZA 724" (Page 88) and "Functions > Data exchange between a non-
S7 DP master and the ZA 724" (Page 113).
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
72 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.2.1 Manipulated value calculation
After the applicable emitter setpoints and field factors have been transferred, the heater
controller calculates the controller outputs for the individual channels of the LA 724I xx power
output modules. When this is being done, line-voltage correct values can also be taken into
consideration.
Setpoint definition
For each channel, up to three setpoints can be stipulated for different operating modes.
Table 7- 1 Values for setpoint calculation
Value Description Range Dimension
Channel setpoint for
start-up
Setpoint for a channel which is used in the
start-up mode.
0 to 100 1 % *
Channel setpoint for
production with profile
1
Setpoint for a channel which is used in the
"production with profile 1" mode.
0 to 100 1 % *
Channel setpoint for
production with profile
2
Setpoint for a channel which is used in the
"production with profile 2" mode.
0 to 100 1 % *
* With a set configuration parameter, 0.5 % increments can be achieved (see "Operation of power
output modules/load switching units", Precision (Page 77)).
Definition of field factor
For each field, up to two factors by which the current channel setpoint is multiplied can be
parameterized.
Table 7- 2 Values for setpoint calculation
Value Description Range Dimension
Factor for production Field factor by which the setpoints for profile 1
and profile 2 in the "production" mode are
multiplied for all channels of the associated
field
0 to 255 0.01
Factor for standby Field factor by which the setpoints for profile 1
in the "standby" mode are multiplied for all
channels of the associated field
0 to 255 0.01
At least 1 field must be configured in each HCS724I.
Definition of line-voltage compensation
For determining the correction value per phase, see "Line-voltage correction" (Page 75)
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 73
Definition of controller outputs for the operating modes
The controller output of a channel depends on the parameterized channel setpoint, the
parameterized field factors and the operating mode used.
Standby mode
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Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
74 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Calculation of controller outputs
The following diagram is a graphic illustration of how controller outputs are calculated.
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Figure 7-1 Principle of controller output calculation
Updating the controller outputs
If new data arrive from the S7 (emitter setpoints and field factors), the controller outputs are
recalculated.
Changed emitter setpoint → The associated channel controller output is
recalculated.
Changed field factor → All channel controller outputs of the field in
question are recalculated.
Changed line-voltage correction
value
→ The controller outputs are recalculated for all
channels of the phase in question.
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 75
7.2.2 Mains compensation
In order to eliminate line-voltage fluctuations, the HCS724I can be equipped with an NE 724
line-voltage sensing submodule as an option.
The central interface module scans the line voltages cyclically and integrates them, using the
integration time transferred during initialization.
Configuration
The function can be activated/deactivated by means of a parameter.
● The function is active and the NE 724 connected
→ The correction values are calculated and reported to the DP master.
● The function is active
→ The correction values are adopted by the DP master.
If the line-voltage sensing submodule is active, the DP master has to distribute the correction
values to all interconnected HCS724I devices.
Determining the correction value
The central interface module calculates a phase-related line-voltage correction value from
the line voltages detected and from the normalizing values transferred during initialization
(desired line-voltage).
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If the line voltage corresponds to the desired line voltage stipulated in advance (normalizing
value), the correction value is 100 %, i.e. the setpoints are multiplied by a factor of 1.
The correction values for all three phases are transferred in the cylical data sent to the DP
master via PROFIBUS DP. The DP master then passes on the current line-voltage
correction values for calculation of the controller outputs to all the connected central interface
modules.
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
76 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Calculation example
The following examples show how the correction value is calculated and also show the
resulting change in the emitter setpoint for a line-voltage smaller or larger than the
normalizing value.
The normalizing value is to be 230 V.
● Line voltage = 210 V (< normalizing value)
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The parameterized emitter setpoint is multiplied by this correction value:
Emitter setpoint before correction: 80 %
Emitter setpoint after correction: 96 %
● Line voltage = 240 V (> normalizing value)
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The parameterized emitter setpoint is multiplied by this correction value:
Emitter setpoint before correction: 80 %
Emitter setpoint after correction: 73 %
Normalizing values
The normalizing values are phase-related and are permanently assigned to the channels.
For each LA 724I xx, the following is applicable:
Channels 1 to 8 Phase L1
Channels 9 to 16 Phase L2
Channels 17 to 24 Phase L3
Malfunction
If the line voltage detected by the NE 724 is below 80 % or above 120 % of the entered
normalizing value, a line-voltage sensing fault is assumed. The correction value is set to "1"
and a signal is sent to the S7 CPU.
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 77
7.2.3 Operation of the power output modules/load switching units
Operation (activation/deactivation) of the power output modules/load switching units with the
controller outputs is synchronized by phase L1.
From this signal, all the subsequent zero passages for L1, L2 and L3 are formed. For each
zero passage signal, the corresponding phase is controlled.
New data
If, during operation, new data arrive from the S7 (emitter setpoints, production setpoints or
line-voltage correction values), processing of the outputs is not stopped. The new values are
processed step by step (for controller output calculation, see "Controller output calculation"
(Page 72)) and used for controlling the power outputs.
Control
The channels can be operated either with half-wave or full-wave control. In the case of half-
wave control, the channel is controlled - in relation to the parameterized controller output -
every time there is a zero passage but, with full-wave control, this is only done for every
mains-supply period.
The controller outputs are set in values from 0 to 100 %.
In the case of half-wave control, the reference basis is 1 second and, for full-wave control, it
is 2 seconds.
Example
1 % in the case of half-wave control
⇒ Switching of the emitter with 1 of 100 half waves.
Precision
The controller outputs are calculated from different variables (see "Line-voltage correction"
(Page 75)). The figures are rounded up to the next integral percentage value.
A "superimposed" cycle can be configured by means of a configuration parameter. The
figures in this case are rounded up to the next 0.5 % value. Here, however, there is an
increase in the cycle to 2 seconds in half-wave mode or 4 seconds in full-wave mode.
Example
At 50.5 %, one cycle is controlled with 50 % and the following cycle with 51 %.
Note
Channel control with 0.5 % only makes sense if slow heat emitters, e.g. quartz emitters or
heating cartridges, are used. In the case of Flash emitters, a satisfactory result cannot be
achieved in this way.
Functions
7.2 Operating the HCS724I
SIPLUS HCS724I
78 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Load distribution
Uniform load distribution over all outputs of a phase is achieved by means of a static control
table. This also applies to the use of several interconnected HCS724I devices linked to a DP
master.
By means of appropriate configuration, uniform load distribution can be achieved over the
three phases.
Direct component
In the case of half-wave control, the channles are controlled without a direct component.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 79
7.3 Monitoring functions of the HCS724I
The heater controller monitors
● the outputs of the power output modules/load switching units
● the temperature of the LA 724I/LA 724I HP power output modules
● the 24 V supply voltage of the LA 724I SSR load switching unit
If a fault has occurred, a fault signal is provided for the DP master.
Each power output can be enabled for the test directly or by means of the associated field.
Communication between the DP master and the HCS724I is monitored on the PROFIBUS
DP.
Note
The temperature of the heat emitters is not monitored by the HCS724I.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
80 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.3.1 Cyclic monitoring of the outputs of the LA 724I xx
During operation, the outputs are monitored by the software. An output is included in the test
if both the channel and the associated field have been enabled for the test.
Test types
For testing, a distinction is made between a) standard diagnosis and b) extended diagnosis
with current measurement.
● Standard diagnosis:
If an emitter is operated from one channel, the focus is on fault localization: Faults on the
module or external faults.
Diagnosis is carried out by means of voltage measurement.
For exact differentiation of the fault, a current measurement is subsequently carried out.
● Extended diagnosis:
If several emitters are operated from one channel, an important factor is the information
as to whether one or several emitters have failed.
For this purpose, a current measurement with power calculation is carried out. The power
calculation is carried out with the voltage values from the NE 724 or with the
parameterized data.
Note
It is only permissible to use extended diagnosis with current measurement for detecting
an emitter failure in a situation where emitters are connected in parallel.
If one emitter per channel is being used, standard diagnosis must be selected.
Note
For current measurement with the LA 724I SSR, an external SM 724I current measuring
module is needed. The diagnosis system assumes that, when standard diagnosis is
used, the signals of the load circuit are fed back to the LA 724I SSR and that, when
extended diagnosis with current measurement is used, only the current measuring
module is connected and no signals are sent back from the load circuit.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 81
Test cycles
If all the outputs have been enabled for the test, the sequence of steps in the test are as
follows:
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Figure 7-2 Channel sequence for diagnostic cycle
If a channel has not been enabled for the test, it is ignored during the sequence.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
82 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Test parameters
For the test cycle, the switching signal of the channel must be changed. This means that the
switching signal is falsified:
● Standard diagnosis:
The measuring cycle covers two full waves; for one full wave, the channel is pulsed and,
for the other full wave, it is de-energized.
It is only in the event of a fault that all the channels of the current phase are de-energized
for a full wave in order to detect the external fault.
● Extended diagnosis:
The measuring cycle covers two full waves. For one full wave, the channel is de-
energized and, for the other full wave, the test channel is pulsed and the remaining
channels of the phase are de-energized. This is necessary for current measurement.
A diagnostic cycle always includes all the channels enabled for the test.
In order to optimally adapt the diagnostic cycle to the process, the following configurations
are possible:
● Channels can be excluded from the test by means of the channel parameters or the field
parameters. A channel is only tested if, in both types of parameter, the channel has been
enabled for testing.
● For each channel, it is possible to parameterize whether current measurement is to be
carried out as a standard measure or not. If standard diagnosis has been chosen, current
measurement is only carried out to locate a fault that has been detected. In other cases,
current measurement with evaluation is carried out for the channel in each test cycle.
● The diagnostic cycle is performed only in Standby and Production modes.
● It is possible to configure how many repeat measurements are to be carried out before a
detected fault is reported to the DP master or indicated by the LED.
● A configurable pause between the tests of two channels can be set (at 50 Hz in
increments of 50 ms).
● A pause between two diagnostic cycles can be configured. After the last channel has
been tested, a start is normally made again with the first channel to be tested. If a pause
is configured, x diagnostic cycles are omitted before a start is made with the first channel
to be tested.
Cycle duration
A test cycle for 384 channels lasts approximately 20 seconds.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 83
Types of fault LA 724I and LA 724I HP
The diagnostic function distinguishes between the following faults in the standard diagnostic
cycle:
● Module fault 1 (fault type 1)
– The circuit-breaker cannot be closed (Triac is highly resistive).
– The module fuse has blown.
These faults cannot be specified in more detail by the diagnostic function of the HCS724I.
● Module fault 2 (fault type 2)
The circuit-breaker cannot be closed (Triac has a short-circuit).
● External fault (fault type 2 external)
The heating circuit has been interrupted due to
– blown external fuse
– cable break
– heat emitter defect.
In the case of extended diagnosis, the following faults are also detected:
● Rated power at the channel is exceeded (fault type 4).
At the output, one or several emitters are being operated at too high a power level. The
rated power and the deviation can be configured.
● Power at the channel falls below the rated power (fault type 3).
At the output, emitters are being operated at too low a power level or at least one emitter
has failed. The rated power and the deviation can be configured.
Note
In the case of heat emitters whose resistance is heavily dependent on the temperature
(e.g. Flash emitters), bear in mind that the resistance and therefore the actual power
depends on the emitter's setpoint. In other words, at 10 %, the power of a half wave is
higher than at 100 %. This is reflected by the measured value.
If this behavior is not taken into account, it can lead to a fault signal of the extended
diagnosis function. If necessary, the value for the tolerance range (permissible deviation
from the rated power) is to be adapted or the diagnostic function is to be deactivated.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
84 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Fault types LA 724I SSR
The diagnostic function distinguishes between the following faults in the standard diagnosis
cycle.
A more differentiated distinction in the case of multiple faults is not possible.
● Module fault (fault type 5)
– The output driver is defective.
– The 24 V switching cable has a short-circuit.
– The 24 V switching cable has been interrupted.
● External fault 1 (fault type 1)
– SSR is defective and cannot be switched on.
– The cable leading to the SSR has been interrupted.
– The external channel fuse has blown.
● External fault 2 (fault type 2)
– SSR is defective and cannot be switched off.
– Emitter defect
– Cable break
In the case of extended diagnosis, the following faults are also detected:
● Rated power at the channel is exceeded (fault type 4).
At the output, one or several emitters are being operated at too high a power level. The
rated power and the deviation can be configured.
● Power at the channel falls below the rated power (fault type 3).
At the output, emitters are being operated at too low a power level or at least one emitter
has failed. The rated power and the deviation can be configured.
Note
In the case of heat emitters whose resistance is heavily dependent on the temperature
(e.g. Flash emitters), bear in mind that the resistance and therefore the actual power
depends on the emitter's setpoint. In other words, at 10 %, the power of a half wave is
higher than at 100 %. This is reflected by the measured value.
If this behavior is not taken into account, it can lead to a fault signal of the extended
diagnosis function. If necessary, the value for the tolerance range (permissible deviation
from the rated power) is to be adapted or the diagnostic function is to be deactivated.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 85
7.3.2 Monitoring of the outputs of the LA 724I xx by means of a "job"
Monitoring of the outputs by means of a separate job is possible, especially for testing and
commissioning.
In the HCS724I, this job triggers a diagnostic cycle via the channels of all the existing LA
724I xx devices. Parameterized pauses or repeat measurements as described in the
previous section are not evaluated.
What is decisive for the test is the type of channel diagnosis selected. Standard diagnosis
(diagnosis by means of current measurement) is set for each channel (default setting).
The result of diagnosis is directly reported to the DP master; it is not stored in the HCS724I.
The description of the job is given in "Functions > Data exchange between an S7 DP master
and the ZA 724" (Page 88) and "Functions > Data exchange between a non-S7 DP master
and the ZA 724" (Page 113).
Note
This job can also be used during operation if a diagnostic cyle is to be carried out explicitly at
certain times.
If this is done, it must be ensured that cyclical diagnosis has been switched off. This is done
by blocking diagnosis for all the fields used.
7.3.3 Controller outputs of the LA 724I xx
The controller output is calculated by multiplication of the channel setpoint by the field factor
and the factor resulting from line-voltage compensation.
If the product exceeds 100 %, the controller output is restricted to 100 % and an alarm is
output. Heating continues.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
86 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.3.4 Temperature at the power outputs
At the LA 724I and LA 724I HP power output modules, the temperature of the heat sink is
monitored permanently.
If the temperature exceeds the set limit (T ≥ 92 °C), this is reported to the DP master.
Exceeding of the alarm threshold does not lead to an interruption of the heating cycle.
WARNING
In the DP master, there must be a reaction to this alarm signal. For example, the user must
take appropriate measures for cooling (use fan).
If the temperature of the heat sink continues to rise, the power outputs of the module are
deactivated at approximately 100 °C.
This fault signal is also sent to the DP master.
Note
When both faults have been eliminated, the operating mode for recommencement of heating
must be reactivated via the DP master.
7.3.5 24 V on the load controllers
The 24 V supply voltage is permanently monitored at the LA 724I SSR load switching unit.
If the 24 V supply voltage fails, this failure is reported to the DP master.
The control outputs of the module are thus rendered inactive.
Note
When both faults have been eliminated, the operating mode for recommencement of heating
must be reactivated via the DP master.
Functions
7.3 Monitoring functions of the HCS724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 87
7.3.6 Communication
The connection between the DP master and DP slave is monitored with the help of
PROFIBUS DP mechanisms.
In the DP master, the failure of a slave is detected and indicated to the user, who can then
react accordingly.
In the HCS724I, a failure of the DP master or communication is detected. The HCS724I
reacts according to the configuration:
The current status of the outputs is maintained or all outputs are de-energized.
Note
When both faults have been eliminated, the operating mode for recommencement of heating
must be reactivated via the DP master.
Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
88 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.4 Data exchange between an S7-DP master and ZA 724
7.4.1 STEP 7 project provided
The
STEP 7
project in the "HS724i.zip" file on the CD supplied contains all the functions and
data needed for operating one or several HCS724I devices on the PROFIBUS DP.
The project must be copied onto the hard disk by selecting "Unzip File..." and loaded into the
STEP 7
Manager.
In addition to the functions, function blocks and data blocks described in the following
chapters, the software contains the following application as an example:
● DB_PLC_TEST
This data block contains all the necessary test data.
● OB1
Cyclical sequence control program which controls the HCS724I.
● OB100
Program used as an example for the reaction to start/restart in an S7-300 CPU
In the project, the following hardware configuration is stored as an example:
● CPU 316-2 DP
● CPU program with blocks for operation of an HCS724I with 384 channels
● Data blocks prepared for the operation of
– one HCS724I unit with 384 channels
– two HCS724I units each with 384 channels
– three HCS724I units each with 384 channels
Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 89
If necessary, the CPU can be replaced with another CPU.
If two or three HCS724I are operated as an interconnected group, the data blocks can be
copied from the corresponding directory (e.g. DBs_for_2_HS) into the CPU data block
directory. The hardware configuration must be supplemented accordingly.
The data blocks can also be generated using the configuration tool supplied on the CD (see
"Generating the data blocks" (Page 107))
The application is designed to support a group of up to 24 HCS724I units. The data blocks
for this purpose must, however, be adapted accordingly.
Numbers have been assigned for the data blocks, functions and function blocks. They can
be renamed (exception: DB_HS_WORK).
If, for some reason, the number of DB_HS_WORK has to be changed, consult HCS724I
Support.
The blocks have not been disabled. The comments are available in German and English. For
changing over between languages, please refer to the Help function of the S7 Manager.
Note
Disclaimer
SIEMENS AG assumes no liability for any claims arising from use of the
STEP 7
project
(examples of data/function blocks) provided in the scope of supply; in particular not for
personal injury, damage to property or financial loss that are the direct or indirect
consequence of using the data/function blocks provided as examples within the scope of
supply.
Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
90 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.4.2 Software structure
The S7 software for operating the HCS724I features an interface composed of data blocks
and function blocks/functions which enable an application to gain access to one or more
HCS724I modules in a relatively simple manner.
The data needed for the sequence of steps involved in control of the equipment are
managed in data blocks. The structure of these blocks has been fixed permanently in
advance.
Access to the HCS724I devices by means of orders in the PROFIBUS DP data is enabled by
means of functions.
Because the entire PROFIBUS data area of an HCS724I, i.e. 32 bytes of input data and 32
bytes of output data, has to be consistent, access to the replica of the peripheral devices
takes place via SFC14 "DPRD_DAT" and SFC15 "DPWR_DAT". These SFCs exist in each
S7 CPU.
If more than 384 heat emitters have to be controlled, several HCS724I modules can be
operated as an interconnected group via the S7 interface. For the purposes of shared
management, the HCS724I modules and their channels are simply numbered in sequence:
● First HCS724I, channel numbers 1 to 384
● Second HCS724I, channel numbers 385 to 768
There is an indirect restriction of the number of modules that can be managed due to the
limited memory of the S7 CPU and due to the time needed for supplying the HCS724I with
data.
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Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 91
Block structure
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'%B+6B
',$*
'%B+6B
,%6
Figure 7-4 Structure of S7 program
The S7 software for the HCS724I is essentially composed of the following areas, which are
explained in the chapters below:
● Data blocks for the management of parameters and configuration data
● Data blocks for storing diagnostic and commissioning information
● Functions in the form of a user interface for the performance of different tasks
● Function block for communication with the HCS724I via PROFIBUS DP
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7.4.3 Data blocks
In the software, data blocks constitute the actual user interface.
The following data blocks are needed for operating the HCS724I modules:
DB_HS_INIT (initializing data)
DB_HS_KANAL (data for parameterizing the individual power outputs)
DB_HS_FELD (data for managing the outputs in groups)
DB_HS_DIAG (information on the status of outputs and power output modules)
The following data blocks are optional for operating the HCS724I modules:
DB_HS_IBS (measured values from the HCS724I - essentially only for
commissioning)
The DB_HS_WORK contained in the structure contains working data. It is managed by the
S7 DP master.
7.4.3.1 DB_HS_INIT
In this data block, all the data are contained which are needed for configuring an HCS724I.
These data are needed once for intialization and are then no longer changed. In addition to
the HCS724I configuration data, there is also the necessary S7 information for assigning
addresses to one or several HCS724I modules. The data block also contains the information
supplied from the HCS724I to the DP master during initialization.
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Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 93
Structure of an entry in the data block
The following table shows the structure of an entry in the data block. The number of
structures corresponds to the number of HCS724I modules operated together. The data
block contains an array composed of these structures.
The data marked with a star are transferred from the HCS724I to the S7 during the
initialization phase and should be checked for correctness by the user.
Name Type Meaning
AnzHS WORD Number of available HCS724I modules
EAdr INT Starting address from the input range of the HCS724I, is set with
HW Config during DP configuration
AAdr INT Starting address from the output range of the HCS724I, is set with
HW Config during DP configuration
NrKanal INT Number of the first channel of the HCS724I (If one HCS724I is
operated, the number 1 is to be entered here. This channel
number must always be in a 24 pattern (1, 25, ...).)
For setting the rotating field test for each LA 724I xx (there is one
bit for each LA 724I module)
Bit = 0: Do not perform test
PrDrehfeld WORD
Bit = 1: Perform test
Reserv BYTE -
Result of the line frequency test
50: 50 Hz
60: 60 Hz
ErgPrNetzfreq* BYTE
0xFF: undefined
Result of the rotating field test (there is one bit for each LA 724I xx
module)
Bit = 0: Test without faults
ErgPrDrehfeld* WORD
Bit = 1: Fault found during rotating-field test
Information on each LA 724I xx found:
0x00: No module present
0x01: LA 724I present
0x02 : LA 724I HP present
0x10: LA 724I SSR present
LaInfo* ARRAY
(BYTE)
0xFF: Old LA 724 found (fault)
Information on the optional NE 724
0: NE 724 is not present
NeInfo* BYTE
1: NE 724 is present
Reserv* BYTE 0 (reserved for later information on the ZA 724)
ZaInfo* ARRAY
(BYTE)
Firmware version of the ZA 724 in the format Vxx.yy.zz
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7.4.3.2 DB_HS_KANAL
In this data block, all the parameters needed for a channel are collected: This data block
must always be present.
Structure of an entry in the data block
The following table shows the structure of an entry in the data block. The number of
structures corresponds to the number of channels that exist. The data block contains an
array composed of these structures.
Note
If a group of interconnected HCS724I modules is used, all the channels have to be entered
here; the DB only exists once.
Name Type Meaning
NrKanal INT Number of the configured channel, value range 1 to xx
(depending on the number of channels used)
Sollwert BYTE Setpoint for production mode with profile 1 and for standby mode in [%],
value range 0 to 100
With Bit7 = 1, 0.5 % can be set.
SwAnlauf BYTE Setpoint for starting [%], value range 0 to 100
With Bit7 = 1, 0.5 % can be set.
Sollwert2 BYTE Setpoint for production mode with profile 2 in [%], value range 0 to 100
With Bit7 = 1, 0.5 % can be set.
Test setting for the channel (see "Job 11: field diagnostics" (Page 124))
0: Channel is not tested
1: Channel is tested with standard diagnosis
Diag BYTE
2: Channel is tested with extended diagnosis
Pnenn INT Rated power to be expected at a channel in [W]
This parameter must have been assigned a valid value if extended
diagnosis with current measurement is used.
Pabw INT Permissible upward and downward deviation from the rated power in [W]
This parameter must have been assigned a valid value if extended
diagnosis with current measurement is used.
Functions
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Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 95
7.4.3.3 DB_HS_FELD
In this data block, all the parameters needed for a field description are contained: This data
block must always be present.
Structures of the possible entries in the data block
The following table shows the structures of the possible entries in the data block. The
number of structures corresponds to the number of fields that are needed. The data block
contains an array of the different structures.
Note
If a group of interconnected HCS724I modules is used, all the fields have to be entered here;
the DB only exists once.
Here, there must be one field per HCS724I as a minimum configuration for operation.
Name Type Meaning
NrFeld BYTE Number of the field, value range 1 to 127
Field type
0: All channels between the beginning and the end
1: Every second channel between the beginning and the end
Type BYTE
2: List with channels
FakProd BYTE Field factor for production mode with profile 1 and profile 2 in [0.00),
range of values 0 to 255
FakStBy BYTE Field factor for standby mode in [0.00],
Value range 0 to 255
Test setting for the channel (see "Job 10: Channel diagnostics"
(Page 123))
0: None of the field's channels are tested.
Diag BYTE
1: All the field's channels enabled for the test are tested.
Reserv BYTE 0
Entries for field types 0 and 1 Entries for field type 2
AKanal INT Number of the first channel in the field -
EKanal INT Number of the last channel in the field -
AnzKanal INT - Number of subsequent
channels
NrKanal ARRAY
(INT)
- Channel numbers in the field
In order to delete a field, field type 2 with AnzKanal = 0 must be used.
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7.4.3.4 DB_HS_DIAG
This data block contains all the diagnostic information. This includes the module-specific
fault signals and alarms as well as the channel-specific fault signals and alarms. This data
block must be present.
Structures of the different entries in the data block
The following table shows the structures of the different entries in the data block. The
number of structures corresponds to the number of HCS724I modules and the number of
channels. The data block contains an array composed of these structures.
Note
If a group of interconnected HCS724I modules is used, the fault information of all power
output modules/load switching units and channels has to be entered here; the DB only exists
once.
Name Type Meaning
NrHS BYTE Consecutive number of the HCS724I
Fault in line voltage sensing L1
0: No fault
ErrNeL1 BYTE
xx: Measured value
Fault in line voltage sensing L2
0: No fault
ErrNeL2 BYTE
xx: Measured value
Fault in line voltage sensing L3
0: No fault
ErrNeL3 BYTE
xx: Measured value
Error during initialization of the HCS724I
0x01: Old power output found
0x02 : Power output module/load switching unit without ID found
0x04: It was not possible to determine the frequency.
ErrInitLa BYTE
Several faults can be signaled at the same time.
Reserv BYTE 0
Fault alarm for the first LA 724I xx (first tier):
1: Temperature warning threshold exceeded
(LA 724I / LA 724I HP)
2: Temperature trip threshold exceeded
(LA 724I/LA 724I HP)
ErrTemp1 BYTE
3: 24 V supply voltage failed
(LA 724I SSR)
.
.
.
ErrTemp16 BYTE Fault alarm for the sixteenth LA 724I xx (second tier)
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Name Type Meaning
NrKanal INT Number of channel
Fault information about the channel
0: Output is o.k.
1: Fault type 1
2: Fault type 2
3: Fault type 2, external
4: Fault type 3
5: Fault type 4
6: Fault type 5
ErrKanal BYTE
(For types of fault, see "Cyclic monitoring of LA 724I xx outputs"
(Page 80))
Alarm that has occurred for this channel
0: Controller output is o.k.
1: Incorrect controller output due to setpoint x field value
WKanal BYTE
2: Incorrect controller output due to line voltage compensation
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7.4.3.5 DB_HS_IBS
This data block contains all the information resulting from the commissioning jobs. This
includes the module-specific actual values as well as the channel-specific actual values. This
data block must be present if commissioning jobs are used.
Structures of the different entries in the data block
The following table shows the structures of the different entries in the data block. The
number of structures corresponds to the number of HCS724I modules and the number of
channels. The data block contains an array composed of these structures.
Note
If a group of interconnected HCS724I modules is used, the commissioning information of all
power output modules/load switching units and channels has to be entered here; the DB only
exists once.
The values are only valid if the HCS724I has been initialized and an operating mode has
been activated. The channel measured values are only valid if expanded diagnosis with
current measurement has been parameterized for the channel.
Name Type Meaning
NrHS BYTE Consecutive number of the HCS724I
ErrTemp1 INT Measured temperature for the first power output module (first tier)
in [°C]
If a measured value is not available, 0 must be entered here.
.
.
.
ErrTemp16 INT Measured temperature for the sixteenth power output module
(second tier)
Name Type Meaning
NrKanal INT Number of channel
Stellgröße BYTE Current controller output of the channel in [%]
Reserv BYTE
Strom INT Measured current belonging to the currently measured nominal
power in [10–2 A]
Leistung INT Currently measured nominal power at the channel in [W]
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Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 99
7.4.4 Functions and function blocks
In addition to the central function blocks for managing the different HCS724I modules, there
are also some functions which are preferably used for controlling the cyclical data.
The tasks of the functions are described in the following sections of this document.
7.4.4.1 FC_HS_INIT
The heater controllers must be initialized once during starting. For this purpose, there is a
function which has to be called after start-up of an HCS724I. The function is responsible for
initializing the HCS724I.
In addition to the data from the DB_INIT, which can be different for every HCS724I, the data
which have to be identical for all HCS724I modules are transferred when the function is
started.
Note
If a group of interconnected HCS724I modules are operated, initialization of all HCS724I
modules must have been completed successfully in order to be able to start operation.
The function can be started cyclically in order to be able to carry out automatic initialization
after a cold start/hot restart of the DP master.
Call interface
Parameter Declaration Data type Description
NrDbInit INPUT BLOCK_DB Number of the data block which contains the configuration
data.
Pulsing of the channels in the event of a fault (PROFIBUS
fault):
0: None of the outputs are pulsed any more
(setpoint 0 %)
ErrDP INPUT BYTE
1: The outputs retain the last value which was
set
Line voltage compensation function
0: deactivated
1: activated
NeFunktion INPUT BYTE
This has an effect on all the HCS724I modules connected.
NeNennSpg INPUT INT Nominal value of the line voltage (e.g. 230 V) is used
as the normalizing value for line voltage compensation
for power calculation without NE 724
Integration time for line voltage compensation
in multiples of 300 ms
0: No repetition of the measurement
1 ... 254: Number of repetitions
NeZeit INPUT BYTE
Only necessary if the function has been activated.
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Parameter Declaration Data type Description
DiagTZyk INPUT BYTE Diagnostic cycle:
Number of pause cycles between two diagnostic cycles 0
to x
DiagTKanal INPUT BYTE Diagnostic cycle:
Number of pause times between two channel diagnoses 0
to x
DiagRepeat INPUT BYTE Diagnostic cycle:
Number of repetitions when a fault is detected, until the
fault is actually reported to the master (0 to 10)
Pulsing of the power outputs with
0: Half-wave mode (time basis s)
1: Full-wave mode (time basis 2 s)
2: Half-wave mode, 0.5 % increments (time
basis 2 s)
LSControl INPUT BYTE
3: Full-wave mode, 0.5 % increments (time
basis 4 s)
Emitters are being operated
0: In star circuit (230 V)
BetStDr INPUT BYTE
1: in delta circuit (400 V) - only LA 724I HP/LA
724I SSR
RetVal OUTPUT WORD Feedback regarding execution
The parameter supplies a fault code:
0000 No fault
See "Alarm, error and system messages > Error
messages in the S7 environment" (Page 133)
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7.4.4.2 FC_HS_AUFTRAG
This function can be used to transfer data which has been changed in the DB_HS_KANAL or
DB_HS_FELD data block to the HCS724I or to read data from the HCS724I into the
DB_HS_DIAG or DB_HS_IBS data block. In the job code, the user must set the
corresponding bit.
More than one job can be inserted in the job code. The cyclical function block works through
all the entered jobs from the LSB (low-value bit) and sends a feedback signal only when
either all jobs have been processed or if a fault has occurred.
Note
Whereas the data blocks DB_HS_INIT, DB_HS_KANAL, DB_HS_FELD and DB_HS_DIAG
always have to be present, the DB_HS_IBS data block is only checked if a corresponding job
has been entered.
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102 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Call interface
Parameter Declaration Data type Description
NrDbInit INPUT BLOCK_DB Number of the data block which contains the
configuration data.
NrDbKanal INPUT BLOCK_DB Number of the data block which contains the channel
descriptions data.
NrDbFeld INPUT BLOCK_DB Number of the data block which contains the field
descriptions.
NrDbDiag INPUT BLOCK_DB Number of the data block which contains the diagnostic
data
NrDbIbs INPUT BLOCK_DB Number of the data block which contains the
commissioning data.
Here, a coded entry is made bit by bit, indicating which
data have changed in the data blocks and are therefore
to be transferred or which data is to be collected for
diagnostic purposes (e.g. new setpoints, new field
values):
0x00000008 Chanel setpoints profile 1/Standby
0x00000010 Channel setpoints profile 2
0x00000020 Channel setpoints start-up
0x00000040 Field definition
0x00000080 Field factor for production mode
0x00000100 Field factor for standby mode
0x00000200 Diagnostic setting for channels
0x00000400 Diagnostic setting for fields
0x00080000 Reading of the general diagnosis
0x00100000 Reading of the channel diagnosis
0x00200000 Reading of the channel alarms
0x00400000 Triggering of a diagnostic cycle with
result
0x20000000 Current channel controller output
(during commissioning)
0x40000000 Current channel measured values
(during commissioning)
0x80000000 Current temperature measured values
(during commissioning)
AuCode INPUT DWORD
Several data can be entered.
RetVal OUTPUT WORD Feedback regarding execution
The parameter supplies a fault code:
0000 No fault
See "Alarm, error and system messages > Error
messages in the S7 environment" (Page 133)
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7.4.4.3 FC_HS_NE
The function is only needed if correction values are to be used for line voltage sensing.
With this function, the line voltage correction values are distributed. The data of the HCS724I
with NE 724 are taken from the input data area and transferred to all HCS724I modules.
Call interface
Parameter Declaration Data type Description
NrDbInit INPUT BLOCK_DB Number of the data block which contains the
configuration data.
Line voltage correction:
0: Values of the HCS724I with line voltage sensing
are transferred to all HCS724I modules
ArtNe INPUT BOOL
1: Values calculated in S7 are transferred to all
HCS724I modules
WertNeL1 INPUT BYTE Correction value for L1 calculated in S7
(only when ArtNe = 1)
WertNeL2 INPUT BYTE Correction value for L2 calculated in S7
(only when ArtNe = 1)
WertNeL1 INPUT BYTE Correction value for L3 calculated in S7
(only when ArtNe = 1)
RetVal OUTPUT WORD Feedback regarding execution
The parameter supplies a fault code:
0000 No fault
See "Alarm, error and system messages > Error
messages in the S7 environment" (Page 133)
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7.4.4.4 FC_HS_BETRIEBSART
This function can be used to control the operating mode of the HCS724I. All the HCS724I
modules are controlled at the same time. The new operating mode should not be selected
until the previously selected operating mode has been acknowledged by all HCS724I
modules.
The feedback must be evaluated by the user. The feedback signals can be found in the
cyclical data (FB_HS_ZYKL).
Call interface
Parameter Declaration Data type Description
NrDbInit INPUT BLOCK_DB Number of the data block which contains the
configuration data.
Operating mode to be selected:
1: Start-up
2: Heating Off
4: Standby mode
5: Production with profile 1 mode
Betriebsart INPUT BYTE
7: Production with profile 2 mode
RetVal OUTPUT WORD Feedback regarding execution
The parameter supplies a fault code:
0000 No fault
See "Alarm, error and system messages > Error
messages in the S7 environment" (Page 133)
7.4.4.5 FC_HS_RESET
This function can be used to reset the HCS724I modules. If interconnected HCS724I
modules are operated as a group, they are all reset.
This function is only performed if a job is not currently being executed and the "Heating Off"
mode has been activated. This function is preferably intended for commissioning.
Call interface
Parameter Declaration Data type Description
Reset_Start INPUT BOOL Start of function performance (possibly by means of
a pulse edge)
NrDbInit INPUT BLOCK_DB Number of the data block which contains the
configuration data.
RetVal OUTPUT WORD Feedback regarding execution
The parameter supplies a fault code:
0000 No fault
See "Alarm, error and system messages > Error
messages in the S7 environment" (Page 136)
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7.4.4.6 FB_HS_ZYKL
This function block is responsible for actual control of the HCS724I modules. It processes
the jobs or new data which are transferred with the functions described above.
Every time this function is started, the current status of each HCS724I is updated and
reported to the user. The information "Reporting back of operating mode" as well as "fault
indication" must be checked and evaluated by the user.
The FB must be cyclically started before the described functions in OB 1.
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Call interface
Parameter Declaration Data type Description
NrDbInit INPUT BLOCK_DB Number of the data block which contains the
configuration data.
Neustart_
FehlerQuitt
IN/OUT BOOL Signal for initialization of the DB_HS_WORK data
block
The signal must be activated by the user
after cold start/hot restart of the S7
for acknowledgement after a job fault
The signal is then reset by the respective function.
Pointer to an area in which the cyclical input data of
each HCS724I can be stored: 4 bytes per HCS724I
Byte 0:
Status of the HCS724I modules (several feedback
signals are possible at the same time)
Bits 7 to 5:
Fault indication, diagnostic information available
0x80 Channel alarm signal
(→ Job Read channel alarms)
0x40 Channel fault signal
(→ Job Read channel faults)
0x20 General fault signal
(→ Job Read general diagnosis)
Bits 4 to 2:
Feedback indicating operating mode
0x04 Feedback signal Start-up mode
0x08 Feedback signal Heating OFF mode
0x10 Feedback signal Standby mode
0x14 Feedback signal Production with profile 1
mode
0x1C Feedback signal Production with profile 2
mode
0x00 Request for selection of a new mode
Bits 1 to 0:
Feedback indicating initialization - for information
purposes
0x00 HCS724I must be initialized
0x03 HCS724I has been initialized and is
ready for operation
0x01
0x02
Serious fault when starting up the
HCS724I
Byte 1:
Line voltage correction value for L1
Byte 2:
Line voltage correction value for L2
HS724i_zust IN/OUT POINTER
Byte 3:
Line voltage correction value for L3
RetVal OUTPUT WORD Feedback regarding execution
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Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 107
7.4.5 Generation of data blocks
7.4.5.1 Prerequisites
The configuration tool is a Microsoft® Excel® based macro.
It is in the file HCS724IConfigToolV1.0.xls in the directory \S7ConfigTool on the supplied CD.
The file must be copied prior to execution to a write-enabled working directory.
The execution of macros must be permitted in the security settings of Microsoft® Excel®.
7.4.5.2 Function
The configuration tool supports the creation of data blocks which are necessary for
communication between the S7 sample program and the heater controller.
After entering the setup information for the heater controller into the input screen of the
configuration tool, STL sources of the following data blocks are generated in the current
directory from which the tool was started:
● DB_HS_INIT (DB241.awl)
● DB_HS_KANAL (DB242.awl)
● DB_HS_FELD (DB243.awl)
● DB_HS_DIAG (DB244.awl)
● DB_HS_IBS (DB245.awl)
Data sources are generated for the STEP7 sample program Version V2.x and higher.
They include all the data that the S7 sample program needs in order to supply the ZA724I
with the setup information and to communicate during normal operation. The basic structure
of the data blocks is described in "Data blocks (Page 92)".
After entering the configuration data and generating the STL sources, these must be inserted
as an external source in the example project ("Insert> External source") and then compiled in
the data blocks ("Edit > Compile").
The entered data can be saved in the MS Excel® file on closing the application.
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7.4.5.3 Description of the input fields
The input screen is divided into three areas:
1. ZA724I setup
2. Channel setup
3. Field setup
Figure 7-5 Input screen for configuration tool
Functions
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Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 109
First area: ZA724I setup
Data entered in this area is generated in the DB_HS_INIT that was described in
"DB_HS_INIT" (Page 92).
● Number of ZY7241
The number of ZA724I that should be controlled using the program. The configuration
tool supports the input of data for a group of up to 24 HCS724I.
Note
A change in the number of ZA724I causes all other entries to be reset.
● LA724I HP
This check box is activated if only LA724I HP should be operated on the ZAs.
In the case of a mixed configuration or exclusive operation of LA724I, the check box
must not be activated.
● Rotation field test
Selection of the rotation field test for all the available LA724I xx power output modules.
● ZA number
The ZA number is selected depending on the entry "Number of ZA7241". For each ZA
number, the four following fields must be completed.
● Input address from HW Config
The hardware input address configured in HW Config is entered here and assigned to the
ZA that is selected with "ZA number".
● Output address from HW Config
The hardware output address configured in HW Config is entered here and assigned to
the ZA that is selected with "ZA number".
● First channel on ZA
The first channel on the ZA is specified here.
● Last channel on ZA
The last channel on the ZA is specified here.
Note
Channel numbering
The channel numbers must be specified in a grid of 24. The first channel of the first ZA must
always be 1. The first channel of the following ZAs must follow the last channel of the
previous ZA without a gap. The number of the last channel of a ZA must always be divisible
by 24.
Example for two ZAs in the maximum configuration of 16 LAs each: Channel numbers 1 to
384 and 385 to 768
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110 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Second area: Channel setup
Data entered in this area is generated in the DB_HS_KANAL that was described in
"DB_HS_KANAL" (Page 94).
● Number of channels
This field is only used for display purposes and is derived from the last configured ZA.
● Channel setpoint 1
The channel setpoint used for operating modes "Production profile 1" and "Standby" is
specified here. The input is in the range from 0 to 100 % and is valid for all configured
channels. Changes are possible via the PLC program.
● Channel setpoint 2
The channel setpoint used for the operating mode "Production profile 2" is specified here.
The input is in the range from 0 to 100 % and is valid for all configured channels.
Changes are possible via the PLC program.
● Channel setpoint startup
The channel setpoint used for the operating mode "Startup" is specified here. The input is
in the range from 0 to 100 % and is valid for all configured channels. Changes are
possible via the PLC program.
● Standard diagnostic
When this option is selected, standard diagnostics is activated for all channels. if no
selection is made here, diagnostics will not be performed.
● Advanced diagnostic
This option only appears after selection of the standard diagnostics. Selection of this
option activates advanced diagnostics for all channels.
● Deviation from rated power
This input field only appears after selection of the advanced diagnostics. The maximum
permissible power deviation is entered here. The power is entered in watts and is valid for
all configured channels.
If emitters of different power ratings are operated on the channels, these values must be
changed later in the generated data block.
● Rated power
This input field only appears after selection of the advanced diagnostics. The connected
power is entered here. The power is entered in watts and is valid for all configured
channels.
If emitters of different power ratings are operated on the channels, these values must be
changed later in the generated data block.
Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 111
Third area: Field setup
Data entered in this area is generated in the DB_HS_FELD that was described in
"DB_HS_FELD" (Page 95).
● Number of fields
The number of fields to be used in setting up the heater controller is entered here.
● Field factor production
The field factor used for the operating modes "Production profile 1" and "Production
profile 2" is entered here. The input is in the range from 0 to 100 %.
● Field factor standby
The field factor that is used for the operating mode "Standby" is entered here. The input is
in the range from 0 to 100 %.
● Field number
Selection field for the field number; derived from the number of fields.
● Field type
Field type of the field selected by field number.
Note
When the check box "LA724I HP" is activated under "ZA setup", all fields with field type 1
are preset to ensure that no other selection is possible.
Note
Field type 2 is not supported. If this field type is used, the generated data blocks must be
adapted manually.
● First channel
The number of the first channel in the field.
● Last channel
The number of the last channel in the field.
Note
Field configuration
First and last channel of a field must be within the same ZA.
Functions
7.4 Data exchange between an S7-DP master and ZA 724
SIPLUS HCS724I
112 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Operator controls
● Clear data
Erases all the data you have entered.
● Generate
Checks the entered data for consistency and generates the STL sources for the data
blocks. If errors occur in the configuration, a message is output with an error description.
Note
The generation process can take several minutes for configurations with more than 6 ZAs
in maximum configuration. There is no progress display.
● Exit
Closes the application and saves the entered data.
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 113
7.5 Data exchange between a non-S7-DP master and ZA 724
7.5.1 PROFIBUS DP interface
The HCS724I is a DP slave which is described by means of a GSD file and can be operated
from any DP master. Because the amount of data needed to operate the HCS724I exceeds
the amount of data possible in the PROFIBUS DP, message frame transfer takes place on
the basis of cyclical DP data. Because message frame transfer takes some time, some of
the cyclica data is kept in the input/output area in order to transfer certain data quickly.
An input area and an output area, each of 32 bytes, is provided for the HCS724I . This area
cannot be enlarged because the data must be read and written consistently by the DP
master (due to message frame transfer)
I/O data
The division into four bytes of cyclical data and 28 bytes for message frame transfer applies
to the input area and the output area in the same way.
In general, the following applies to the following lists: Input data are data which are
transferred from the slave to the master; output data are data which are transferred from the
master to the slave.
Table 7- 3 Input/output area PROFIBUS DP
Byte Description
0-3 4 bytes of cyclical data
4-31 28 bytes of message frame data
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
114 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.2 Datagram data
The last 28 bytes in the DP data are reserved for message frame transfer between master
and slave. Each message frame consists of a header of two bytes which contains the job
code and of useful data in which the job data, including the total length of the job, are placed.
The message frame data are described in "Message frame procedure" (Page 115).
Table 7- 4 Message frame structure
Byte Bit Meaning
0 Job code - is acknowledged by the HCS724I
6-0 Sequence number - is acknowledged by the HCS724I.
If a fault occurs during transfer, the fault number is entered
here by the HCS724I.
Fault in the job, indicated by the HCS724I
0: No fault
Message frame
header 1
7
1: Faults
2-3 Byte In the first job (message frame with sequence number 0),
the net data length of the whole job is entered here.
The length of the whole job must not exceed 2000 bytes.
Big Endian is applicable to storage of the word value.
4 Byte Data 1 …
…
Useful data
27 Byte
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 115
7.5.3 Datagram sequence
The job in the reading direction is sent according to the same principle but the data are in the
acknowledgement message frame of the HCS724I and are received and evaluated by the
DP master.
Combined write/read jobs are handled in the same way: Here, both the job of the DP master
and the acknowledgement response of the HCS724I contain useful data.
For purposes of detecting a new job, it is necessary in the HCS724I to cyclically scan and
evaluate the first byte, which contains the job code. In quiescent mode, this byte is set to 0
by the DP master. A new job is initiated and processed as the result of a valid job code being
entered. After acknowledgement of the last message frame of the job by the HCS724I, the
DP master sets the job byte to 0 in quiescent mode. Two jobs are always separated from
each other as a result of assumption of the quiescent mode between the DP master and the
HCS724I. The remaining 27 bytes are irrelevant in quiescent mode.
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Figure 7-6 Message frame sequence
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
116 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.4 Cyclic data
In the cyclical data, information is transferred between the master and slave and should
immediately lead to a reaction. These are data which exist once for each HCS724I.
These cyclical data bytes are cyclically scanned and evaluated both in the DP master and
the HCS724I.
These data are listed and explained in the tables below.
Table 7- 5 Meaning of the cyclical input data
Byte Bit Meaning
Initialization phase (information provided by the HCS724I)
00: HCS724I is in the initialization phase
11: Initialization phase ended, HCS724I is ready
1-0
01 or 10: Initialization phase ended, HCS724I not ready
Feedback indicating the operating mode (response to preselection of the master)
001: Start-up
010: Heating Off
100: Standby mode
101: Production with profile 1 mode
111: Production with profile 2 mode
Indication of a mode change by the HCS724I (after fault)
4-2
000: Reselection of the mode is necessary
1: General fault has occurred in the HCS724I. 5
The bit indicates changes and remains until information is received via job 20:
Diagnosis has been generally collected
1: Channel fault has occurred in the HCS724I. 6
The bit indicates changes and remains until information is received via job 21:
Diagnosis of channel has been collected
1: Channel warning has occurred in the HCS724I.
0
7
The bit indicates changes and remains until information is received via job 22:
Warning regarding channel has been collected
1 Byte Line voltage correction value of the NE 724 for L1
2 Byte Line voltage correction value of the NE 724 for L2
3 Byte Line voltage correction value of the NE 724 for L3
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 117
Table 7- 6 Meaning of the cyclical output data
Byte Bit Meaning
1-0 Reserved
Preselection of the mode (by the master)
001: Start-up
010: Heating Off
100: Standby mode
101: Production with profile 1 mode
4-2
111: Production with profile 2 mode
0
7-5 Reserved
1 Byte Line voltage correction value from master for L1
2 Byte Line voltage correction value from master for L2
3 Byte Line voltage correction value from master for L3
Bits 2 to 4 in byte 0 of the cyclical data are master-control or slave-feedback bits which
corresponding with each other.
7.5.5 Requests (datagram data)
Jobs in the data area of message frames are used to transfer large amounts of data between
the DP master and the HCS724I when this amount of data cannot be exchanged cyclically in
the input/output area of the PROFIBUS DP.
Jobs 01, 02 and 03 are initialization jobs. They must be transferred in this sequence. All
other jobs can be transferred in any sequence with any number of jobs.
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
118 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.6 Request 01: Read module information
The purpose of this job is to read out the current status of the HCS724I during start-up and
to evaluate it in the DP master application.
It is a purely "reading" job.
Table 7- 7 Read module information
Byte 1 Meaning
Information on the first module after the ZA 724 (first module tier)
0x00: No module present
0x01: LA 724I present
0x02 : LA 724I HP present
0x10: LA 724I SSR present
0
0xFF: Old LA 724 found (fault)
... ...
Information on the sixteenth module after the ZA 724 (second module tier)
0x00: No module present
0x01: LA 724I present
0x02 : LA 724I HP present
0x10: LA 724I SSR present
15
0xFF: Old LA 724 found (fault)
Information on the NE 724
0: No module present
16
1: NE 724 is present
Information on the ZA 724 17
0: Reserved
18-23 Information on the HCS724I firmware (length 6 bytes)
Version xx.yy Build zz
1 The byte numbering of this and all subsequent jobs relates to the message frame data area which
begins at byte 4 in a message frame. In the first message frame of a job only at byte 6 because the
net data length is entered here.
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 119
7.5.7 Request 02: Download configuration parameters
This job is used to configure the HCS724I and, depending on this, corresponding
initializations are carried out in the HCS724I firmware.
This job is a purely "writing" job.
Table 7- 8 Load configuration parameters
Byte Meaning
0, 1 Number of the first channel of the HCS724I modules, if an interconnected group of HCS724I
modules are operated from one DP master
Pulsing of the channels in the event of a fault (PROFIBUS fault):
0: None of the outputs are pulsed any more (setpoint 0%)
2
1: The outputs retain the last value which was set
Line voltage compensation function
0: deactivated
1: activated
3
This has an effect on all the HCS724I modules connected.
4, 5 Nominal value of the line voltage (e.g. 230 V) is used
as the normalizing value for line voltage compensation
for power calculation without NE 724
6 NE 724 integration time for line voltage compensation in multiples of 300 ms
7 Configuration of diagnosis (1)
Length of the pause between diagnostic cycles in multiples of the duration of one diagnostic
cycle.
If 255 is entered, the diagnostic cycle is switched off.
8 Configuration of diagnosis (2)
Length of the pause between tests of two channels in multiples of the duration of a channel
test.
Number of repetitions until a fault is transferred to the DP master.
0: Fault is detected and reported immediately
9
1 ... 10: Fault must have been detected in 1 to 10 successive diagnostic cycles.
Selection for triggering the circuit-breakers
0: Half-wave mode (time basis s)
1: Full-wave mode (time basis 2 s)
2: Half-wave mode, 0.5 % increments (time basis 2 s)
10
3: Full-wave mode, 0.5 % increments (time basis 4 s)
Selection of the operating mode for the connected heat emitters
0: Operation with 230 V
11
1: Operation with 400 V
... Other necessary parameters or reserved for future additions (e.g. phase firing)
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
120 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.8 Request 03: Execution of tests
With this job, certain tests can be triggered in the HCS724I. The result must then be
evaluated in the DP master application. This job is therefore a writing and reading job. The
job must be executed because, otherwise, the HCS724I cannot progress from the INIT state.
Table 7- 9 Performance of tests
Byte Meaning
Line frequency test Test result of HCS724I
50: 50 Hz
0
1: Test is performed
60: 60 Hz
Rotating field test
0: Test is not performed
1
1: Test is performed
Test result of HCS724I
For setting the rotating field test for each LA
724I xx (there is one bit for each LA
724I module)
Result of the rotating field test (there is one
bit for each LA 724I xx module)
Bit = 0: Do not perform test Bit = 0: Test without faults
2,3
Bit = 1: Perform test Bit = 1: Fault found during rotating-field
test
7.5.9 Requests 04, 05 and 06: Transfer of channel setpoint values
These jobs are used to transfer the setpoints for a channel. Depending on which operating
mode is used, one or all jobs must be transferred to the HCS724I .
If, for example, the "start-up" or "profile 2" modes are not needed, it is sufficient to transfer
the setpoints for production mode (profile 1) by means of job 04 (operating mode as in
HCS724I).
Any of the setpoints can be overwritten at any time. As long as no setpoints have been
transferred, the initialization value 0 % is applicable. The value range for the setpoint is from
0 to 100 (basis 1 %).
Setting bit 7 in the setpoint enables a lower-level setting of 0.5 % to be made.
Table 7- 10 Transfer of channel setpoints
Byte Bit Meaning
of job 04
Meaning
of job 05
Meaning
of job 06
0, 1 Channel number
6-0 Setpoint for standby and
production mode with profile
1
Setpoint for production
mode with profile 2
Setpoint for start-up
0: Setpoint 0
2
7
1: Setpoint 5
3, 4 Channel number
… … … … …
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 121
7.5.10 Job 07: Field allocation
This job is used to put channels together in fields in order to change the setpoints of the
channels by means of a common field factor.
There are three types of field:
● Indication of the first and last channel of a field with use of each channel
● Indication of the first and last channel of a field with use of every second channel
● Indication of all channels
A maximum of 127 fields can be defined, starting with number 1 (field 0 is reserved).
Table 7- 11 Field allocation
Byte Meaning
0 Field number
1 Field type 0: All channels between the beginning and the end
2, 3 Starting number, channel
4, 5 End number, channel
6 Field number
7 Field type 1: Every second channel between the beginning and the end
8, 9 Starting number, channel
10, 11 End number, channel
12 Field number
13 Field type 2: List with channels
14, 15 Number of subsequent channels
16, 17 Number of channel a
18, 19 Number of channel b
… …
18+x,
19+x
Number of channel z
… …
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
122 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.11 Job 08: Field factor for production mode
In this job, the production value for each defined field is transferred. The value range for the
production value is from 0 to 255 (basis factor 0.01). If configured, this value applies to both
profiles of production mode.
If the value 100 % is exceeded when the channel setpoint and the field factor are multiplied,
the value is set to 100 % and an alarm signal is sent to the DP master.
Table 7- 12 Field factor for production mode
Byte Meaning
0 Field number x
1 Production value for field x
…
7.5.12 Job 09: Field factor for standby mode
In this job, the standby value for each defined field is transferred. The value range for the
standby value is from 0 to 255 (basis factor 0.01).
If the value 100 % is exceeded when the channel setpoint and the field factor are multiplied,
the value is set to 100 % and an alarm signal is sent to the DP master.
Table 7- 13 Field factor for standby mode
Byte Meaning
0 Field number x
1 Standby value for field x
…
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 123
7.5.13 Request 10: Channel diagnostics
For each channel, it is possible to parameterize how the channel is to be tested. Here, a
distinction is made between standard diagnosis and extended diagnosis with current
measurement.
The latter is only useful for detecting heat emitters connected in parallel and, for each
channel, two values are defined:
● The nominal power to be expected
● The maximum permissible deviation from this value
If there is no NE 724 in the system, the value of the parameter "Nominal value of line
voltage" is used for the necessary power calculation.
After initialization, testing of a channel is always enabled. Higher-level control takes place by
means of field diagnosis.
Table 7- 14 Channel diagnostics
Byte Meaning
0, 1 Channel number x
2 0: Channel x is not tested
…
n,
n+1
Channel number y
n+2 1: Channel y is tested with standard diagnosis
…
m,
m+1
Channel number z
m+2 2: Channel z is tested with extended diagnosis
m+3,
m+4
Rated power to be expected at a channel in [W]
This parameter must have been assigned a valid value if extended
diagnosis with current measurement is used.
m+5,
m+6
Permissible upward and downward deviation from the rated power in [W]
This parameter must have been assigned a valid value if extended
diagnosis with current measurement is used.
…
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
124 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.14 Request 11: Field diagnostics
All fields have been blocked for diagnosis (default). For each field, diagnosis of all the
channels belonging to the field can be enabled.
The type of diagnosis (standard diagnosis or diagnosis by means of current measurement)
must be set separately for each channel. A channel is only tested if diagnosis has been
enabled in both the channel description and the field description.
Table 7- 15 Field diagnosis
Byte Meaning
0 Field number x
Setting of diagnosis for field x:
0: None of the channels of field x are tested.
1
1: All the channels of field x which have been enabled for the test are tested.
…
7.5.15 Request 20: General diagnosis
With this job, general faults can be read out of the fault buffer of the HCS724I. The job is to
be triggered if a fault is indicated in the cyclical data. The fault buffer is not deleted when the
fault is read out.
The job is always transferred with a fixed length and, if there is no fault, the contents of all
fault bytes is "0".
Table 7- 16 General diagnosis
Byte Meaning
0 Fault in line voltage sensing for phase L1
1 Fault in line voltage sensing for phase L2
2 Fault in line voltage sensing for phase L3
Error during initialization of the HCS724I
0x01: Old power output found
0x02 : Power output module/load switching unit without ID found
0x04: It was not possible to determine the frequency.
3
Several faults can be signaled at the same time.
Fault on the first module (first module tier)
1: Temperature warning threshold exceeded (LA 724I/LA 724I HP)
2: Temperature trip threshold exceeded (LA 724I/LA 724I HP)
4
3 24 V supply voltage failed(LA 724I SSR)
… …
Fault on the first module (second module tier)
1: Temperature warning threshold exceeded (LA 724I/LA 724I HP)
2: Temperature trip threshold exceeded (LA 724I/LA 724I HP)
19
3: 24 V supply voltage failed(LA 724I SSR)
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 125
7.5.16 Request 21: Channel diagnostics
With this job, channel faults can be read out of the fault buffer of the HCS724I. The job is to
be triggered if a fault is indicated in the cyclical data. The fault buffer is not deleted when the
fault is read out. Only changes are transferred; a response of the length 0 means "No new
information available".
Table 7- 17 Channel diagnostics
Byte Meaning
0, 1 Channel number
Channel fault
0: Output is o.k.
1: Fault type 1
2: Fault type 2
3: Fault type 2, external
4: Fault type 3
5: Fault type 4
6: Fault type 5
2
(For types of fault, see "Cyclic monitoring of ZA 724I xx outputs" (Page 80))
3, 4 Channel number
5 Channel fault
… …
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
126 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.17 Request 22: Channel warning
With this job, alarms resulting from calculation of channel setpoints can be read out of the
alarm buffer of the HCS724I. The job is to be triggered if an alarm is indicated in the cyclical
data. The alarm buffer is not deleted when the alarm is read out. Only changes are
transferred; a response of the length 0 means "No new information available".
Table 7- 18 Channel alarm
Byte Meaning
0, 1 Channel number
Channel alarm
0: Output is o.k.
1: Incorrect controller output due to setpoint x field value
2
2: Incorrect controller output due to line voltage compensation
3, 4 Channel number
5 Channel alarm
… …
7.5.18 Request 23: Initiate diagnostics cycle
With this job, a complete, one-off diagnostic cycle can be triggered for testing all channels.
This is useful during commissioning or for heating processes which must not be affected
cyclically by a diagnostic cycle. A diagnostic cycle triggered by means of this job can also be
triggered if a diagnostic cycle has not been configured. The results of this cycle are not
entered in the fault buffer of the HCS724I but are immediately transferred to the DP master
application by means of response message frames.
The status of all channels of all power output modules detected during start-up is reported
because the job does not know which channels are actually connected.
For feedback, see "Job 21: Channel diagnostics" (Page 125)
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 127
7.5.19 Request 30: Read the actual manipulated variable of the channel
Because the channel controller output is formed from the channel setpoint, the currently valid
field factor and the correction value of line voltage compensation, the current value can be
read out of the HCS724I.
The controller output is between 0 and 100 (basis 0.5 %).
The controller output for all channels of all the power output modules/load switching units
detected during start-up is transferred.
Table 7- 19 Read out current channel controller output
Byte Bit Meaning
0, 1 Channel number x
6-0 Controller output for channel x
0: Controller output 0
2
7
1: Controller output 5
… … …
7.5.20 Job 31: Read out current actual channel values
This job is used to read the measured current and power values of the channel to which the
job is addressed.
The measured channel values are only valid if the HCS724I has been initialized and an
operating mode (production/standby; see previous section) has been activated. For the
channel, extended diagnosis with current measurement must have been parameterized.
Table 7- 20 Read out current actual channel values
Byte Meaning
0, 1 Channel number x
2, 3 Measured current belonging to the currently measured nominal power in [10–2 A]
4, 5 Currently measured nominal power at the channel in [W]
… …
Functions
7.5 Data exchange between a non-S7-DP master and ZA 724
SIPLUS HCS724I
128 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
7.5.21 Request 32: Read actual temperature values
This job is used to read out the current measured temperature value at the LA 724I/LA
724I HP. A measured value for all detected power output modules/load switching units is
transferred in each case. At the slots which are fitted with an LA 724I SSR, 0 is transferred.
If the upper temperature threshold is exceeded, the measured value is invalid.
Table 7- 21 Read out current temperature values
Byte Meaning
0 Module numbers 1 to 16 (first and second tier)
1, 2 Measured temperature value (0 SSR, 0xFFFF invalid)
… …
7.5.22 Request 40: Reset
With this job, the HCS724I restarts by carrying out a SW reset. The DP master has to
reinitialize the HCS724I.
The job is acknowledged before the reset is carried out.
The job does not contain any data apart from the job code. It can always be executed.
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 129
Alarm, error and system messages 8
8.1 Diagnostics with LED display
8.1.1 LED indications on the ZA 724
ZA 724
LED indications on the ZA 724:
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Alarm, error and system messages
8.1 Diagnostics with LED display
SIPLUS HCS724I
130 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Status and faults indicated by LEDs on the ZA 724
The ZA 724 has 2 LEDs for indicating the current operating state:
● LED Ready (green)
● LED Error (red)
The following table shows the status and fault indications shown on the ZA 724.
Table 8- 1 Status and fault indications on the ZA 724
LED Error LED Ready Description
The firmware has detected a serious problem (FEPROM contents are
not valid) or has received - via the serial interface - a request for a
firmware update and is now in the Flash loader.
On Off
After establishment of the PROFIBUS connection, the HCS724I sends
zeros in the cyclical data in order to show that initialization by the DP
master is necessary. The DP master (S7 CPU) must send three
initialization jobs. These are jobs 01, 02 and 03. These jobs are
executed when the S7 software is used by the FC_INIT function.
On Flashing Initialization of the hardware and firmware and the PROFIBUS
connection The firmware waits until the DP master detects the
HCS724I and has included it in the PROFIBUS cycle.
On On Start-up of the HCS724I
HCS724I has been detected by the DP master and is waiting for
initialization jobs.
Off On The initialization phase has ended. The HCS724I reports back the
result in a cyclical bit.
The HCS724I is now ready. Data exchange with the DP master is
possible: Parameters/diagnosis by means of jobs, operating mode
selection by means of the cyclical data.
Off Flashing If communication with the DP master breaks down, the HCS724I
assumes a safe status and waits for communication to be restarted.
The data which have been configured and parameterized are retained.
The DP master does not carry out an initialization after communication
has restarted.
Alarm, error and system messages
8.1 Diagnostics with LED display
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 131
8.1.2 LED indications on the LA 724I/LA 724I HP
LA 724I/LA 724I HP
LED indications on the LA 724I/LA 724I HP:
581 /
(55
Status and fault indications by LEDs on the LA 724I/LA 724I HP
The LA 724I/LA 724I HP has 4 LEDs for indicating the current operating state:
● LED RUN (green)
● LEDs ERR L1 / L2 / L3 (red)
The following table shows the status and fault indications on the LA 724I/LA 724I HP.
Table 8- 2 Status and fault indications on the LA 724I/LA 724I HP
LED
RUN
LED
ERR L1
LED
ERR L2
LED
ERR L3
Meaning
Off Off Off Off Load switching unit is not operating
It was not detected by the ZA during start-up
Off x x x The upper temperature threshold has been exceeded;
power outputs are deactivated.
Flashing x x x Load switching unit is operating
The temperature alarm threshold has been exceeded.
On Off Off Off Load switching unit is operating
There are no channel faults
On On x x Load switching unit is operating
At least 1 channel of phase L1 is defective
On x On x Loas switching unit is operating
At least 1 channel of phase L2 is defective
On x x On Load switching unit is operating
At least 1 channel of phase L3 is defective
x = Status not relevant
Alarm, error and system messages
8.1 Diagnostics with LED display
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132 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
8.1.3 LED indications on the LA 724I SSR
LA 724I SSR
LED indications on the LA 724I SSR:
581 / (55
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/
/$L
665
581 (55
Status and fault indications on the LA 724I SSR
The LA 724I SSR has 4 LEDs for indicating the current operating state:
● LED RUN (green)
● LEDs ERR L1 / L2 / L3 (red)
The following table shows the status and fault indications on the LA 724I SSR.
Table 8- 3 Status and faults indicated by LEDs on the LA 724I SSR
LED
RUN
LED
ERR L1
LED
ERR L2
LED
ERR L3
Meaning
Off Off Off Off Load switching unit is not operating
It was not detected by the ZA during start-up
Off x x x 24 V supply voltage has failed
On Off Off Off Load switching unit is operating
There are no channel faults
On On x x Load switching unit is operating
At least 1 channel of phase L1 is defective
On x On x Load switching unit is operating
At least 1 channel of phase L2 is defective
On x x On Load switching unit is operating
At least 1 channel of phase L3 is defective
x = Status not relevant
Alarm, error and system messages
8.2 Error messages in the S7 environment
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 133
8.2 Error messages in the S7 environment
The following tables show the codes of all faults which are reported by means of the S7
software during communication with the HCS724I.
Error messages from the S7 software
Table 8- 4 Error messages from the S7 software
Error
code
Meaning
System fault
808x System fault in respect of the external DP interface connection
8090 For the logical base address indicated,
you have not configured a module,
you have exceeded the maximum permissible length of the consistent data, or
you have not entered the start address in the LADDR parameter in hexadecimal format.
8092 A type other than BYTE has been specified in the ANY reference.
8093 No DP module from which you can read consistent data was found at the logical address
declared at LADDR.
80A0 The system has detected an I/O access fault (reading access).
80A1 The system has detected an I/O access fault (writing access).
80B0 Failure of a slave connected to the external DP interface connection
80B1 The declared length of the target area is unequal to the useful data length configured with
STEP 7
.
80B2 System fault in respect of the external DP interface connection
80B3 System fault in respect of the external DP interface connection
80C0 The data have not been read yet by the module
80C1 The module has not yet processed the data of the previous write job.
80C2 System fault in respect of the external DP interface connection
80Fx System fault in respect of the external DP interface connection
85xy System fault in respect of the external DP interface connection
87xy System fault in respect of the external DP interface connection
Program status/program error
A000 Job is still being processed
(This message does not have to be acknowledged.)
A001 Invalid job code transferred to FC_HS_AUFTRAG
A002 There are no channels or too few fields have been parameterized.
A003 Channel number 0 is not permissible.
A004 In the DB_HS_DIAG or DB_HS_IBS data block, an invalid number has been entered for the
HCS724I.
A005 In the DB_HS_DIAG or DB_HS_IBS data block, an incorrect channel number 0 has been
entered.
A007 FC_HS_RESET can only be started if the "Heating Off" mode has been activated and no
job is being processed.
Notice message
AFFF FC_HS_INIT is necessary, at least one HCS724I has not been initialized
Alarm, error and system messages
8.2 Error messages in the S7 environment
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134 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Error messages of the HCS724I
Table 8- 5 Error messages of the HCS724I
Error
code
Meaning
A081 General: incorrect job code
A082 General: incorrect message frame header in the first message frame
A083 General: incorrect message frame header in the second message frame
A084 General: It is only permissible for the job to be executed during INIT
A085 General: Only reset job is permissible
A086 General: It is only permissible for the job to be executed after INIT
A08A FC_HS_RESET job: Incorrect job length
A090 FC_HS_INIT job: incorrect job length of DP job 02
A091 FC_HS_INIT job: Error in the parameter of first channel number
A092 FC_HS_INIT job: Error in substitute values parameter
A093 FC_HS_INIT job: Error in pulsing mode parameter
A094 FC_HS_INIT job: Error in parameter for number of repeat diagnoses
A095 FC_HS_INIT job: Error in parameter for mains connection
A09A FC_HS_INIT job: Incorrect job length of DP job 03
A09B FC_HS_INIT job: Error in test setting
A0A0 Channel setpoint 1 job: Incorrect job length
A0A1 Channel setpoint 1 job: Incorrect channel number
A0A2 Channel setpoint 1 job: Incorrect setpoint (0.5 % setting is not permissible due to type of
pulsing)
A0A3 Channel setpoint 1 job: Incorrect setpoint (> 100 %)
A0AA Channel setpoint 2 job: Incorrect job length
A0AB Channel setpoint 2 job: Incorrect channel number
A0AC Channel setpoint 2 job: Incorrect setpoint (0.5 % setting is not permissible due to type of
pulsing)
A0AD Channel setpoint 2 job: Incorrect setpoint (> 100 %)
A0B0 Channel setpoint start-up job: Incorrect job length
A0B1 Channel setpoint start-up job: Incorrect channel number
A0B2 Channel setpoint start-up job: Incorrect setpoint (0.5 % setting is not permissible due to
type of pulsing)
A0B3 Channel setpoint start-up job: Incorrect setpoint (> 100 %)
A0C0 Field definition job: Incorrect field number
A0C1 Field definition job: Incorrect field type
A0C2 Field definition job: Incorrect channel number
A0C3 Field definition job: First channel number is larger than the second channel number (field
types 0 and 1)
A0CA Field factor production job: Incorrect job length
A0CB Field factor production job: Incorrect field number
A0DA Field factor standby job: Incorrect job length
A0DB Field factor standby job: Incorrect field number
Alarm, error and system messages
8.2 Error messages in the S7 environment
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 135
Error
code
Meaning
A0BA Diagnosis setting channel job: Incorrect job length
A0BB Diagnosis setting channel job: Incorrect setting for the type of diagnosis
A0D0 Diagnosis setting channel job: Incorrect job length
A0D1 Diagnosis setting field job: Incorrect field number
A0D2 Diagnosis setting field job: Incorrect setting for the type of diagnosis
Alarm, error and system messages
8.3 Error messages in the non-S7 environment
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136 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
8.3 Error messages in the non-S7 environment
The following table lists the numbers of errors which can occur during the transfer of jobs.
The error is indicated when the job is acknowledged as described in "Message frame data"
(Page 114).
Table 8- 6 Error messages from the HCS724I during transfer of jobs
Error
code
Meaning
0x80 Everything o.k.
0x81 Incorrect job code
0x82 Incorrect message frame header in the first message frame
0x83 incorrect message frame header in the following message frame
0x84 It is only permissible for the job to be executed during INIT
0x85 Only reset job is permissible
0x86 It is only permissible for the job to be executed after INIT
0x8A Job 40: Incorrect job length
0x90 Job 02: Incorrect job length
0x91 Job 02: Error in the parameter of first channel number
0x92 Job 02: Error in substitute values parameter
0x93 Job 02: Error in pulsing mode parameter
0x94 Job 02: Error in parameter for number of repeat diagnoses
0x95 Job 02: Error in parameter for mains connection
0x9A Job 03: Incorrect job length
0x9B Job 03: Error in test setting
0xA0 Job 04: Incorrect job length
0xA1 Job 04: Incorrect channel number
0xA2 Job 04: Incorrect setpoint (0.5 % setting is not permissible due to type of pulsing)
0xA3 Job 04: Incorrect setpoint (> 100 %)
0xAA Job 05: Incorrect job length
0xAB Job 05: Incorrect channel number
0xAC Job 05: Incorrect setpoint (0.5 % setting is not permissible due to type of pulsing)
0xAD Job 05: Incorrect setpoint (> 100 %)
0xB0 Job 06: Incorrect job length
0xB1 Job 06: Incorrect channel number
0xB2 Job 06: Incorrect setpoint (0.5 % setting is not permissible due to type of pulsing)
0xB3 Job 06: Incorrect setpoint (> 100 %)
0xC0 Job 07: Incorrect field number
0xC1 Job 07: Incorrect field type
0xC2 Job 07: Incorrect channel number
0xC3 Job 07: First channel number is larger than the second channel number
(field types 0 and 1)
0xCA Job 08: Incorrect job length
0xCB Job 08: Incorrect field number
Alarm, error and system messages
8.3 Error messages in the non-S7 environment
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 137
Error
code
Meaning
0xDA Job 09: Incorrect job length
0xDB Job 09: Incorrect field number
0xBA Job 10: Incorrect channel number
0xBB Job 10: Incorrect setting for the type of diagnosis
0xD0 Job 11: Incorrect job length
0xD1 Job 11: Incorrect field number
0xD2 Job 11: Incorrect setting for the type of diagnosis
Alarm, error and system messages
8.4 Troubleshooting
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8.4 Troubleshooting
Faults during operation
In the event of faults during operation, the heater controller behaves as indicated in the
following table.
CAUTION
Damage to property if error messages are ignored
Many faults can result in significant damage to property. Identify the fault using the fault list
below and respond via your application.
Table 8- 7 Faults during operation
Faults Response Actions
Serious faults Automatic hardware reset with
restart of the ZA 724
(initialization)
Transfer all jobs again to the
ZAs
Bus fault
(timeout, e.g. due to defective
bus cable or failure of the S7
CPU)
All the outputs are reset or
retain their values depending on
the parameterization
Power down the machine if
necessary
Reactivate the operating
mode
Channel fault (module fault,
Triac short-circuit, external fault)
Signal sent to DP master Switch off machine
Rectify fault
Restart machine
Overtemperature; 1st stage (92
°C)
Signal sent to DP master Find cause (e.g. check cooling
system) and rectify
Overtemperature; 2nd stage
(100 °C)
Power outputs are switched off
Switch off machine
Find cause (e.g. check
cooling system) and rectify
Restart machine
No 24 V supply voltage for the
LA 724I SSR
Control outputs SSR are
switched off
Check 24 V power supply
Reactivate the operating
mode
Value error
The controller output has
exceeded the 100 % value.
Signal sent to S7 CPU
Processing is then continued
with 100 % controller output.
Test and adjust program
Alarm, error and system messages
8.4 Troubleshooting
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 139
Overtemperature
Overtemperature on an LA 724I / LA 724I HP power output module can occur if the ambient
temperature or switching capacity is too high (see "Ambient conditions for all HCS724I
components" (Page 150), "Technical data of the LA 724I" (Page 144) and"Technical data of
the LA 724I HP" (Page 146)) or a fan has failed.
Fuse blown
Each channel of the LA 724I/LA 724I HP power output module has a 5 A quick-response/16
A T fuse which blows if there is a short-circuit at the output, for example.
These channel fuses are located directly on the front of the power output module (see
illustration below).
The three phase leads are each protected with a 32/40 A fuse.
/$L /$L
+3
/V
)
) )
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
1
/
/
/
1
/
/
/
/V
/V
/V
/V
/V
Figure 8-1 Position of the channel fuses on the LA 724I/LA 724I HP power output module
Alarm, error and system messages
8.4 Troubleshooting
SIPLUS HCS724I
140 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Replacing defective channel fuses
WARNING
Before changing a fuse, you must isolate the load circuit from the supply.
CAUTION
Use only the prescribed fuse types. If you use the LA 724I/LA 724I HP with fuses that are
not permissible, the device could be destroyed.
1. Remove the cover of the fuse holder.
2. Replace the fuse with one of the same type.
3. Reattach the cover.
Note
The ordering data for the fuses can be found in "Order numbers > Accessories"
(Page 153).
Defective phase fuses
If a phase fuse is defective, the LA 724I/LA 724I HP must be sent to the manufacturer for
repair.
Reaction to interruption of the supply voltage
An interruption of the supply voltage for the ZA lasting longer than 20 ms triggers a restart of
the HCS724I heater controller.
The outputs of the LA 724I xx power output modules/load switching units are reset after
voltage recovery.
The HCS724I must be reparameterized (see "Initialization (start-up)" (Page 69)).
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 141
Maintenance and service 9
9.1 Loading the firmware for the HCS724I
As-delivered condition of the ZA 724 central interface module
When the ZA 724 central interface module is delivered, the current firmware has already
been loaded on the module.
In the event of a fault or if an update is necessary, you can load the firmware by means of
the HSSETUP.EXE program which is supplied with the product.
NOTICE
The ZA 724 is delivered with the current firmware version and is ready to switch on.
You only have to carry out the steps described below if the ZA 724 has to be updated with
a different firmware version.
Prerequisite for loading the firmware
You need a null modem cable for loading the firmware. If you do not have such a cable, a
cable with the following pin assignment is sufficient:
RxD 2--------3 TxD
TxD 3--------2 RxD
Gnd 5--------5 Gnd
Note
If you use a 25-pin connector, Pin 7 is to be used for Gnd instead of Pin 5 !
Maintenance and service
9.1 Loading the firmware for the HCS724I
SIPLUS HCS724I
142 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
To install the firmware, proceed as follows:
1. Switch off the ZA 724.
2. Connect the RS 232 serial interface of the ZA 724 to COM1 or COM2 on the PC, using
the interface cable.
3. Start HSSETUP.EXE and enter the interface which is used on the PC (COM1 or COM2).
4. Switch the ZA 724 on.
All the remaining steps are carried out automatically. The progress of programming can be
followed on the PC.
After the firmware has been downloaded, the ZA 724 carries out a restart.
Note
The load voltage must be disconnected when the firmware is being loaded.
Note
The Flash loader in the FEPROM of the ZA 724 is normally not overwritten. If the voltage
supply or the serial connection is interrupted before the end of the loading process, the
process can be repeated.
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 143
Technical specifications 10
10.1 Technical data ZA 724
Table 10- 1 Technical specifications for the ZA 724
Supply voltage 230 VAC
Permitted range 187 V to 264 V
Rated frequency 50 / 60 Hz
Permitted range 47 Hz to 63 Hz
Non-periodic overvoltage (acc. to EN 60204, Part 1)
Limit value 2 x Urated
Duration 1.5 ms (single pulse)
Rise/fall time 500 ns to 500 µs
Momentary voltage interruption
(initial conditions: Lower limit of rated voltage = 187 V)
Interruption time Max. 20 ms
Restoration time minimum 1 s
Events per hour Max. 10
Power consumption Typically 35 W,
maximum 46 W
Dimensions of the ZA 724 (W x H x D) 50 mm x 480 mm x 210 mm
Approx. weight 4.2 kg
10.2 Technical data for NE 724
Table 10- 2 Technical data for NE 724
Voltage supply 230 V AC
Permitted range 187 V to 264 V
Rated frequency 50/60 Hz
Permitted range 47 Hz to 63 Hz
Technical specifications
10.3 Technical data of the LA 724I
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144 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
10.3 Technical data of the LA 724I
Table 10- 3 Technical data of the LA 724I
Outputs per power output module (LA 724I) 24
Galvanic isolation from control section by means of opto-triac and optocoupler which
are specified in acc. with VDE 0884
Insulating voltage
Opto-triac 5 kV
Optocoupler 5.3 kV (to EN60747-5-2)
Galvanic isolation of power outputs from each other No
Load voltage (for star circuit)
Nominal value 230 V AC
Permitted range 187 to 264 V (TN system)
Frequency 50 / 60 Hz (47 to 63 Hz)
Total current per phase and module max. 32 A
Current per conductor rail 120 A, maximum
Output voltage Full or half-waves switched during zero
passage
Output current per channel
Maximum value 5 A
Residual current max. 7 mA
Power loss Typ. PV = 0.7 W / A ∙ I + 0.18 W / A2 ∙ I2
(I = control current in the channel)
Switching capacity (100 % simultaneity) Max. 1150 W per channel at 230 V
Note:
The total current per phase of 32 A must not
be exceeded.
Min. 75 W per channel
Parallel connection of heat emitters to one channel
Number Typ. 5
Minimum power per heat emitter 200 W
Total switching capacity per LA 724I (TU = 40 °C)
without forced ventilation 14.4 kW
with forced ventilation 22 kW
Load type Resistive load with a maximum of 15 times
the cold current.
In the case of Flash emitters, this can lead to
a reduction of the permissible switching
capacity. These emitters can be measured at
Siemens.
Overload Five times the rated current for 20 ms
Technical specifications
10.3 Technical data of the LA 724I
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 145
Yes (by NTC thermistor)
92 °C ±3 °C: Alarm to higher-level
controller via PROFIBUS DP
Thermal protection
100 °C ±3 °C: Deactivation of the power
outputs
Short-circuit protection One 5 A F/250 V fuse per output
Overvoltage protection By Transil diodes
Connecting cable Rmax = 14 Ω
(this ensures short-circuit protection)
Dimensions of the LA 724 (W x H x D) 50 mm x 480 mm x 210 mm
Approx. weight 5.3 kg
Technical specifications
10.4 Technical data of the LA 724I HP
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146 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
10.4 Technical data of the LA 724I HP
Table 10- 4 Technical data of the LA 724I HP
Outputs per power output module (LA 724I HP) 12
Galvanic isolation from control section by means of opto-triac and optocoupler which
are specified in acc. with VDE 0884
Insulating voltage
Opto-triac 5 kV
Optocoupler 5.3 kV (to EN60747-5-2)
Galvanic isolation of power outputs from each other No
Load voltage (for star and delta circuit configuration)
Nominal value 230 V / 400 V AC
Permitted range 187 V to 264 V / 340 V to 460 V (TN system)
Frequency 50 / 60 Hz (47 to 63 Hz)
Total current per phase and module max. 40 A
Current per conductor rail 120 A, maximum
Output voltage Full or half-waves switched during zero
passage
Output current per channel
Maximum value 10 A
Note:
16 A T/500 V fuses are used for fuse
protection
These connecting cable must be
appropriately dimensioned.
Residual current max. 7 mA
Power loss Typ. PV = 0.7 W / A ∙ I + 0.16 W / A2 ∙ I2
(I = control current in the channel)
Switching capacity (100 % simultaneity) Max. 2300 W per channel at 230 V
Max. 4000 W per channel at 400 V
Note:
The total current per phase of 40 A must not
be exceeded.
Min. 75 W per channel
Parallel connection of heat emitters to one channel
Number Typ. 5
Minimum power per heat emitter 200 W
Total switching capacity per LA 724I HP (TU = 40 °C)
Total switching power of the delta connection
without forced ventilation
with forced ventilation
22.6 kW
36.5 kW
Technical specifications
10.4 Technical data of the LA 724I HP
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 147
Total switching power of the star connection
without forced ventilation
with forced ventilation
13 kW
21 kW
Load type Resistive loads with max. 15 times the cold
current
Overload Five times the rated current for 20 ms
Yes (by NTC thermistor)
92 °C ±3 °C: Alarm to higher-level
controller via PROFIBUS DP
Thermal protection
100 °C ±3 °C: Deactivation of the power
outputs
Short-circuit protection Per output: One 16 A T/500 V fuse
Note:
The maximum permissible output current is
10 A. Fuse protection is implemented by
means of a 16 A fuse.
Overvoltage protection By Transil diodes
Connecting cable Rmax = 14 Ω
(this ensures short-circuit protection)
Dimensions of the LA 724I HP (W x H x D) 50 mm x 480 mm x 210 mm
Approx. weight 5.3 kg
Technical specifications
10.5 Technical data of the LA 724I SSR
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148 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
10.5 Technical data of the LA 724I SSR
Table 10- 5 Technical data of the LA 724I SSR
Outputs per load switching unit (LA 724I SSR) 24
Galvanic isolation from control section by means of opto-couplers which are
specified in acc. with VDE 0884
Insulation voltage of the optocouplers 5.3 kV (to EN60747-5-2)
Galvanic isolation of diagnostic inputs from each other No
Diagnosis voltage
(for star and delta circuit configuration)
Nominal value 230 V / 400 V AC
Permitted range 187 V to 264 V / 340 V to 460 V
Frequency 50 / 60 Hz (47 to 63 Hz)
Total current per phase and module See "SM 724I current measuring module"
(Page 38)
Current per conductor rail 120 A, maximum
24 V supply voltage for pulsing the SSR
Nominal value 24 V
Permitted range 20.4 V to 28.8 V
Fuse 1.5 A/250 V fuse link (external)
Triggering voltage for the SSR
at rated supply voltage Typ. 23.3 V
min. 22 V
Triggering current Max. 50 mA (per control output)
Length of cable
Control cable for the SSR 30 m, maximum
SM 724I connecting cable 30 m, maximum
24 V supply voltage 10 m, maximum
Note:
Cables not to be laid outside buildings
Dimensions of the LA 724I SSR (W x H x D) 50 mm x 480 mm x 210 mm
Approx. weight 3.3 kg
Note
Cables carrying low voltage must be laid separated from cables carrying mains voltage (e.g.
in a separate cable duct).
As an alternative, shielded cables are possible for low-voltage connections. All cables can
then be laid in a shared cable duct.
Note
The ordering data for the recommended solid state relays can be found in "Order numbers >
Accessories" (Page 153).
Technical specifications
10.6 Technical data of the LM 724
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 149
10.6 Technical data of the LM 724
Table 10- 6 Technical data of the LM 724
Installation 1 fan module for every 2 modules
(2 x LA 724I xx or 1 x ZA 724 and 1 x 724I xx)
Supply voltage
Nominal value 230 VAC
Permitted range 187 V to 264 V
Frequency 50 / 60 Hz (47 to 63 Hz)
Power consumption 6 W
Volumetric rate of air flow 45 m3 / h
Dimensions of the LM 724 (W x H x D) 100 mm x 50 mm x 162 mm
Approx. weight 0.8 kg
10.7 Technical data of the SM 724I
Table 10- 7 Technical data of the SM 724I
Rated current
primary 3 x 400 A
secondary 3 x 200 mA
Precision approx. 1 %
Frequency band 50 Hz to 400 Hz
Cable entry openings ∅ 22 mm
Dimensions of the SM 724I (W x H x D) 150 mm x 77.5 mm x 115 mm
Approx. weight 1.25 kg
Technical specifications
10.8 Ambient conditions for all HCS724I components
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150 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
10.8 Ambient conditions for all HCS724I components
Table 10- 8 Climatic ambient conditions
Operating temperature
Permitted range 0 °C to 55 °C
Relative humidity at 25 °C 95 %
Temperature gradient ≤ 10 K/h
Storage temperature
Permitted range –40 °C to +70°C
Relative humidity at 25 °C 95 %
Temperature gradient ≤ 20 K/h
Air pressure during operation
Minimum 860 hPa (= 1500 m above sea-level) (reduced
cooling performance at lower air pressure)
Maximum 1080 hPa
Air pressure during storage
Minimum 660 hPa (= 3500 m above sea-level)
Maximum 1080 hPa
Ventilation Separate or forced ventilation
Table 10- 9 Mechanical ambient conditions
Vibration during operation (stationary use) EN 60068-2-6 Test Fc (10 cycles per axis)
10 Hz to 58 Hz 0.075 mm amplitude
58 Hz to 150 Hz 9.8 m/s2 (= 1 g constant acceleration)
Vibration during transport/storage
(in delivery packaging)
EN 60068-2-6 Test Fc (10 cycles per axis)
5 Hz to 9 Hz 3.5 mm amplitude
9 Hz to 500 Hz 9.8 m/s2 (= 1 g constant acceleration)
Shock during operation (stationary use) IEC 60068-2-27 test, Ea
150 m/s2 ≈ 15 g, half-sine
11 ms duration
3 shocks per axis and direction
Shock during transport/storage
(in delivery packaging)
EN 60068-2-29 test, Eb
250 m/s2 ≈ 25 g, half-sine
6 ms duration
1000 shocks per axis and direction
Technical specifications
10.8 Ambient conditions for all HCS724I components
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 151
Table 10- 10 Electromagnetic compatibility
The HCS724I is installed in the switching cabinet
Radio interference suppression (emitted
interference)
Limit value class A in accordance with EN 55011
Group 1
Immunity to conducted interference (burst) according to EN 61000-4-4
AC voltage supply cables 2 kV with switching network
Signal lines that exit the device 2 kV with clamp
Immunity to conducted interference
(HF-irradiation)
acc. to EN 61000-4-6
10 V (0.15 MHz to 80 MHz)
Interference immunity against static electricity
(ESD)
according to EN 61000-4-2
Contact discharge 4 kV
Air discharge 8 kV
Immunity to RF interference EN 61000-4-3
3 V/m (1.4 GHz to 2.0 GHz)
1 V/m (2.0 GHz to 2.7 GHz)
Immunity to high-energy pulses (surge) according to EN 61000-4-5
Mains supply cables
- symmetric
- asymmetric
1 kV
2 kV
PROFIBUS cable
- asymmetric
1 kV
Technical specifications
10.8 Ambient conditions for all HCS724I components
SIPLUS HCS724I
152 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 153
Order numbers 11
11.1 Components of the HCS724I
Table 11- 1 Order numbers of the components of the HCS724I
Components Order No.:
ZA 724 central interface module 6BK1700-2BA30-0AA0
LA 724I power output module 6BK1700-2BA00-0AA0
LA 724I HP power output module 6BK1700-4BA70-0AA0 1)
LA 724I SSR load switching unit 6BK1700-2BA10-0AA0
NE 724 line-voltage sensing submodule 6ES7171-1XX00-6AA0
LM 724 fan module 6ES7171-3AA00-0AA0
SM 724I current measuring module 6BK1700-2BA40-0AA0
1) Replaces 6BK1700-2BA20-0AA0
11.2 Accessories
Table 11- 2 Order numbers of the accessories for the HS 724i
Accessories Order No.:
ZA 724
Heater controller flat ribbon cable for
connection of 2nd tier
6ES7171-1XX00–5AA0
LA 724I/LA 724I HP
Mating connector for connecting heat emitters
(three connectors: L1s, L2s, L3s)
Made by Phönix, IC 2.5/8STF-5.08
Siemens I IA CE: 40018384
Phönix: 1825378
Replacement fuses for LA724I
(for 6BK1700-2BA00-0AA0)
5 A quick-response / 250 V
Ceramic housing 5 x 20 mm
Siemens I IA CE: 200021116
Littlefuse: 216005.MA000
Replacement fuses for LA 724I HP
(for 6BK1700-4BA70-0AA0)
16 A T / 500 V
Ceramic housing 6.3 x 32 mm
Siemens I IA CE: A5E01204540
SIBA: 189140.16SA
Replacement fuses for LA 724I HP
(for 6BK1700-2BA20-0AA0)
16 A gRL/400 V
Ceramic housing 6.3 x 32 mm
Siemens I IA CE: A5E02183242
SIBA: 7006584.16
Busbar for connecting components 6ES7171-2XX00-6DA0
Order numbers
11.2 Accessories
SIPLUS HCS724I
154 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Accessories Order No.:
LA 724I SSR
Mating connector for 24 V supply
(one connector)
Made by Weidmüller, BL 3.5/2F
Siemens I IA CE: A5E00210675
Weidmüller: 160664
Mating connector for connecting the SSR
(three connectors: SSR L1, SSR L2, SSR L3)
Made by Weidmüller, BL 3.5/8
Siemens I IA CE: A5E00043661
Weidmüller: 159742
Mating connector for connecting the SM 724I
current measuring module
(Current Sense)
(one connector)
Made by Weidmüller, BL 3.5/6
Siemens I IA CE: A5E00210670
Weidmüller: 159740
Mating connector for voltage monitoring of the
phase Lx
(three connectors: L1d, L2d, L3d)
Made by Phönix, IC 2.5/8STF-5.08
Siemens I IA CE: 40018384
Phönix: 1825378
Solid State Relay (SSR) SIRIUS SC semiconductor relay/contactor
e.g. 3RF2350-1AA02:
semiconductor contactor 50 A, 40 °C,
control voltage 24 V, screw-type connection
Busbar for connecting components 6ES7171-2XX00-6DA0
Note
The mating connnectors are not included in the scope of supply. You have to order these
separately.
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 155
Appendix A
A.1 Recycling and disposal
The HCS724I can be recycled owing to its low pollutant content. For ecologically compatible
recycling and disposal of your old device, contact a certificated disposal service for electronic
scrap.
A.2 Service & Support
Contacts
Please talk to your Siemens contact (http://www.siemens.com/automation/partner) at one of
our agencies or local offices if you have any questions about the products described here
and do not find the answers in this manual.
Technical Support
You can access technical support for all IA/DT projects via the following:
● Phone: + 49 (0) 911 895 7222
(€ 0.14 /min. from the German landline network, deviating mobile communications prices
are possible)
● Fax: + 49 (0) 911 895 7223
(€ 0.14 /min. from the German landline network, deviating mobile communications prices
are possible)
● E-mail (mailto:support.automation@siemens.com)
● Internet: Online support request form: (http://www.siemens.com/automation/support-
request)
Appendix
A.2 Service & Support
SIPLUS HCS724I
156 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
Industrial Automation and Drive Technologies Service & Support
You can find various services on the Support homepage
(http://www.siemens.com/automation/service&support) of IA/DT on the Internet.
There you will find the following information, for example:
● Our newsletter containing up-to-date information on your products.
● Relevant documentation for your application, which you can access via the search
function in "Product Support".
● A forum for global information exchange among users and specialists.
● 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
(www.siemens.com/hcs).
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).
Training center
We offer appropriate courses to get you started. Please contact your local Training Center or
the Central Training Center in
D-90327 Nuremberg.
Phone: +49 (0) 180 523 56 11
(€ 0.14 /min. from the German landline network, deviating mobile communications prices are
possible)
For information about courses, see the SITRAIN homepage (http://www.sitrain.com).
FAQs
You can find the answers to frequently asked questions on the Internet FAQs
(http://support.automation.siemens.com/WW/view/en/10807371/133000).
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 157
Index
7
724 bus connection, 48
C
Configuration tool, 107
Connecting heat emitters, 52, 58
Delta connection, 56, 62
Star connection, 55, 61
Connecting the parallel bus, 48
Connecting the supply voltage, 51
Connection
724 bus, 48
Delta connection of heat emitters, 56, 62
Heat emitter, 58
NE 724, 63
Parallel bus, 48
PROFIBUS DP, 47
Star connection of heat emitters, 55, 61
Supply voltage, 51
Controller outputs
Calculation, 74
Definition for the operating modes, 73
Updating, 74
Correction values, 75
Courses, 156
Cycle duration, 82
D
Data blocks
Commissioning, 98
DB_HS_DIAG, 96
DB_HS_FELD, 95
DB_HS_IBS, 98
DB_HS_INIT, 92
DB_HS_KANAL, 94
Generation, 107
DB_HS_DIAG, 96
DB_HS_FELD, 95
DB_HS_IBS, 98
DB_HS_INIT, 92
DB_HS_KANAL, 94
Defective phase fuses, 140
Disposal of old equipment, 155
E
Error messages
during transfer of jobs, 136
HS 724I heater controller, 133, 134
Notice messages, 133
Program errors, 133
System fault, 133
Evaluation example
Star connection, 30
F
Fault identifiers, 133
Fault management, 138
Defective phase fuses, 140
Fuse blown, 139
Interruption of the supply voltage, 140
Overtemperature, 139
Replacing channel fuses, 140
Fault rectification, 138
FB_HS_RESET, 104
FB_HS_ZYKL, 105
FC_HS_AUFTRAG, 101
FC_HS_BETRIEBSART, 104
FC_HS_INIT, 99
FC_HS_NE, 103
Function blocks
FB_HS_RESET, 104
FB_HS_ZYKL, 105
FC_HS_AUFTRAG, 101
FC_HS_BETRIEBSART, 104
FC_HS_INIT, 99
FC_HS_NE, 103
Fuse blown, 139
H
HS 724I components
Climatic ambient conditions, 150
Electromagnetic compatibility, 151
Mechanical ambient conditions, 150
HS 724I heater controller
Error messages, 134
Installation, 39
Index
SIPLUS HCS724I
158 Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618
I
Initialization, 69
Installation
Central interface module, 41
HS 724I heater controller, 39
LM 724 fan module, 43
Load control, 41
Power output modules, 41
Interruption of the supply voltage, 140
L
LA 724I HP power output module
Evaluation examples, 30
Indicator elements, 131
Performance profile, 29, 31
Plug-in connectors, 28
Product features, 26
Technical Data, 146
LA 724I power output module
Evaluation examples, 24
Features, 21
Indicator elements, 131
Performance profile, 24
Plug-in connectors, 23
Suppressor circuit, 23
Technical Data, 144
Temperature monitoring, 23
Voltage isolation, 23
LA 724I SSR load switching unit
24 V monitoring, 34
Indicator elements, 132
Product features, 32
Technical Data, 148
Voltage isolation, 34
Line-voltage correction
Configuration, 75
Correction value, 75
Normal operation, 75
Normalizing value, 76
LM 724 fan module
Features, 37
Installation, 43
Technical data, 149
M
Monitoring
Load switching, 80, 87
Power output, 80, 87
Temperature, 86
Monitoring of the outputs of the LA 724I, 80
N
NE 724 line-voltage sensing submodule
Features, 35
Function, 35
Plug-in connectors, 36
Normal operation, 71
Normalizing values, 76
O
Operating cycle, 71
Operating Instructions
Special notes, 7
Output fuse, 139
Overtemperature, 139
P
Power output module/load switching unit
Control, 77
Cycle duration, 82
Monitoring of the outputs, 80, 87
Temperature monitoring, 86
Test cycles, 81
Test parameters, 82
Test types, 80
Types of fault, 83
PROFIBUS DP
Connecting, 47
Setting the bus address, 40
R
Recycling of old equipment, 155
Replacing defective channel fuses, 140
S
S7 software
Error messages, 133
Setting the bus address
PROFIBUS DP, 40
SM 724I current measuring module
Technical data, 149
Special notes
regarding the Operating Instructions, 7
Start-up behavior, 69
Index
SIPLUS HCS724I
Operating Instructions, 09/2011, J31069-D0430-U001-A5-7618 159
T
Technical Support, 155
Temperature monitoring, 86
Test cycles, 81
Test parameters, 82
Test types, 80
Testing the outputs of the LA 724I xx, 86
Training, 156
Types of fault
external fault, 83
LA 724I HP power output module, 83
LA 724I power output module, 83
LA 724I SSR load switching unit, 84
Module fault, 83
The Triac has a short-circuit, 83
V
Voltage interruption, 140
W
Warm restart, 140
Z
ZA 724 central interface module
Features, 17
Indicator elements, 130
Mains supply synchronization, 19
Plug-in connectors, 20
Technical specifications, 143
Voltage supply, 19
