PCS TC50 Series User manual

TC50-6 TC50-12

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Table of Contents
Chapter 1 Safety Precautions ........................................................ 3
Chapter 2 Features............................................................................ 4
Chapter 3 Appearance and Electronic Control System.............. 5
3.1 Appearance ...................................................................................... 5
3.2 Electronic Layout ........................................................................ 8
3.3 Temperature Control Module................................................ 9
3.4 Bus Board .....................................................................................10
3.5 Output Module .......................................................................... 11
3.6 I/O Board......................................................................................12
3.7 HMI Module ................................................................................13
Chapter 4 Convenient Functions ...................................................14
4.1 Mold Self-Diagnostics..............................................................14
4.2 Thermocouple Abnormal Behavior.....................................14
4.3 Synchronous Heating...............................................................15
4.4 Synchronous Cooling...............................................................15
4.5 Leakage Detection ....................................................................16
Chapter 5 Preparations ...................................................................17
5.1 Connection between TC50 and Mold ................................17
5.2 Parameter Setup........................................................................17
Please read through this user manual carefully before operating the TC50 to avoid damage
to machinery or injury to personnel from improper operation. The controller should also be
placed in a well-ventilated area to ensure the stability of the instrumentation.

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Chapter 6 HMI Instructions............................................................18
6.1 Monitoring.................................................................................18
6.2 Zone Parameter Setup .........................................................28
6.3 System Setup...........................................................................34
Chapter 7 Troubleshooting...........................................................46
Chapter 8 Connector Wiring ........................................................48
8.1 Connection Type C25............................................................48

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Chapter 1 Safety Precautions
To ensure the safe and effective operation of the TC50 Multi-Cavity Hot Runner
Temperature Control System, please read through this user manual carefully before
operating the TC50 and follow the warnings and instructions provided. Precautions
before use:
1. Must be installed on a flat, stable floor in a well-ventilated area. Avoid
humid, dusty or high-temperature environments. Installation in the above
environments increases the risk of equipment failure or malfunctions and
may even cause a fire.
2. Pay attention to the type of power supply, voltage and power capacity
before connecting the TC50 to the power supply. Using a power supply that
does not meet specifications will cause serious system damage. When the
main power switch is turned on, if the Over Voltage Source (OVS) light lights
up it means the power supply's voltage is too high (≧280Vac). The main
power switch must be turned off at once and the power distribution verified.
3. Before turning on the main power switch for the TC50, make sure that the
system ground (FG) is properly connected. Improper grounding may lead to
electrocution of personnel or damage to equipment.
4. Check that the TC50 and mold cable connection type are compatible with
each other before connecting. Incompatible connection type poses an
electrocution hazard and will damage equipment.
5. Make sure that the TC50 cooling fan is working at all times. A blockage will
impact on heat dissipation so always keep the fan clean and running.
6. Do not attempt to modify or change this control system without proper
training. Improper modifications may lead to electrocution, injury,
equipment damage, fire and other hazards.
7. Immediately turn off the main power switch if there is any smoke, sparks,
strange smells or odd noises during the operation of the TC50 and have a
technician conduct an inspection. Do no turn on the power again before the
problem is resolved.
8. The TC50 may only be maintained by trained personnel. The main power
switch must be turned off before maintenance. Disassembling the TC50
while the power is connected poses serious electrocution hazard.
9. Storage temperature: -20~70°C/-4~158°F
Operation temperature: -10~50°C/14~122°F
Operation humidity: 0~80%RH (No condensation)

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1. The power configuration is simple and easy to change, making it compatible
with most electrical systems around the world.
2. Automatic detection of short-circuit protection of heater.
3. Multiple types of module anomaly detection for quick troubleshooting.
4. Simple and easy to use HMI interface.
5. Mold self-diagnostics function that shortens maintenance time by quickly
identifying problems with the control module and molds.
6. If thermocouple abnormality occurs, can choose automatic switching to
Manual, Slave mode to maintain the output, so that the product can be
produced continuously.
7. Synchronous heating function to avoid power being tripped by excessive
loading. This also prevents residue in the tip from becoming carbonized by
high temperatures for extended periods of time and impacting product
quality.
8. Synchronous cooling and standby function for the tip to prevent tip
deformation due to the tip and manifold cooling at different rates.
9. The three-phase of power balance efficiency statistics can provide the basis
for the user to adjust the power load balance to reduce the power loss.
10. The mold leakage detection function can detect the initial mold leakage,
and early detection of leakage can avoid serious damage to the mold and
save huge mold maintenance costs.
Chapter 2 Features

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TC50 Dimensions
Chapter 3 Appearance and Electronic Control System
3.1 Appearance(Dimensions、Components)

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TC50_6 ZONES Components

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TC50_12 ZONES Components

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3.2 Electronic Layout

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1. Number of zones controlled: 6 zones.
2. Power Input: 1Φ, 230Vac±10% (overvoltage protection)/24Vdc±5%,
50/60Hz.
3. Power Consumption: 24Vdc/4W
4. Thermocouple: J/K type
5. Temperature Control Range: 0~600°C/32~999°F
6. Control Precision: ±0.25%FS
7. Measurement Precision: ±0.25%FS
8. Fuse: 250Vac/5A, 20mm
9. Output Mode: Zero cross/Phase angle.(compatible output module)
10. Detection Functions: temperature detection/Current detection (compatible
output module)/Overvoltage Protection(≧280Vac start)
11. Temperature Alarm Mode: Higher limit/Lower limit/Standby higher
limit/Standby lower limit/Absolute alarm.
12. Anomaly Detection:
Thermocouple: Short/Break/Reverse.
Heater: Short/Break/Overload.
TRIAC: Short.(compatible output module)
Fuse break.(compatible output module)
13. Communication Mode: RS-485 (Standard MODBUS, Isolated)/
UART (Choose one of two)
14. Communication Rate: 38400/57600
15. ID Setup: DIP switch Setup
16. Storage Temperature: -20~70°C/-4~158°F
17. Operating Temperature: -10~50°C/14~122°F
18. Operation humidity: 0~80%RH (No condensation)
3.3 Temperature Control Module (BAC0200001)