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Project Specification — TK512DC-L PLC HMI PCB Design
Project Overview
Status: Draft / Preliminary Schematic Allowed
Design a PCB based on the uploaded TK512DC-L / Proface 4 PLC HMI wiring diagram. The board will use 230 VAC input and route/control external field loads. The user confirmed these load ratings:
- Heater: 10 A at 230 VAC, controlled by external SSRs
- Fan: 1 A at 230 VAC
- Light: 0.5 A at 230 VAC
- Buzzer: 0.2 A at 230 VAC
The heater current is high, so the safer design direction is to keep heater switching in external SSRs and use the PCB primarily as a clearly labeled terminal/fuse/interface board unless the user later requests high-current copper routing.
Intended Use
Industrial/control-panel PCB or interface board for connecting a PLC/HMI system to external 230 VAC loads:
- Heater through external SSRs
- Fan
- Light
- Buzzer
- Lift up/down controls from the uploaded wiring diagram, ratings still TBD
- Thermocouple sensor routing
- Manual DPDT switch routing
What the Device Should Do
- Accept 230 VAC line, neutral, and protective earth.
- Provide fused line distribution for output branches.
- Route heater control/load wiring to external SSR terminal connections.
- Provide field terminals for fan, light, buzzer, lift, thermocouple, and switch wiring.
- Maintain safe separation between mains, earth, thermocouple/signal wiring, and any low-voltage PLC/HMI signals.
- Use clear silkscreen labels and terminal naming that matches the wiring diagram.
Main Features
- AC input terminal: L, N, E
- Main fuse and branch fuses
- External SSR terminal blocks for heater control/load path
- Fan output terminal, 1 A
- Light output terminal, 0.5 A
- Buzzer output terminal, 0.2 A
- Placeholder lift UP/DOWN terminal positions pending ratings
- Thermocouple input terminals with polarity marking
- DPDT switch connector terminals
System Architecture
Diagram
Hardware Subsystems
Power Input and Protection
- Input: 230 VAC.
- Main branch current excluding heater: 1 A + 0.5 A + 0.2 A = 1.7 A continuous for fan/light/buzzer.
- Heater branch: 10 A, but switching is through external SSRs. If heater current is routed on PCB, high-current trace/copper/clearance design is required and must be confirmed.
- Recommended preliminary fuse sizing direction:
- Main/control distribution fuse: TBD based on whether heater current enters the PCB.
- Fan branch fuse: >1 A load rating, time-delay may be needed for motor inrush.
- Light branch fuse: >0.5 A load rating.
- Buzzer branch fuse: >0.2 A load rating.
- Heater branch fuse: >10 A load rating, normally external or panel-mounted for safety and serviceability.
PLC/HMI Terminal Interface
- Need exact Proface/TK512DC-L terminal pinout to map PLC outputs to terminal blocks.
- Current schematic will use labeled connector blocks until exact mating connector / terminal order is confirmed.
Heater / External SSR Block
- SSRs are external, per user confirmation.
- PCB should provide labeled terminals for SSR control and/or load-side wiring as shown in the wiring diagram.
- Need confirmation whether the PCB carries the 10 A heater line current or only provides low-current SSR control terminals.
- Preferred safe assumption: do not route 10 A heater current through PCB unless explicitly requested.
Fan / Light / Buzzer Outputs
- Fan: 230 VAC, 1 A. Motor load may need snubber/surge suppression depending on wiring and relay/SSR type.
- Light: 230 VAC, 0.5 A.
- Buzzer: 230 VAC, 0.2 A.
- Outputs should have rated terminal blocks and branch protection.
Lift UP/DOWN Outputs
- Still missing lift voltage/current and whether these outputs drive contactor coils or motor power.
- Leave as placeholder terminals until ratings are confirmed.
Thermocouple Input
- Need thermocouple type.
- Current assumption: route thermocouple to PLC/HMI terminals only, no on-board measurement IC.
- Keep thermocouple wiring away from 230 VAC traces/terminals.
DPDT Switch Interface
- Need exact switch terminal mapping and voltage/current.
- Current schematic can provide a labeled 6-position terminal/header matching the diagram.
Interfaces and Connections
Table
| Interface | Known Labels | Confirmed Rating | Missing Information |
|---|---|---|---|
| AC Input | L, N, E | 230 VAC | Total current path / fuse strategy |
| Heater | SSR 1, SSR 2, To Heater | 10 A, external SSRs | Whether 10 A is routed on PCB or only terminalized |
| Fan | FAN | 230 VAC, 1 A | Inrush and suppression need |
| Light | LIGHT | 230 VAC, 0.5 A | Load type |
| Buzzer | BUZZER | 230 VAC, 0.2 A | Load type |
| Lift | LIFT UP, LIFT DOWN | TBD | Voltage/current, interlock method |
| Thermocouple | +, - | TBD | Type K/J/etc., routing vs measurement |
| DPDT Switch | 1, 2, 3, 4, 5, 7 | TBD | Exact switch schematic |
Power and Runtime Expectations
Externally powered from 230 VAC. No battery/runtime target.
Power Tree and Power Budget
Table
| Load / Branch | Voltage | Current | Apparent Power | Notes |
|---|---|---|---|---|
| Heater | 230 VAC | 10 A | 2300 VA | External SSRs confirmed. Prefer off-board high-current path. |
| Fan | 230 VAC | 1 A | 230 VA | Motor inrush likely; branch fuse/suppression TBD. |
| Light | 230 VAC | 0.5 A | 115 VA | Load type TBD. |
| Buzzer | 230 VAC | 0.2 A | 46 VA | Load type TBD. |
| Fan + Light + Buzzer subtotal | 230 VAC | 1.7 A | 391 VA | Non-heater branch total. |
| Total including heater | 230 VAC | 11.7 A | 2691 VA | Only if heater current passes through PCB/panel distribution. |
Sizing guidance:
- Any connector/terminal path carrying all loads must be rated above 11.7 A continuous with margin.
- If the PCB only carries fan/light/buzzer and SSR control wiring, the on-board mains output current can be closer to 1.7 A, plus lift current once known.
- Heater 10 A paths should use appropriately rated terminal blocks, wide copper, heavy copper, or preferably off-board wiring/SSR/fuse hardware.
Manufacturing and Assembly Expectations
- Use 230 VAC-rated terminal blocks with suitable current ratings.
- Use conservative mains creepage/clearance; keep low-voltage/thermocouple wiring physically separated from 230 VAC.
- Provide silkscreen warning labels for LIVE/NEUTRAL/EARTH and load outputs.
- Include mounting holes and board-edge terminal placement for control-panel wiring.
Firmware-Relevant Hardware Requirements
No firmware is assumed unless the board later includes a microcontroller. Current design is a passive/interconnect/control interface board.
Physical Design Expectations
TBD:
- Board size
- Mounting hole pattern
- Enclosure/control-panel mounting method
- Connector edge orientation
- Whether heater current should stay off-board
Important Design Decisions
- Treat as a PCB design per user confirmation.
- Use 230 VAC as the input and output load voltage.
- Use external SSRs for the 10 A heater branch.
- Prefer not to route 10 A heater current through the PCB unless explicitly confirmed.
- Use terminal-block field wiring with clear labels until exact connector MPNs are chosen.
Assumptions
- The uploaded PDF is a wiring diagram, not a complete PCB schematic.
- Some OCR labels may be incorrect, especially
LIFT DO/LIFT UPWN. - External SSRs handle heater switching.
- Thermocouple is routed to the PLC/HMI rather than measured on this PCB.
Change Notes
- 2026-06-01: User confirmed PCB design target.
- 2026-06-01: User confirmed 230 VAC input, 10 A heater, 1 A fan, 0.5 A light, 0.2 A buzzer, and external SSRs.
Project Overview
Intended Use
What the Device Should Do
Main Features
System Architecture
Hardware Subsystems
Power Input and Protection
PLC/HMI Terminal Interface
Heater / External SSR Block
Fan / Light / Buzzer Outputs
Lift UP/DOWN Outputs
Thermocouple Input
DPDT Switch Interface
Interfaces and Connections
Power and Runtime Expectations
Power Tree and Power Budget
Manufacturing and Assembly Expectations
Firmware-Relevant Hardware Requirements
Physical Design Expectations
Important Design Decisions
Assumptions
Change Notes
