System Configuration / Hardware

TCS can be provided as engineered kits, designed specifically to defined barrel diameters and zone lengths. 

TCS Sections are defined by voltage, length and diameter, though the power, amperage limits and space constraints must also be verified.

Voltage, Power, Amps, Diameter and Length


TCS will be designed to conform to the incumbent heater supply voltage.

NOTE:  TCS is provided in (2) Half Cylinders which can be wired in series or parallel to one another.

If wired in Parallel, the TCS halves will be designed to a voltage equal to that of the Supply Voltage. 

If wired in Series, the TCS halves will be designed to a voltage equal to half that of the Supply Voltage.

*Default is to engineer TCS to be wired in Series


Requirement is defined by cumulative power of all heater bands in each zone, multiplied by the % On-Time of that zone, during the most demanding machine/tool set-up.

TCS is typically provided with a power rating of 80% that of the incumbent heater bands as the added efficiency and heat containment reduces the requirement.

TCS parts rated at even less than 80% that of the incumbent heater bands may be employed if the % On-Time of a Zone is low.


Select machines limit the allowable current provided to the barrel heating system via a breaker.

This is somewhat typical on newer Engel machines. 

The maximum allowed current should be compared to the value of the design Current of the TCS Heaters, which is shown in the part description for any given voltage/size configuration.

Diameter and Length

TCS can be supplied to customer requirements, in terms of inside diameter and length.  

Ranges include:

  • TCS Inside Diameter (Barrel Outside Diameter): 100 mm - 355 mm
  • TCS Length: 150 mm - 400 mm


Straps and cable trays are typically kitted and sold with TCS sections under one-part number, while gasket material and junction boxes must be ordered separately.

Insulative spacers can be provided with kits, or ordered separately.

Electrical Connectors (Posi-Lock) and high-temperature shrink wrap is provided with all TCS sections.


Available in (3) Sizes based on TCS Inside Diameter:

TCS Inside Diameter < 228 mm (9”)

TCS Inside Diameter 229 mm - 330 mm (9”-13”)

TCS Inside Diameter >330 mm (13”)


Straps include metal tab which is used with the worm gear to secure the cable trays in place.

Straps are Teflon Coated to prevent damage to the exterior coating of the TCS Sections during installation or removal.

Cable Trays

Available in 30 cm, 45 cm and 70 cm long (12”, 18”, 28”),

Gasket Material/Kit

Gasket Kits available with either 100 or 500 linear feet of gasket material and securing devices.

Amount of gasket material required depends on the difference between the Barrel Outside Diameter and TCS ID.

Gasket material is 1.6 mm thick (0.0625") and may be wrapped around the barrel as many as 8 times to adapt the TCS to the barrel.

Gasket material is 25 mm wide (1") and TCS touch points are 12.5 mm wide (0.5"), so the gasket will fit across two adjacent TCS Sections.

Insulative Spacers

Spacers, sized in accordance with the selected TCS Sections, are available in 32 mm (1.25") widths, to improve barrel coverage and heat containment


Standardized TCS parts do not contain Cooling Channels, and as such, Cooling Option is not available.  If cooling is required please contact an RMG Representative.  System can be designed for Future Cooling upon request

83 mm (3.25”) of clearance is required around the entire circumference of the barrel.

Thermocouple Extensions, which are required due to the thickness of TCS, must be purchased separately, typically from the Machine Manufacturer or Spare Parts provider.

 Cable Tray Organizes and Protects Electrical Lines and Connections


Gasket Materials provides a secure fit between the Barrel Outside Diameter and the TCS Inside Diameter, when using Standard TCS Parts

Straps Secure the System onto the Barrel and hold Cable Tray in Place.



Metal Tab on Straps (arrow #2)
is used in conjunction with
Worm Gear (arrow #1)
to hold the Cable Tray in place











Spacers, 32 mm wide (1.25") can be added where necessary to better insulate the Barrel or to allocate space for Future Cooling Rings (see "Design for Future Cooling" on Cooling Page).

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