Visions 3000 machine

Visions 3000 Control Systems

A Serious Intelligent Hot Runner
Temperature Control System


The VISIONS 3000 hos been designed for those whose production and quality systems require :
 
  • Full record keeping of all operational events for a 12 month period of time
  • The ability to save and recall over 100 different tool sets
  • Full tool protection with comprehensive suite of alarms
  • Exceptional accuracy
  • Down loadable diagnostic reports and graphs
  • Remote system monitoring
  • Real time Mold Water System Monitoring (optional)
  • Molding System stoppage/stand-by capabilities

Ease of Use

VISIONS 3000
common sense engineering approach provide o fully featured system which is intuitively simple to operate, just turn power
on and enter set -points. The intelligent, start up function tokes the mold from worm up to steady state in a manner which eliminates uneven thermal expansion.

RELIABILITY:
 
  • Industrial Grade Cabinet
  • All fuses and cards easily accessible through front door
  • Normal maintenance items can be swapped in a. matter of seconds with little or no interruption
  • Buss Bar circuitry minimizes wiring connections
  • Rugged modular construction
  • Display - Impact resistant Touchscreen

AFFORDABILITY/VIABILITY:
 
  • Low Cost of Ownership - Reasonable Cost. Longevity, Reliability. Usability. Advanced Features. Upgradable
  • Reliability - Visions 3000 are manufactured for Industrial Environments
  • Usable Features - Visions 3000 suite of operational and diagnostic features are second to none and intuitively easy to use and understand
  • Accurate Control - Adoptive Thermal Control provides superior accuracy, every savings, precise monitoring and protection
  • Maintainability - VISIONS 3000 is designed so everything is easily viable and accessible
  • History - All production data stored and viewable for the past year
  • Water Flow - Manifold operating data is displayed with hot runner zones
  • Technology - AS updates become available they are backward compatible for a 10 year period
Adaptive thermal control image

Adaptive Thermal Control:

  • Balanced Power Output saves energy and improves heater life reducing down-time
  • Auto Tuning, which is adjustable for problematic situations
  • Individual Heater P.I.D Tuning
  • Individual Heater Alarm Tolerance Settings
  • Individual Heater Power Consumption Monitoring
  • Separate Manifold and Cavity Control
  • Programmable Minifold Pre-heat Start Up Groups
  • Manifold Pre-heat
Alert window

ALARMS:

There are various alarm triggering events within the VISIONS 3000 System, allowing management to make intelligent operational decisions, such as allowing the system to continue operation, placing the tool in standby, audible or visual alarms and/or to shut down the tool. This allows management the ability to determine a strategy for the molding operation. Alarm initiations are saved for 12 months.
Brochure visions 3000 rev 2 52 page 3 image 0001
DATABASE:
The VISIONS 3000 has the ability to store and retrieve all Hot Runner and WaterFlo operational set-up and alarm parameters of over 100 mold tool sets. Downloadable and transferable to other VISIONS 3000 control systems.

SECURITY:
There are three levels of security with the ability to define new passwords

TOOL VALIDATION:
When initiated on a new or reconditioned tool, a full suite of diagnostic tests automatically perform functional analysis on all aspects of the too l and controller. on a zone by zone basis. providing Information on any errors which may exist. The results can be stored and downloaded . providing a historical baseline for comparison checks and providing a record of the tools history.

PRO-ACTIVE DIAGNOSTICS:
During normal operation, the VISIONS 3000 constantly monitors all elements to determine functionality o f the tool When the VISIONS 3000 senses a wiring or heating problem an alarm will activate with a description of the error, which is saved to the Alarm History Log.

VISUAL DIAGNOSTICS:
LED's indicators are visible through the front door providing evidence of Output Activity. CPU Communications and Fuse Conditions.

TOOL MOTION DETECTION:
When a signal is provided from the molding machine indicating activity, the VISIONS 3000 activates a count down clock. If another signal is not received in the selected time frame, the VISIONS 3000 is automatically placed in stand-by mode.
Diagnostic status window

SELF DIAGNOSTIC CAPABILITIES:

The VISIONS 3000 Tool Diagnostic Suite performs a full set of functional tests to determine the condition of the mold, controller and machine operation and provide full protection of the tool.
 
  • Swapped heater or the thermocouple wires. If one is found, the controller indicates the affected zone.
  • Heater Power Monitoring and Alarm (Amperage and Wattage) - High/Low limits set to monitor heater operation and detect possible material leakage in the manifold or disruption in the cooling system.
  • Heater Resistance Monitoring and Alarm - helps predict in advance when a heatr is about to fail.
  • Thermocouple Open, Reversed Thermocouple, Cold Thermocouple, Open Fuse, Open Heater, Shorted heater, Etc.
System shutdown graphic
SYSTEM SHUT DOWN:
Selectable failures in the hot runner or WaterFlo operations can trigger an alarm, which will shut down the molding operation, preventing damage.

POWER TEMPERATURE COMPARATOR GRAPHS:
A scalable display of the actual measured value of temperature and power against time for each zone. The Power Temperature Comparator Graph used in conjunction with the Surface Graph feature, allows for expeditious troubleshooting.
HISTORY LOG:
All Hot Runner and WaterFlo production and alarm data is automatically stored for a period of 12 months, becoming an invaluable resource for today's quality systems and production management. Data includes:
 
  • Individual heater power usage and temperature during the production cycle on a second by second basis
  • Individual water channel flow rate and temperature during the production cycle
  • All initial set-up settings
  • All user and set-point changes made during production
  • Alarm activations
  • Tool diagnostic reports and set-up files
  • All data is time and date stamped, allowing for searches by time and date
  • All History Even logs are viewable from the VISIONS 3000 controller and are downloadable
Usb drive
COMMUNICATIONS:
Network capable for off site monitoring USB, Smartphone, Network Compatible
Screen
INDUSTRIAL HARDENED IMPACT RESISTANT COLOR TOUCH SCREEN;
Large 12" Impact Resistant Safety Glass Color Touch Screen

Top Box/Touch Screen can be easily removed for machine mounting.

SLAVING:
When one or more zones do not have the thermocouple feedback, they can be linked to zones with similar characteristics. This function can be included in the database setup and noted in the History Log.
Graphs
GRAPHS:
A picture is worth a 1000 words. Graphic Visualization provides immediate insight into the operation of the tool. Scrolling through data from each zone is tedious
and time consuming. Now at a single glance, output power, temperature and water flow are shown in a three dimensional live graph, line graphs and bar graphs. Graphs are color coordinated for Power, Temperature and Water Flow.
Boost
BOOST:
User selectable for time and temperature

SOFT START:
An automatic feature within the Run Function which slowing brings the temperature of the mold up to 200˚ F (93˚C), then ramps up power until the temperature is within the proportional range.
Stand by
STAND-BY:

Lowers temperature of a zone or group of zones when the molding process is inactive for a short period of time.

This function is either user selectable of automatic via peripheral interface and can be set-up in the database.

MULTI-LINGUAL:
English, Spanish, Dutch, German, Italian
WATERFLO (OPTION):
WaterFlo is an extremely powerful Real Time Water Flow Rate and Temperature Monitoring tool for a molds water cooling system. By incorporating it with our Hot Runner Control you achieve maximum production, quality and cost benefits. The Optional ITC Smart Manifold and WaterFlo Interface is an extremely accurate (1.5% full range) system, with the ability to Monitor, Measure and Graph fow rate and temperature on a real time basis as well as log 12 months of historical data for each cooling channel. this integrated package of actual water cooling and hot runner data allows for molding efficiencies hereto unavailable. Additionally a warning signal can be generated to activate and external warning device or even disable connected equipment. WaterFlo functions are integrated to display along side hot runner zones.
S20 d3c header
A superior Temperature Control Module designed for those applications where ease of operation, cost and features are of concern.
 
  • E X C E P T I O N A L VA L U E
  • E A S E O F O P E R AT I O N
  • P R E F E R R E D D I A G N O S T I C S F E AT U R E S
  • S U P E R I O R O P E R AT I N G
  • F E AT U R E S
  • D U R A B I L I T Y
  • WA R R A N T Y
S20 d3c fisa 2
The S20-D3C Temperature Control Module has been intelligently designed, making it easy to set up and simple to use, while maximizing productivity, and providing an
exceptional range of features, in order to meet the rigorous requirements of today's plastics industry. The Microprocessor
based circuitry of the S20-D3C performs a full array of diagnostic and operational functions. Set-point temperatures are automatically maintained by means of our fully Adaptive-auto-tuning PID/FUZZY LOGIC function.

The S20-D3C Module has been designed with the operator in mind; therefore it is easy to use. What could be simpler than,
just turning it on, setting the operating temperature using the pinwheel set-point, then letting it run?

FEATURES:
• Automatic or Manual Operation
• Advanced Anti-Arcing Circuitry w/"ITC" Main frames
• Automatic Soft Start
• Amperage Measurement & Display
• Type "J" or "K" Thermocouple
• "F" or "C" Temperature ranges
• Selectable Control Methods – Adaptive-auto-tuning PID or Fuzzy Logic
• Manual Control for non-thermocouple applications
• Blown Fuse indicator
• This Module operates all "ITC" 15 and 30 amp main frames
• Compatible with "G" series main frames

DIAGNOSTICS:
The multifunction digital readout displays actual temperature, amps, percent of power, as well as various error codes:
• Open Thermocouple
• Reverse Thermocouple
• Shorted Thermocouple
• Open Triac or Heater
• Shorted Triac
• Over Current Condition Individual LED's indicate:
• Manual Operation
• Soft Start
• High/Low Temperature – +/- 30° F
• Power output to the mold
• Blown Fuse
• "F" or "C" Temperature ranges
• "J" or "K" type thermocouple indicator
• Amp Measurement & Display
Uatc 20 header
The UATC-20 Temperature Control Module has been designed with the latest in microprocessor technology for Hot Runner Applications where state-of-the-art operational and diagnostic features are a requisite. There are many little features, such as gold-plated edge connector, incorporated within the UATC-20 which greatly enhances its operation. The UATC-20 is a rugged, simple to set-up and easy to use module which is versatile enough to move from project to project, with all the sophistication necessary for today's demanding molding requirements.
Uatc 20 unit
Some of the exceptional analytical functions found on the UATC-20 are:
• A diagnostic snapshot of the heaters operating characteristics are revealed when the current sensing feature is employed.
• Detects and alerts to the potentially dangerous condition of current leaking to ground.
• If power to the heater exceeds a selected value, the module will alarm and disables power to the heater preventing damage.
• Advance circuitry detects alarms and disables power to the heater in the event the triac fails in a shorted condition.
• In the event of a Thermocouple, Open or Shorted condition, the module will automatically go into APO (Average Power
Output) mode, allowing operations to continue by providing the same average power to the heater as applied prior to the failure.
• Control algorithms are by means of our Adaptive-auto-tuning PID or FUZZY logic which makes intelligent control decisions
and minimizes electrical stress on the heaters.
• Real time diagnostics fault detection & display.
Uatc 20 fisa 2
Enhanced Diagnostic Features:
• Ground fault detection (selectable range)
• High amperage alarm (selectable range)
• Thermocouple - open, shorted & reversed alarm
• Triac - shorted & open alarm
• Heater open alarm
• High and low temperature alarm
• Blown fuse indicators

Safety Features
• High voltage thermocouple protection (fused)
• Module high current protection (fused)
• Power disabled to heater:
o Triac shorted
o Triac open
o Heater open
o Over temperature
o High amperage
• Audible alarm (selectable on/off)

Features:
• All functions & parameters are fully selectable from the "menu" feature on the keypad
• Amperage measurement & display
• Percent of power display (selectable range)
• Automatic or manual operation
• Automatic soft start
• Anti-arcing
• Boost (selectable temperature & time)
• Standby
• "F" or "C" temperature ranges
• Type "J" or "K" thermocouple
• Selectable control method – Adaptive-auto-tuning PID or Fuzzy Logic
• Panel lock out (selectable on/off)
• Electrically Isolated Front Panel
• APO (average power output) for T/C failure conditions
• Automatic test of LED segments
• Operating voltage 240V, 50/60 Hz or 120V
• Cold junction compensation
• Zero crossing triac
• This module operates both of our 15 and 30 main frames
Temp control system fisa page 1 image 0001
Features
Full Compliment of Systems
Reliability
Simplicity of Operation
Exceptional Value
Customer Service

PORTABLE FLOOR STANDS

Manufactured of heavy gage steel tubing and provided with swivel
& lockable casters.
Stands are shipped un-assembled.
Temp control system fisa page 2 image 0002
PFS-1
MF1, MF2 & MFHP-1
PFS-5
MF5 & MFHP-3
PFS-812
MF8, MF12 & MFHP-6

TRANSFORMER PACKAGES

Step-down 480v to 240v 3-phase

Pre-wired and assembled – includes Transformer, Welded stand with casters, Fused disconnect and 10 ft. AC input power cable (no connector on end).
Temp control system fisa page 2 image 0003
TP-6-5
6 kva with 5 zone stand
TP-9-8
9 kva with 8 zone stand
TP-15-8
15 kva with 8 zone stand
TP-15-12
15 kva with 12 zone stand
TP-30-8
30 kva with 8 zone stand
TP-30-12
30 kva with 12 zone stand
TP-45-12
45 kva with 12 zone stand

MOLD CABLES

Custom lengths and connector configurations are available upon request.
PWC5-10 (15) 10 FT.
THC5-10
PWC5-20 (15) 20 FT.
THC5-20
PWC8-10 (15) 10 FT.
THC8-10
PWC8-20 (15) 20 FT.
THC8-20
Temp control system fisa page 2 image 0007
PWC12-10 (15) 10 FT.
THC12-10
Temp control system fisa page 2 image 0004
PWC12-20 (15) 20 FT.
THC12-20
PWCHP3-10 (30) 10 FT.
PWCHP3-20 (30) 20 FT.
PWCHP6-10 (30) 10 FT.
PWCHP6-20 (30) 20 FT.

MOLD CONNECTORS

Power - (Amps) - Thermocouple
Temp control system fisa page 2 image 0005
MPC-5
(15)
MTC-5
Temp control system fisa page 2 image 0006
MPC-8
(15)
MTC-8
MPC-12
(15)
MTC-12
MPCHP-3
(30)
MPCHP-6
30)

1 & 2 ZONE CABLES (Combination Power & T/C)

Custom Lengths and configurations are available upon request.

• Main Frames, Temperature Control Modules, Cables and other components are all sold separately.
• Please specify Voltage and Current requirements when ordering.
• ITC will gladly modify standard main frames, cables, etc., to accommodate your application.
• All modular components are “G” series compatible.
Temp control system fisa page 3 image 0016
PTC1-10
(15) Amps • 10 ft. long
PTC1-20
(15) Amps • 20 ft. long
PTCHP1-10
(30) Amps • 10 ft. long (High Power)
PTCHP1-20
(30) Amps • 20 ft. long (High Power)

CONNECTOR KITS

Number - (Amps) - Description
MEK-5TC
(15) Amps • Cable, Mold End Kit, 5 Zone, Thermocouple (Female)
MEK-8TC
(15) Amps • Cable, Mold End Kit, 8 Zone, Thermocouple (Female)
Temp control system fisa page 3 image 0003
MEK-12TC
(15) Amps • Cable, Mold End Kit, 12 Zone, Thermocouple (Female)
Temp control system fisa page 3 image 0004
MEK-PR
(15) Amps • Cable, Mold End Kit, 5, 8 & 12 Zone, Power (Female)
Temp control system fisa page 3 image 0005
FEK-PR
(15) Amps • Cable, Frame End Kit, 5, 8 & 12 Zone, Power (Male)
FEK-TC
(15) Amps • Cable, Frame End Kit, 5, 8 & 12 Zone, Thermocouple (Female)
Temp control system fisa page 3 image 0002
FCK-PR
(15) Amps • Main Frame, Connector, 5, 8 & 12 Zone, Power (Female)
Temp control system fisa page 3 image 0006
FCK-TC
(15) Amps • Main Frame, Connector, 5, 8 & 12 Zone, Thermocouple (Male)
MF-EC
All Amps • Card Edge Connector Kit w/Contacts - All Main Frames
MF-ECC
All Amps • Card Edge Connector - Contacts - All Main Frames
MF-CG
All Amps • Card Guide, 6” - All Main Frames
ABC-15
All Amps • Module Fuse - Special Fast Blow
MEKHP-3PR
(30) Amps • Cable, Mold End Kit, 3 Zone, Power (Female) (High Power)
MEKHP-6PR
(30) Amps • Cable, Mold End Kit, 6 Zone, Power (Female) (High Power)
FEKHP-3PR
(30) Amps • Cable, Frame End Kit, 3 Zone, Power (Male) (High Power)
FEKHP-6PR
(30) Amps • Cable, Frame End Kit, 6 Zone, Power (Male) (High Power)
FCKHP-3PR
(30) Amps • Main Frame, Connector, 3 Zone, Power (Female) (High Power)
FCKHP-6PR
(30) Amps • Main Frame, Connector, 6 Zone, Power (Female) (High Power)

1 & 2 ZONE CONNECTOR KITS

(Combination Power & T/C)
Temp control system fisa page 3 image 0009
1Z-ME
(15) Amps • Cable End, Male Connector, 1 & 2 Zone
Temp control system fisa page 3 image 0012
1Z-FE
(15) Amps • Cable End, Female Connector, 1 & 2 Zone
Temp control system fisa page 3 image 0008
1Z-MC
(15) Amps • Mold Connector, Male, 1 & 2 Zone
Temp control system fisa page 3 image 0007
1Z-FC
(15) Amps • Frame Connector, Female, 1 & 2 Zone
Temp control system fisa page 3 image 0011
1Z-MEL
(15) Amps • Cable Coupler Hood, w/Latch, Male, 1 & 2 Zone
Temp control system fisa page 3 image 0010
1Z-ME90
(15) Amps • Cable End, Male Connector, 90º
1Z-IPP
(15) Amps • Input Power Cord Plug, Female
MPTCHP-1
(30) Amps • Mold Connector, 1 & 2 Zone (Male) (High Power)

MAIN FRAME HARNESSES

MF-PH5
5 Zones • MF-TH5 Thermocouple
MF-PH8
8 Zones • MF-TH8 Thermocouple
Temp control system fisa page 3 image 0013
MF-PH12
12 Zones • MF-TH12 Thermocouple
Temp control system fisa page 3 image 0014

MOLD WIRING JUNCTION BOX (EMPTY)

Connectors must be ordered separately.
Temp control system fisa page 3 image 0015
MJB-5
5 Zones
MJB-8
8 Zones
MJB-12
12 Zones

MOLD WIRING JUNCTION BOX (PRE-WIRED)

Pre-wired with terminal strip & connectors.
Temp control system fisa page 3 image 0018
MJBW-8
8 Zones
MJBW-12
12 Zones

MAIN FRAME BLANK PANEL

Temp control system fisa page 3 image 0017
MFBP
Fits all 15 & 30 amp
main frames.

STANDARD ITC 15 AMP MAIN FRAME

Temp control system fisa page 4 image 0002
MF1
1-Zone
Temp control system fisa page 4 image 0002
MF2
2-Zone
Temp control system fisa page 4 image 0003
MF5-150
5-Zone w/50 amp breaker
Temp control system fisa page 4 image 0004
MF8-150
8-Zone w/50 amp breaker
Temp control system fisa page 4 image 0005
MF12-150
12-Zone w/50 amp breaker
MF16-250
16-Zone w/(2) 50 amp breakers
MF16-170
16-Zone w/70 amp breaker
MF20-250
20-Zone w/(2) 50 amp breakers
MF20-170
20-Zone w/70 amp breaker
Temp control system fisa page 4 image 0006
MF24-250
24-Zone w/(2) 50 amp breakers
MF24-170
24-Zone w/70 amp breaker
MF28-350
28-Zone w/(3) 50 amp breakers
MF32-350
32-Zone w/(3) 50 amp breakers
MF40-450
40-Zone w/(4) 50 amp breakers
MF44-450
44-Zone w/(4) 50 amp breakers
MF48-450
48-Zone w/(4) 50 amp breakers

STANDARD ITC 30 AMP (HIGH POWER) MAIN FRAME

All ITC 15 & 30 amp Main Frame use our standard S20-D3C & UATC-20 control modules.
Unless otherwise specified all main frames are 240v, 3-phase except MF1 & MF2 which are 240v single phase.
All components are neatly contained within the main frame.
Special or Larger Control Systems are available upon request.
Stacks of 2 or more main frames are rigidly fastened together into a single prewired unit.
Temp control system fisa page 4 image 0007
MFHP-1-130
1-Zone w/30 amp breaker
MFHP-3-150
3-Zone w/50 amp breaker
MFHP-6-1100
6-Zone w/100 amp breaker

VISIONS 3000 INTELLIGENT TEMPERATURE CONTROL SYSTEM

Unless otherwise specified all VISIONS 3000 systems are 240v, 3-phase.
Systems are available for both 15 and 30 amp zones.
VISIONS 3000 offered with standard Key-pad Interface or Optional Touch-screen interface.
Valve Gate Sequencing Option.
Special or Larger Control Systems, as well as Dual or Low Voltage Systems are available upon request.
VCS-16-16-70
16 - Zone w/70 amp breaker
VCS-32-18-100
18 - Zone w/100 amp breaker
VCS-32-20-100
20 - Zone w/100 amp breaker
VCS-32-22-100
22 - Zone w/100 amp breaker
VCS-32-24-100
24 - Zone w/100 amp breaker
VCS-32-26-100
26 - Zone w/100 amp breaker
VCS-32-28-100
28 - Zone w/100 amp breaker
VCS-32-30-100
30 - Zone w/100 amp breaker
VCS-32-32-100
32 - Zone w/100 amp breaker
VCS-48-34-125
34 - Zone w/125 amp breaker
VCS-48-36-125
36 - Zone w/125 amp breaker
VCS-48-38-125
38 - Zone w/125 amp breaker
VCS-48-40-125
40 - Zone w/125 amp breaker
VCS-48-42-125
42 - Zone w/125 amp breaker
VCS-48-44-125
44 - Zone w/125 amp breaker
VCS-48-46-125
46 - Zone w/125 amp breaker
VCS-48-48-125
48 - Zone w/125 amp breaker
VCS-64-50-125
50 - Zone w/125 amp breaker
VCS-64-52-125
52 - Zone w/125 amp breaker
VCS-64-54-125
54 - Zone w/125 amp breaker
VCS-64-56-125
56 - Zone w/125 amp breaker
VCS-64-58-125
58 - Zone w/125 amp breaker
VCS-64-60-125
60 - Zone w/125 amp breaker
VCS-64-62-125
62 - Zone w/125 amp breaker
VCS-64-64-125
64 - Zone w/125 amp breaker
VCS-80-66-150
66 - Zone w/150 amp breaker
VCS-80-68-150
68 - Zone w/150 amp breaker
VCS-80-70-150
70 - Zone w/150 amp breaker
VCS-80-72-150
72 - Zone w/150 amp breaker
VCS-80-74-150
150 74 - Zone w/150 amp breaker
VCS-80-76-150
76 - Zone w/150 amp breaker
VCS-80-78-150
78 - Zone w/150 amp breaker
VCS-80-80-150
80 - Zone w/150 amp breaker
VCS-96-82-150
82 - Zone w/150 amp breaker
VCS-96-84-150
84 - Zone w/150 amp breaker
VCS-96-86-150
86 - Zone w/150 amp breaker
VCS-96-88-150
88 - Zone w/150 amp breaker
VCS-96-90-150
90 - Zone w/150 amp breaker
VCS-96-92-150
92 - Zone w/150 amp breaker
VCS-96-94-150
94 - Zone w/150 amp breaker
VCS-96-96-150
96 - Zone w/150 amp breaker
VCS-96-96-150
96 - Zone w/150 amp breaker
VCS-112-98-175
98 - Zone w/175 amp breaker
VCS-112-100-175
100 - Zone w/175 amp breaker
VCS-112-102-175
102 - Zone w/175 amp breaker
VCS-112-104-175
104 - Zone w/175 amp breaker
VCS-112-106-175
106 - Zone w/175 amp breaker
VCS-112-108-175
108 - Zone w/175 amp breaker
VCS-112-110-175
110 - Zone w/175 amp breaker
VCS-112-112-175
112 - Zone w/175 amp breaker
VCS-128-114-200
114 - Zone w/200 amp breaker
VCS-128-116-200
116 - Zone w/200 amp breaker
VCS-128-118-200
118 - Zone w/200 amp breaker
VCS-128-120-200
120 - Zone w/200 amp breaker
VCS-128-122-200
122 - Zone w/200 amp breaker
VCS-128-124-200
124 - Zone w/200 amp breaker
VCS-128-126-200
126 - Zone w/200 amp breaker
VCS-128-128-200
128 - Zone w/200 amp breaker
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