Temperature

Control Systems
Table of Contents
Modular Temperature Controllers .........................................................1
VC-M 15 Amp Module...........................................................................2
Single Zone Hot Runner Temperature Controller.....................................3
Modular Temperature Controller Guide..................................................4
Over/Under Temperature Alarm............................................................5
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Mold End Prewired Terminal Mounting Boxes.........................................7
Mold End Blank Combination Terminal Mounting Boxes...........................9
Mold Power & Thermocouple Cables....................................................10
Mold Connectors................................................................................11
OEM Mold End Prewired Terminal Mounting Boxes..........................12
OEM Mold End Blank Combination Terminal Mounting Boxes............14
OEM Mold Power & Thermocouple Conversion Cables......................15
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Replacement Parts............................................................................17
Accessories.......................................................................................19
Mainframe Wiring Diagram.................................................................20
Replacement Parts Diagram................................................................21
Visions 3000/2.0 Controller System................................................22
Visions 3000/2.0 WaterFlo/Smart Manifold Option...........................27

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Modular Temperature Controllers

Product Features

PCS Modular Controllers incorporate many

user-friendly features.
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Series® style temperature control modules and 1 Zone
mainframe systems
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control modes
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and manual control modes
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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 
VC-M 15 Amp Module
CONTROLS

1. Power Switch(ON/OFF)
2. Process Temperature Display
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3a. Setpoint Temperature Display (Shown at Right)
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3b. Load Power (%) Output Display
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3c. Amps(Load Current) Display

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4. Increment Key
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5. Decrement Key
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6. View Key
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7. Automatic/Manual Control Mode Select Key
8. Plastic Retention/ Locking Device  
INDICATORS  
9. Automatic (Closed Loop) Control Mode Indicator
10. Start-Up Power Ramp Indicator
11. Load Power Indicator
 
12. Manual (Open Loop) Control Mode Indicator
13. Thermocouple Fault Indicator  
14. Output (Power) Fault Indicator
15. Fahrenheit Temperature Scale Indicator
16. Celsius Temperture Scale Indicator 
17. User Executed Boost Power Output Mode:
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 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Single Zone Hot Runner Temperature Controller

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CONTROLS AND INDICATORS
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 Setpoint Temperature Display (Auto)
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Diagnostics Diagnostics
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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 

Modular Temperature Controller Guide
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9&) correct mainframes and accessories for
Mainframe Mainframe
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Combination Combination
Qty. Qty. Qty.
Zone(s) Mainframe Volts Thermocouple Thermocouple Module
Req. Req. Req.
Power Cable Power Connector

 9&) Y 9&037&  &.37,&  1$ 1$

 9&) Y 9&037&  &.37,&  1$ 1$

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9&)
Mainframe
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Mainframe Mold Power Qty. Thermocouple Qty. Mold End Pre-Wired Qty. Qty
Zones Module
Cable Req. Cable Req. Terminal Mounting Boxes Req. Req.

 9&) 9&3&  9&7&  9&7%76  VC-M 

8 9&) VC-8PC  9&7&  9&7%76  VC-M 8

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 9&) VC-8PC  9&7&  9&7%76  VC-M 
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PCS Company offers affordable and fast repair services for your Modular Temperature Controllers.

 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Over/Under Temperature Alarm
1 Amp - 240 VAC
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Notes:
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temperature control modules.

CONTROLS AND INDICATORS

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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 

Modular Temperature Controller
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10 Amp Breaker

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Frame

VC-1ZF VC-2F VC-5F VC-8F VC-12F

10 Amp 20 Amp 50 Amp 50 Amp 50 Amp
Breaker Breaker Breaker Breaker Breaker

18” H
Stack
Frames

VC-16F VC-20F VC-24F

70 Amp Breaker 70 Amp Breaker 70 Amp Breaker

27” H
Stack
Frames

VC-28F VC-32F VC-36F

70 Amp Breaker 70 Amp Breaker 70 Amp Breaker

36” H
Stack
Frames

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 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Mold End Prewired
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VC-12TB-TS

Mold End Prewired Terminal Mounting Boxes

Mainframe Item Qty. Additional Additional
Zone Number Required Item Number Qty. Required
 9&7%76 

 9&7%76 

8 9&7%76 

 9&7%76 

 9&7%76 

 9&7%76  9&7%76 

 9&7%76 

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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Mold End Prewired
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Mold End Prewired Terminal Mounting Boxes

Dimensions in inch
Item Number Includes
Y X H M1 M2
9&7%76        &.37,&

9&7%76      9&03&9&07&

9&7%76      9&03&9&07&

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8 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Mold End Blank Combination
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Dimensions in inch
Item Number Accepts
Y X H M1 M2
9&7%        &.37,&

9&7%      9&03&9&07&

9&7%      9&03&9&07&

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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 9

Mold Power & Thermocouple Cables
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Special Power and Thermocouple Cables Available Upon Request.

Mold Power cables

Item Number of From 15 Amp To
Length
Number zones (Max.) mainframe(s) mold end

9&3&  ]RQH 9&03& IW

9&3& 8 ]RQH VC-8MPC IW

9&3&  ]RQH 9&03& IW

9&3&  ]RQH 9&03& IW

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Thermocouple cables
Item Number of From 15 Amp To
Length
Number zones (Max.) mainframe(s) mold end

9&7&  ]RQH 9&07& IW

9&7& 8 ]RQH 9&07& IW

9&7&  ]RQH 9&07& IW

9&7&  ]RQH 9&07& IW

9&7& 8 ]RQH 9&07& IW

9&7&  ]RQH 9&07& IW

9&7&  ]RQH 9&07& IW

9&7& 8 ]RQH 9&07& IW

9&7&  ]RQH 9&07& IW

Power & Thermocouple combination

cable 10 & 15 ft. lengths

Item Number Number of zones (Max.) From 10 Amp mainframe(s) To mold end

9&037&  ]RQH &.37,&

9&037&  ]RQH &.37,&

*Custom lengths and connectors available upon request.
 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299
Mold Connectors
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Mold Power Input Connectors

Item Number of Amps (Max.) Dimensions in inch
Number zones (Max.) per zone X Y
9&03&    

VC-8MPC 8   

9&03&    

VC-5MTC VC-8MTC VC-12MTC

Mold Thermocouple Connectors

Item Number Number of Dimensions in inch
Number of Pins zones (Max.) X Y
&.37,&   1$ 

9&07&    

9&07&  8  

9&07&    

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Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 

 OEM Mold End Prewired
Terminal Mounting Boxes

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 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

OEM Mold End Prewired
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HBE24 Generic Mold Masters DME High
Double Latch Style Style Style Power Style

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 

 OEM Mold End Blank Combination
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OEM Mold End Blank Combination Terminal Mounting Boxes

Item OEM Dimensions in inch
Accepts
Number Style Y X H M1 M2
37&(7% +%('RXEOH/DWFK6W\OH      3,&(07&(

37&(7% +%('RXEOH/DWFK6W\OH      3,&(07&(

37&(7% +%('RXEOH/DWFK6W\OH      3,&(07&(

 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

 O
OEM Mold Power & Thermocouple
Conversion Cables
OEM Mold Power Conversion Cables
Item OEM # of zones From 15 Amp To Double Latch
Length
Number Style (Max.) mainframe(s) Mold End
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 3,&( IW
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH 8 =RQH 3,&( IW
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 3,&( IW
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 3,&( IW
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH 8 =RQH 3,&( IW
03&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 3,&( IW

OEM Thermocouple Conversion Cables

Item OEM # of zones From 15 Amp To Double Latch
Length
Number Style (Max.) mainframe(s) Mold End
7&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 07&( IW
7&( +%('RXEOH/DWFKWR3&6'0(6W\OH 8 =RQH 07&( IW
7&( +%('RXEOH/DWFKWR3&6'0(6W\OH  =RQH 07&( IW
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Item OEM # of zones From 15 Amp To
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Item #of zones From 15 Amp
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Number (Max.) mainframe(s)
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Item Number of Amps (Max.) Dimensions in inch
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Replacement Parts

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 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Replacement Parts Diagram

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 Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Visions 3000/2.0 Controller System
WaterFlo/Smart Manifold Option






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Visions 3000/2.0 Controller System
WaterFlo/Smart Manifold Option
Why Water Flow Monitoring & Hot Runner Controls in One Package ?
It just makes sense!
For the first time PCS offers Injection Molders an affordable solution for the precise monitoring of flow rate and
temperature within each channel of a tools cooling system combined with VISIONS 3000 Hot Runner
Temperature Controller.
The integration of Smart Manifold with the VISIONS 3000 Hot Runner Control, provides insight into the molding
process far beyond what can be derived from the individual systems.

x All Hot Runner & Water Cooling information is displayed together.

“Cavities (Gray)” “Manifolds (Red)” “Water (Blue)”
x The system provides precise data for temperature and flow rate of
each water channel. (+/-1.5%)
x System can also be configured to monitor the main water input
and output pressure.
x By bringing this information together in one place, the linkage of
how events in one system affect the behavior of the other can be
easily recognized.
x Reduces back and forth time trying to figure out what the problem
is and how to best to solve it.
x The ability to see how a change in one cooling channel affects hot runner heating in unassociated areas of
the tool.
x The two systems together as a package can greatly improve the efficiency of the molding cycle.
x Improves consistency in quality and deformation stability to a much higher level.
x Provides accurate up to the minute data.
x More effectively protects the mold from catastrophic failures, by alarming if any area is suspect. The VISIONS
3000 has several alarm options ranging from screen notification to molding machine shut down.
x Often overlooked by many molders; the efficiency of each cooling circuit is critical to a stable molding process
and the production of high quality, dimensionally stable parts.
x The VISIONS 3000 stores in one place, one year of step by step historical data for each zone of both cooling
and hot runner heating operations. This invaluable information is date & time stamped for future reference.
There is no more guessing as to what transpired and who did it.
x Tool setting for both the Hot Runner & Cooling Systems can be stored on the VISIONS 3000 database and
called up the next time the tool is set-up. The database can store in excess of 100 tool sets.
x Like all VISIONS 3000 systems, the Smart Manifold is a robust unit which can withstand the rigors of
industrial environments.

The Smart Manifold has been meticulous engineered and designed to provide exceptional accuracy. This is only
possible by the exclusive design and exacting machining of the manifold extrusion which allow for proper
placement of the advanced vortex sensors.
x The Smart Manifold works on the Bernoulli principal, meaning
there are no moving parts to wear out, which equates to a long
service life while also allowing for operation with heavily
contaminated water.
x Sensor placement within the Smart Manifold have been
precisely engineered for maximum temperature and flow
accuracy.
x The advanced sensors are retained by a simple clip.

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Visions 3000/2.0 Controller System
WaterFlo/Smart Manifold Option
The PCS Intelligent Water Flow Monitoring System can protect your mold, improve quality while also improving
cycle time. This is done by quickly identifying cooling problems and alerting to various common cooling channel
problems such as:
x No or reduced water flow from the water chiller/heater
x Blocked waterways on a cooling circuit by circuit basis
x Reduction in system operating pressure
x Scale / rust build up
x Inconspicuous / minor leaks
x Incorrect setting of the water chiller / heater
x Faulty water chiller / heater operation
x Incorrect piping

Often overlooked is the importance of historical data. With the PCS system, information is stored for one year, is
date and time stamped for tractability. Recording historical data means a performance log for each channel in
the water cooling system is stored in the systems memory, allowing the user to track channel by channel perfor-
mance and identify problems. This Data can be downloaded onto a USB stick or via Ethernet connection.

More importantly historical information provides operational insights not normally available to the user. By
displaying data in a graphic format, the user can easily spot trends in deteriorating performance for any channel.

Tool Validation:
The tool Validation function of the VISIONS 3000 can provide documentation certifying the condition of the tools
hot runner & cooling systems prior to installation in the molding press. Without proper Tool Validation the
molder can only hope there are no problems with all cooling and hot runner zones. Until now it has been both
difficult and/or very expensive to measure actual flow rate and temperature for each cooling channel in the
mold. Now with the VISIONS 3000 and the Smart Manifold you have the ability to read actual flow & tempera-
ture elements. With the VISIONS 3000 both the tools hot runner and cooling system can be fully validated and
results recorded to establish a base line before the tool is put into production. You now have the ability to com-
pare known actual base line date with actual in-process performance, thereby fully understand tool operation.
Now the VISIONS 3000 with the optional Smart Manifold, allows the user to bring all processes elements
(Molding Machine, Hot Runner Control & Mold Cooling System) to the light of day, by provide actual feedback on
the tools operation, allowing for intelligent decision making.

As any good process engineer will testify, it is not what the machine is told to do that is important; it is what
the machine is actually doing that matters.

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Visions 3000/2.0 Controller System
WaterFlo/Smart Manifold Option
Hardware:

SMART MANIFOLD: 
 a 

The intelligent design of the Smart Manifold allow for the sensors to be
located within the Manifold. This produces a slim line unit with a small
footprint. The design also provides protection for the sensors by keeping
them enclosed within the manifold assembly.
The Smart Manifolds are manufactured from custom aluminum
extrusions which are black anodized to resist corrosion. These
extrusions are designed to specifically produce a precise linear flow path
for each sensor. With meticulous attention to detail the sensors locations are positioned to provide accurate
measurement.
The manifolds can be mounted on machine platens or the mold with “roll-in” “T-nuts” which fit in Integrated
extruded slots, which are located on two faces of the extrusion. The
compact slim line design of the manifold enables it to be mounted in
the smallest space possible next to the machine, on platens or on the
mold, keeping the pipe runs to the absolute minimum.
The Smart Manifold has 1-1/2” ports on both ends of the manifold to
accommodate main water “in/out” flow. This allows maximum flexi-
bility when connecting the water supply. There are 1/2” ports for the
individual channels for both “in” and “return” lines

SENSOR:
The Smart Manifold is equipped with very compact sensors that are capable of reading both
flow rate & temperature. The sensor is based on the vortex flow measurement principal,
which uses a bluff body in the middle of the flow path to create a small eddy current (vortices)
and the pressure of this current is measured to determine the flow through a given cross
sectional area.
The sensors have no moving parts, this combined with a large flow path, make them ideally
suited to mold cooling, even when using heavily contaminated water.
The sensors are integrated directly into the manifold, keeping size to a minimum while
protecting them from damage.
Sensors are available with two flow ranges to suit the application (4 gpm/15 lpm & 10 gpm/40 lpm). Sensors
are held in place with a simple clip arrangement which makes replacement effortless therefor
keeping maintenance very simple.
Sensors are also available which will read out the main system water in-put and out-put pressure,
allowing for up to the minute and historical review.

INTERFACE MODULE
The system is equipped with a interface module which is mounted on the VISIONS 3000 system.
The interface module allows multiple manifolds to be daisy-chained together, to seamlessly
monitored the system and facilitate true “plug and play” with a simple connection. The interface
module allow for the user to easily add additional Smart Manifolds at any time.

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Visions 3000/2.0 Controller System
WaterFlo/Smart Manifold Option
Technical Specifications:
Smart Manifold Sensor

Manifold Feed 1-1/2” NPT Sensor Type Vortex

Manifold Ports 1/2” NPT Series 1 = 4 gal/min (15 liters/min)
Range (flow)
4/8/12 Standard Series 2 = 10 gal/min (40 liters/min)
Number of Ports
(other sizes on request) Accuracy (flow) 1.5% full scale
Color coded ball valves per channel Range (temperature) 32ƒ - 195ƒ F ( 0ƒ - 90ƒ C )
Valves (optional)
(optional)
Resolution (temperature) .5ƒ
Operating Temperature (max) 32ƒ F - 195ƒ F ( 0ƒ - 90ƒ C ) Accuracy (temperature) +/- 1.5% full scale
Operating Pressure (max) 140 PSI
Sensor Signal +/- 0.35 - 3.5Vdc
Temperature Sensing Per Channel (return)
Output Signal Voltage
Flow Sensing Per Channel (return)
Response Time < 1 sec.
Temperature Sensing Main Inlet Yes (optional)
Power Supply 5 Vdc
Power Supply 12 - 24 Vdc
Burst Pressure 200 PSI @ 100ƒ F

Item # Item Description

WF-SM4-1 Water Flow - Smart Manifold - 4 Channel - 4 gpm

WF-SM4-2 Water Flow - Smart Manifold - 4 Channel - 10 gpm

WF-SM8-1 Water Flow - Smart Manifold - 8 Channel - 4 gpm

WF-SM8-2 Water Flow - Smart Manifold - 8 Channel - 10 gpm

WF-SM10-1 Water Flow - Smart Manifold - 12 Channel - 4 gpm

WF-SM10-2 Water Flow - Smart Manifold - 12 Channel - 10 gpm

WF-INT Water Flow - Interface

WF-IOPS Water Flow - In/Out Pressure Option

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299 

Notes

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Notes

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

 34488 Doreka Dr. 3KRQH
TCS0315 )UDVHU0, Fax: 1-800-505-3299 www.pcs-company.com