I. Safety and Wiring Preparation Before Powering On
Confirm that the on-site power supply voltage is 220V AC, matching the equipment's rated input voltage to avoid damage from abnormal voltage.
Check that the signal generator's output test leads are undamaged and the terminals are free of oxidation. Confirm that the equipment is powered off.
Disconnect the on-site thermocouple/sensor wiring to the hot runner temperature control channel to be verified. Connect the signal generator's output terminals to the input port of that channel according to the positive and negative markings. Record the wiring to avoid reverse connection later.
II. Power-On Self-Test and Mode Configuration
Press the power button on the equipment panel and wait 30 seconds for the entire machine to complete its self-test. After the screen displays normal operation without errors, it enters standby mode.
Based on the signal type of the channel to be verified, select the corresponding mode in the equipment menu: K-type thermocouple millivolt mode / 4~20mA standard current mode.
Combined with the normal operating range of the hot runner, set the output signal range and lock the equipment's output accuracy class to ±0.05%FS.
III. Full-Range Standard Signal Output Operation
For the K-type thermocouple channel: Input four standard temperature analog signals sequentially via the digital keys: 0℃, 100℃, 200℃, and 300℃. Hold each signal for 30 seconds after it stabilizes, and simultaneously record the displayed value of the corresponding channel on the hot runner temperature controller.
For the 4~20mA current channel: Output three standard current signals sequentially: 4mA, 12mA, and 20mA, covering the full range of industrial signals. Record the temperature controller's displayed value after each signal stabilizes.
After each signal output is completed, check the deviation between the channel's displayed value and the theoretical value. A deviation ≤ ±0.5%FS indicates acceptable accuracy.
IV. Fault Linkage Verification Operation
Switch to interference pulse output mode and inject a small interference signal into the channel to verify the temperature controller's anti-interference capability and whether the alarm triggering logic is normal.
Output open/short circuit analog signals to verify whether the temperature controller's over-limit protection function triggers normally, and confirm that the channel response delay meets the equipment's factory specifications.
V. Power Off and On-Site Reset
After all verifications are completed, first reset the signal generator output to zero, then turn off the equipment power and disconnect the test leads.
Reconnect the original sensor wiring to the hot runner channel according to the previous wiring markings. Power on to confirm that the channel temperature display has returned to normal. Perform one short-time temperature rise test to confirm that the signal link is normal, completing the entire operation.
VI. Key Operational Precautions
Hot-swapping of signal interfaces is prohibited: Connect the test leads before starting the output, and turn off the output before disconnecting the wiring to avoid impact damage to the channel module.
Unauthorized personnel must not operate the equipment. Perform electrostatic discharge (ESD) protection throughout the operation to prevent ESD damage to the signal ports.
This detailed procedure is fully adaptable to hot runner on-site maintenance scenarios and can quickly complete channel verification and troubleshoot hidden faults.
