Pre-Replacement Channel Correspondence Marking and Locking
Wire-by-Wire Photography: To preserve a comprehensive view of the original wiring as the only reference for future wiring, utilise a high-definition camera to fully capture the channel number, cable colour, and connection position of every terminal before disconnecting the old equipment.
Physical Labelling: Print the matching channel number (such as CH1, CH2) on both ends of each signal cable using special cable label paper. To avoid label separation or hazy printing that could result in identification mistakes, manually check the label with a marker after labelling.
Channel Mapping Table Registration: On-site, manually complete a paper channel mapping table, noting each cable's channel number, matching hot runner cavity number, and thermocouple calibration number. Before archiving, the record is double-checked and signed by two personnel.
Error-Proofing While Disassembling:
Single Labelling and Single Cable Dismantling: Don't disconnect every cable at once. To prevent misunderstanding and the inability to discern correspondence after cable mixing, immediately examine the label and validate the channel number after unplugging one cable.
Terminal Positioning: To guarantee full channel alignment after the new equipment is installed, mark each channel's physical location on the cabinet terminal block with a marker prior to removing the old equipment.
Verification of New Equipment Wiring Matching
Wire-by-Wire Connection: Connect the wires sequentially, one by one, strictly referring to the previously taken panoramic images and channel mapping table. After connecting, mark each wire on the mapping table to prevent mistakes or omissions.
Initial Continuity Test Verification: After all wiring is finished, test the continuity at both ends of the cables for each channel using a digital multimeter in continuity mode to make sure there are no misconnections or cross-connections and that the channel numbers match the mapping table exactly.
Channel Signal Verification: Turn on the new signal generator and use channel CH1 to output a typical 4 mA current signal. To verify that the signal is transmitted normally, measure the signal at the matching hot runner temperature control channel end. To 100% ensure that the channel numbers match exactly, perform point-to-point signal verification for each channel in turn.
Final Verification of Linkage
Full-channel linkage test: Attach the thermocouple millivolt analogue signal for each channel to the hot runner temperature control system. Verify that there are no channel misalignment or signal crosstalk problems and that the temperature value shown by the temperature control system is exactly in line with the signal generator output value.
Dual-person cross-verification: Every channel number's matching relationship is independently confirmed by two maintenance engineers. The system is not formally implemented until both engineers attest that everything is in order.
The issue of mismatched wiring channel numbers is totally resolved by this end-to-end error-proofing procedure, which also prevents following injection moulding process flaws from their source and prevents erroneous hot runner temperature control calibration brought on by improper channel connections.
