The installation quality of hot runner temperature control boxes directly affects the temperature control accuracy, equipment lifespan, and production safety of the injection molding system. Correct installation should follow the principles of "environmental compatibility, electrical specifications, heat dissipation assurance, and accurate wiring" to ensure long-term stable operation in industrial environments with high temperature, high humidity, and strong electromagnetic interference. The following are systematic installation precautions, covering the entire process from preliminary preparation, physical installation, electrical connection, and power-on verification.
I. Pre-installation Preparation: Confirming Environmental and Hardware Conditions
Choose a suitable installation location
Install to the side of the injection molding machine or inside an independent electrical control cabinet, avoiding direct exposure to the melt splash area.
Control the ambient temperature between 0 and 55℃, and the humidity below 85%RH to prevent short circuits caused by moisture on the circuit boards.
Leave ≥30cm of ventilation space around the perimeter to ensure smooth front and rear ventilation, and avoid proximity to other heat-generating equipment.
Check the power supply and grounding
Confirm that the power supply voltage is AC. 220V±10% (or as per model requirements), frequency 50/60Hz. Equipped with an independent air switch and fuse to prevent power grid fluctuations from affecting the control card. Must be reliably grounded (grounding resistance < 4Ω) to avoid leakage risk and signal interference.
Check the completeness of accessories.
Check that the temperature control box body, wiring terminals, mounting bracket, instruction manual, etc., are complete.
Prepare necessary tools: Phillips screwdriver, torque wrench, wire stripper, multimeter, label paper, etc.
II. Physical Installation: Fixing and Heat Dissipation
Fixing the Box
Use M6 bolts to firmly install the temperature control box onto the control cabinet rails or brackets to prevent vibration and loosening. The box tilt angle should not exceed 5° to ensure even stress on internal components.
Ensuring the proper functioning of the heat dissipation system
Check that the fan operates smoothly and that air intake is adequate. Unobstructed opening.
If installed in a closed electrical control cabinet, it is recommended to install an external exhaust device to improve heat dissipation efficiency.
Clean the filter screen regularly (recommended every 3 months) to prevent overheating shutdown.
III. Electrical Connections: Wiring Specifications and Anti-interference Measures
Connecting the Heater Circuit
Use high-temperature resistant cables (such as silicone wire) to connect the heating coil. The wire diameter should be selected according to the power (commonly 1.5~2.5mm²).
Connect the wires according to the corresponding channel numbers to avoid incorrect connections that could cause localized overheating.
The terminals must be firmly crimped to prevent poor contact that could lead to arcing or abnormal temperature rise.
Connecting the Temperature Sensor (Thermocouple)
Use dedicated compensating wires (K-type with KX, J-type with JX). Polarity must not be reversed (red is positive, white is negative). Signal lines should use double-shielded cables with independent cable trays and must not be run parallel to power lines. Cable Laying
The shielding layer is grounded at a single point on the temperature control box side to avoid ground loops that introduce noise.
Multi-channel Cabling Management
Each channel corresponds to an independent cable harness, labeled with the channel number and corresponding nozzle position.
The cable bending radius should not be less than 5 times the outer diameter to prevent internal breakage.
IV. Function Settings and Power-on Testing
Pre-Power-on Inspection
Confirm all wiring is secure and there are no exposed copper wires.
Check that the air switch is in the off position.
Use a multimeter to check for short circuits in the heating circuit; the insulation resistance should be greater than 20MΩ.
Initial Power-on Operation
First turn on the main power switch, then enable each channel output one by one.
Observe whether the display screen starts normally and whether there are any alarm codes.
Set the target temperature (e.g., 250℃) and observe whether the actual temperature rises steadily.
Preliminary Parameter Setting
Select Corresponding Thermocouple Type (K-type/J-type)
Enable PID self-tuning to allow the system to automatically optimize control parameters.
Set soft-start time (recommended 5-15 minutes) to prevent cold current surges.
V. Operation Verification and Record Archiving
No-load Test
Run for 30 minutes without connecting the mold and observe whether the temperature control of each channel is stable.
Use an infrared thermometer to compare the actual heating block temperature; the deviation should be ≤±2℃.
Load Operation Verification
Perform a trial run after installing the mold and record the temperature fluctuations for the first 5 cycles.
If overshoot, oscillation, or slow response occurs, the PID parameters need to be readjusted.
Establish Installation Record
Record the installation date, operator, initial parameter settings, wiring diagram, etc.
Affix an equipment identification card, indicating the model, channel configuration, and maintenance cycle.
