This hot runner controller troubleshooting guide is assumed that the installation and maintenance of the hot runner system is based on proper instructions. All wiring is correct and that the power to the system is as specified on the controller.

When a mold is running improperly due to hot runner temperature, gather as much information as possible to define the problem properly is the first step. It usually starts with the accessories directly related to temperature control. Include hot runner controllers, coil heaters, thermocouples.

Note:

-Do not replace fuses or failed modules without first identifying the cause of the failure. Dangerous voltage exist inside the control enclosure, in the mold wiring and at all connection points.

-Do not operate the controller without covers or panels.

-Do not operate the controller with connectors which are damaged, removed or if any wiring exposed.

(this guide is for Hitcontrols Hot runner control modules & Mainframes only).

1. Check the mainframe circuit breaker is working
2. Check module fuses and replace them if blown

1. Controller may not be plugged in.
2. Fuses or air circuit breaker may be blown
3. Input power incorrectly wired or damaged

1. Short in power circuit
2. Current draw of the heater exceeds the rating of the circuit breaker
3. Do not turn on additional zones until working zones comes up to target temperature

1. Short in power circuit
2. Current draw of the heater exceeds the rating of the circuit breaker

1. Check input voltage to mainframe if equals to rating of the module

1. Check LCD board pins connect to main PCB well

1. Triac shorted or driver
2. Change parameter “t”=0 (factory setting is t=1)
3. Try this module in another good heater zone

1. Give module more time to settle on the set point
2. Check if changes in the display temperature correspond to the molding process
3. Check incoming power for fluctuations in voltage
4. Injection barrel heat may be set too low
5. Water temperature may be set too low
6. Heaters wattage size may be insufficient to achieve desired results

1. Heater may be too small
2. Wrong thermocouple zone
3. Heater may open
4. Check cable connection
5. Input voltage to module is low
6. Triac open
7. Try this module in another good heater zone

1. Heater may be too small
2. Wrong thermocouple zone
3. Heater may open
4. Check cable connection
5. Input voltage to module is low
6. Triac open
7. Try this module in another good heater zone

1. Checking all parameters setting correctly
2. Fuses may be blown
3. Check relay has click action

1. Usually caused by heat from adjacent zones
2. The melted plastic temperature is higher than the set temperature
3. Thermocouple may not be connected to the same control module as the heater

1. Heater may not be connected
2. Heater is too small for the application
3. Heater failed
4. Heater to far from thermocouple
5. Try this module in another good heater zone

1. Soft-start is turned “OFF”
2. Mold temperature above 100℃ (212℉)

1. Swap module to see if problem follows module
2. Swap mold power cable to see if problem folows cable
3. Swap thermocouple cable to sse if problem folows cable
4. Switch to “Manual” mode to see if heat is applied in manual operation. If zone heats up fault may be in thermocouple sensor or cable
5. If soft-start functions properly and error occurs after switching out of soft start, thermocouple sensor or cable may be faulty

1. Improper fit, heater may not be making good contact resulting in the lack of proper heat transfer
2. Contamination by moisture, oils, dirt, etc.
3. Severe flexing of the heaters leads
4. Operating temperature in excess of heaters rated capacity
5. Corrosion prevents proper heater contact

1. This is usually caused by the location of the thermocouple being too far from the heater it is controlling. Proper procedures dictate that the heater & thermocouple should be within 1/2″ of each other.
2. Oscillation can also be caused when the melt temperature is significantly above or below the setpoint temperature.
3. Does the molding process have a wide temperature variation? Check to see if changes in the display temperature corresponds to the opening and closing or injection cycle of the molding process.
4. Check incoming power for fluctuations in voltage.
5. Mold water temperature set too low
6. Heater size may be too small for application
7. Heater may not be loose or contamination may prevent heater making good contact

(for Hitcontrols™ HC15-S Hot Runner Control Module)