Hot Runner Alarm System
A reliable hot runner alarm system is critical for protecting tooling, preventing scrap, and avoiding unplanned downtime. The Pulse Hot Runner Controller™ includes a real-time alarm and diagnostics system designed to identify issues the moment they occur, not after damage has already been done.
As soon as the controller is powered on, it begins monitoring every zone that is set to Auto or View mode. If a thermocouple is not connected, the system immediately triggers an alarm. This prevents heaters from energizing without proper feedback and eliminates one of the most common causes of startup damage.
The controller continuously checks thermocouple health and wiring integrity. It can detect open thermocouples, reversed polarity wiring, and thermocouple shorts caused by pinched or damaged cables. Each condition is clearly identified on the interface so operators know exactly what needs attention.
In addition to thermocouple monitoring, the alarm system tracks power status, temperature status, and amperage status for every zone. Heater open conditions, triac failures, over-temperature, under-temperature, and abnormal amperage are all detected in real time. These alerts give technicians immediate insight into heater health and overall system performance.
Alarm thresholds are fully configurable at the zone level. Temperature alarm bands can be set around each setpoint to define acceptable operating ranges. If temperatures drift beyond those limits, the controller generates an alarm. If more severe limits are exceeded, abort actions can be configured to shut down a single zone or stop the entire system.
Power-based alarms provide another layer of protection. Percent power alarms monitor demand once the system reaches steady production. Unexpected increases in power can indicate material leaks, blocked gates, or insulation issues. By identifying these problems early, operators can stop the process before tool damage occurs.
All alarms can be routed through the controller’s I/O outputs. This allows alerts to be sent directly to injection molding machines, robots, conveyors, or plant monitoring systems. Events can also be logged into machine histories for traceability and process analysis.
By delivering instant diagnostics at startup and during production, the Pulse Hot Runner Controller™ turns alarms into a proactive tool protection system rather than a reactive warning.
FAQs
What happens if a thermocouple is missing at startup?
The controller immediately alarms and prevents normal operation until the issue is resolved.
What thermocouple faults can be detected?
Open thermocouples, reversed wiring, and thermocouple shorts.
Can alarms stop production automatically?
Yes. Abort actions can be configured to shut down zones or stop the system.
What is a percent power alarm used for?
It detects abnormal power demand that may indicate leaks or process issues.
Can alarms trigger external equipment?
Yes. Alarms can be sent through I/O outputs to machines, robots, or monitoring systems.
