How to Quickly Replace and Repair a Leaking Heater

I. Preparatory Work (Complete 10 minutes in advance, without downtime) Prepare a spare original high-temperature resistant heating coil that perfectly matches the power, size, and interface of the faulty heater. Also prepare a 500V digital megohmmeter, torque wrench, high-temperature resistant gloves, and brand-new perfluoroelastomer rubber sealing rings. Disconnect the main power supply to the hot runner beforehand and activate local ventilation to cool the equipment rapidly from 320℃ to below 100℃, preventing burns and significantly reducing waiting time. II. Quickly Disassemble the Faulty Heater (Complete in 15 minutes) Quickly remove the heater's aviation connector, marking the live and neutral wire connections to avoid reverse wiring later. Use a torque wrench to loosen the fixing screws of the hot runner nozzle diagonally, quickly remove the faulty heater, and clean any dried thermal grease and oxide residue from the runner surface. Use a megohmmeter to retest the removed faulty heater to confirm the leakage point and simultaneously check surrounding cables for any potential insulation damage. III. Quick Installation of the New Heater (Completed in 20 minutes) Apply a 0.02mm thick layer of high-temperature resistant thermally conductive silicone grease evenly to the inner wall of the new heater. Align it with the flow channel positioning groove and quickly insert it, avoiding misalignment and compression of the internal insulation layer. Replace the new perfluoroether rubber sealing ring. Tighten the fixing screws gradually in a diagonal sequence, precisely controlling the torque to 8 N·m, ensuring a tight, gapless fit between the heater and the flow channel. Quickly connect the aviation connector according to the previous markings, confirming that the wiring is secure and not loose, and that one end of the shielding layer is reliably grounded. IV. Quick Verification and Production Resumption (Completed in 2.5~3 hours) Retest the insulation resistance of the new heater with a megohmmeter at room temperature, confirming ≥5MΩ and no static leakage. Raise the temperature to the rated operating temperature of 320℃ at a safe rate of 50℃/h, and hold for 1.5 hours to allow the system to quickly enter stable operating conditions. Use an AC millivoltmeter to test the voltage between the heater casing and ground at high temperature, confirming that the leakage voltage is <1V. Observe the temperature controller readings continuously for 30 minutes; there should be no jumps, and the sensor should show no crosstalk. Produce 10 molds of the product in a small batch to confirm that the product quality is up to standard, then full-scale production can be resumed.