The Synventive LEC (Linear Enhanced Control) Series represents a significant breakthrough in hot runner temperature controller performance and affordability. Designed specifically for smaller hot runner system applications, the LEC brings field-proven Gammaflux performance and reliability to a wider market segment. This controller is the ideal solution for injection molders who demand high precision and advanced diagnostics without the premium cost typically associated with high-end control systems.

Advanced PID2 Control Algorithm

• Triangulated Control Technology®: The LEC employs Gammaflux's proprietary Triangulated Control Technology®, which is a three-part system: SENSE, CONTROL, and ACTUATE. This integrated approach ensures the most stable and accurate temperature control possible in a hot runner system.
• Sensing Precision: The controller measures the exact temperature of each zone 20 times per second (every 50 ms), providing a near real-time view of the thermal dynamics within the hot runner system.
• Self-Optimizing PID2 Control: The core of the system is the patented PID2 algorithm. Unlike a standard PID loop, the PID2 monitors the second derivative—the rate of change of the temperature. When a deviation of just 0.03°F (0.014°C) from the setpoint is detected, the algorithm proactively adjusts the power output. By anticipating the thermal trajectory, it limits or completely eliminates temperature overshoot and undershoot, a common problem in injection molding that leads to part defects.
• Phase Angle Actuation: The final step in the Triangulated Control loop is power delivery. The LEC uses sophisticated phase angle control, firing the output at a resolution of 0.1% across 1,000 steps. This results in a silky-smooth power delivery in precise 0.24 VAC increments, as opposed to the abrupt on/off cycling of mechanical relays. The benefit is extended heater life and incomparably stable melt temperatures.

Modular Design and Scalability

• Simple Control Card Management: One of the most practical features of the LEC is its truly modular architecture. Control cards can be easily removed, added, or replaced without the need for specialized tools or factory service. This minimizes downtime and simplifies field repairs, directly reducing the total cost of ownership.
• Flexible Zoning: The system is available in 2, 6, and 12-zone enclosures. For applications requiring up to 24 zones of control, a daisy-chaining network module can seamlessly link two 6- or 12-zone enclosures together. This scalability allows the LEC to grow with your application needs, from a single manifold to a more complex multi-cavity tool.

Comprehensive Diagnostics and Networking

• Optional Network Module: Each 6 and 12-zone LEC enclosure comes pre-wired and ready to accept an optional network module. This module unlocks a suite of advanced features by connecting the LEC to a laptop or PC.
• Gammavision Software: Provides powerful SPC data and graphing analysis. Users can monitor process stability in real-time, review historical data, and generate comprehensive reports for quality assurance and process optimization.
• Mold Doctor: An advanced troubleshooting tool that provides a wiring analysis of the tool to quickly identify miswired or faulty components like thermocouple issues, open fuses, and heater shorts. This dramatically reduces troubleshooting time during mold setup, saving valuable production time.
• Field Calibrator and Monitoring: The software also allows for precise field calibration of the controller. Furthermore, the network module enables a direct link to plant-wide monitoring systems, facilitating the integration of the controller into your overall smart-factory or Industry 4.0 strategy.

Applications

• Smaller-scale hot runner systems (2 to 24 zones)
• Automotive, electronics, packaging, and medical injection molding
• Applications demanding high precision and repeatability on a budget