Index. 9/12 Subject to technical changes. Page Materials

Index Materials 3 Reference values for maximum throughput in cm /s Reference values for gate diameter Processing temperatures for common plastics Processing of POM, TPE, PP and shear-sensitive materials Gate point Gate geometry, gate inspection Reworking the gate Gate diameters < 1,2 mm, reducing gate ø Vacuoles under the gate, gate ø for reinforced materials Potential error sources in the gate area Gating Injection into an intermediate gate Gating into an angled surface Gating into a high gloss facing surface Part with a film hinge Hot runner nozzles Nozzle length at room temperature, modified forechamber geometry, use of a titanium sleeve References values for screw sizes Designation/assignment of the cables BlueFlow product description OktaFlow assembly notes Extended nozzle tips, side gating Reference notes on a disassembly of a multi-tip nozzle Valve-gate technology Commissioning of valve-gate system, operating pressure levels for drive mechanisms NEST single valve-gate nozzle assembly Drive mechanisms Notes on valve-gate needle / maintenance of the sliding cam mechanism Hot runner systems / manifolds Manifolds Heater connections, straight / frame version Structural notices for air circulation and high-temperature applications Screw fastenings for _MT/_TT nozzles Manifold power calculation, correlation of cables Construction of the hot-runner system Complete mold halves hot halves Service program CADHOC System-Designer Delta tool calculation program, application database Online-catalog, MoldCae/Moldflow analyse Seminars for users and designers Page 1.4. 2 + 3 1.4. 4 + 5 1.4. 6 1.4. 7 1.4. 10 1.4. 10 1.4. 11 1.4. 11 1.4. 12 1.4. 20 1.4. 20 1.4. 21 1.4. 21 1.4. 30 1.4. 31 1.4. 32 1.4. 33 + 34 1.4. 35 1.4. 36 1.4. 37 1.4. 40 1.4. 41 1.4. 42 1.4. 43 1.4. 50 1.4. 51 1.4. 52 1.4. 53 1.4. 54 1.4. 55 1.4. 56 1.4. 60 1.4. 61 1.4. 62 1.4. 63 9/12 Subject to technical changes 1.4. 1

Materials Reference values for maximum nozzle throughput per second Nozzle length: 50/ 100 mm 3 Throughput in cm /s Low viscosity material: e. g. PA, PS, PP 120 100 80 60 40 20 0 ø 4 mm Nozzle length 50 mm Nozzle length 100 mm ø 5 mm ø 6 mm The specified throughputs are reference values. Considerable deviations for specific materials cannot be excluded. We will be glad to assist you with the selection of channel Ø. Additional applications which have already been implemented can be found in the application database on our website menu item: Application Database. Medium viscosity material: e. g. ABS, PPO 120 3 Throughput in cm /s 100 80 60 40 20 0 ø 4 mm Nozzle length 50 mm Nozzle length 100 mm ø 5 mm ø 6 mm High viscosity material: e. g. Polycarbonate, Bayblend, Polysulfon 30 3 Throughput in cm /s 25 20 15 10 5 0 ø 4 mm Nozzle length 50 mm Nozzle length 100 mm ø 5 mm ø 6 mm 1.4. 2

Materials The specified throughputs are reference values. Considerable deviations for specific materials cannot be excluded. We will be glad to assist you with the selection of channel Ø. Additional applications which have already been implemented can be found in the application database on our website menu item: Application Database. Reference values for maximum nozzle throughput per second Nozzle lengths: 60/ 100 mm 3 Throughput in cm /s Low viscosity material: e. g. PA, PS, PP 2500 2250 2000 1750 1500 1250 1000 750 500 250 0 ø 8 mm ø 10 mm ø 12 mm Nozzle length 60 mm Nozzle length 100 mm Medium viscosity: e. g. ABS, PPO 2500 2000 3 Throughput in cm /s 1500 1000 500 0 ø 8 mm ø 10 mm ø 12 mm Nozzle length 60 mm Nozzle length 100 mm 3 Throughput in cm /s High viscosity material: e. g. Polycarbonate, Bayblend, Polysulphone 500 450 400 350 300 250 200 150 100 50 0 ø 8 mm ø 10 mm ø 12 mm Nozzle length 60 mm Nozzle length 100 mm 1.4. 3 Subject to technical changes 7/12

Materials Determining the gate diameter for standard materials depending on the part weight Gate diameter Please note: All specified reference values for the gate diameter apply only to hot runner nozzles with vertical gating. Gate diameter for fibre reinfor-ced materials The gate diameters for glass fibre reinforced materials or materials containing additives (flame retardants, heat stabilisers) 0.2 to 0.3 mm larger. The same applies to multi-tip nozzles. Please contact us for all other types of gating. Article weight Material: PC + ABS Material: PE Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Material: PMMA Material: POM, PA 6, ABS Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g 1.4. 4

Materials Material: PBT Material: PA 6.6 (glas filled + 0.3 mm) Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Material: PS Material: TPU, TPE Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Material: PPO Material: SB, SAN Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Material: PSU, PC Material: PP Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 1 3 5 8 10 100 1000 Article weight g Material: LCP Ø D mm 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.1 0,5 1 3 5 8 10 100 1000 Article weight g 1.4. 5 Subject to technical changes 7/12

Materials Material PP PE PS ABS SAN PA 6 PA 6.6 POM PC PMMA PBT ABS / PC LCP* PPS PEEK Recommended processing temperature ( C) 220-280 220-280 220-280 220-250 220-250 240-250 270-290 205-215 280-310 220-250 245-270 260-270 300-345 310-340 360-400 Recommended WZ-temperatur ( C) 20-60 20-60 20-70 40-80 40-80 40-60 40-80 60-120 80-120 40-90 60-80 70-100 80-120 140-145 140-180 Processing window for common plastics Further information on selecting nozzles depending on the material can be found in nozzle chapter 2. * depending on polymer-type Price / performance The performance pyramid High temperature resistant plastics (HDT > 150 C) Technical plastics (HDT = 100-150 C) COC PAR PES PC PPO PI PEI PSU PEK FP LCP PAI PPS PA 46 PPA PET PBT PA6.6 POM LFT High temperature resistant plastics High temperature resistant plastics with processing temperatures >300 C: Liquid Crystal Polymer (LCP) Polyphenylene sulphide (PPS) Polyetherketone / Polyetheretherketone (PEK/ PEEK) Polysulphone (PSU) Polyether-Imide (PEI) etc. Standardplastics SAN ABS PMMA PP PS SAN PVC PE-LD amorphous PE-HD semy-crystalline 1.4. 6

Materials ØD1 ØD2 Fig. Gate design A and hot-runner nozzle with nozzle piece version C Polyacetal (POM) and Thermo Plastic Elastomers (TPE) Gate design A When processing polyacetal (POM) and thermoplastic elastomers (TPE) with a hot runner nozzle with nozzle piece, version C and the gate design A, a good injection gate quality should be attained. Hot runner nozzles with nozzle piece, version C can be used for injection onto an intermediate gate and also for direct gating. In direct gating a higher residual sprue must be expected than when a nozzle with tip is used. The gate design A must be used for nozzles with tip and for open nozzles. It must be taken into account here that the injection gate diameter in gate bushing "D1" must be smaller than the diameter in the nozzle piece "D2 (D1 < D2). When a nozzle piece, version C is used, the shear in the melt in the area of the injection gate is lower than when a nozzle with tip is used. Shear-sensitive materials Gate design C Single nozzles are mostly used when processing shearsensitive materials through an intermediate gate. The gate design C is exclusively used for open nozzles with a nozzle piece, version A. ØD2 It must be taken into account here that the injection gate diameter in the "D1" gate bushing must be larger than the diameter of the nozzle piece "D2" (D1 > D2). ØD1 Fig. Gate design version C and hot-runner nozzle with nozzle piece version A 55 2,5...3,5 Parts made of Polypropylene (PP) Hot runner nozzles with modified tip geometry should be used to process polypropylene. At a height of 2.5 to 3.5 mm (depending on the nozzle type) the tip angle is reduced from 55 to 40. This modified geometry must be ordered separately. 40 Fig.Tip geometry for polypropylene 1.4. 7 Subject to technical changes 7/12

Gating 80 6,3 Gating The hot runner nozzle s function is essentially influenced by gate size diameter D. d H An enlargement of gate size must be done at an 80 angle. The edge must be sharp to achieve clean separation. Fig. Gate geometry ØD sharp-edged Note: The most frequented faults on commissioning a mould are due to the incorrect design of the gate geometry. H [mm] 4,0 d = 4 mm Inspecting the gate The correct position of the 80 angle is inspected with a measuring ball. 3,5 d = 3 mm 3,0 2,5 2,0 1,0 1,5 2,0 2,5 3,0 Ø D [mm] Fig. Inspecting the gate Reworking the gate It is wrong to rework the gate by boring it out. The flow gap will not be substatially enlarged but the tear-off height on the part will become larger. Wrong Fig. Reworking the gate 1.4. 10

Gating L + L + 0.02 Reworking the gate With gate diameters smaller than ØD = 1.2 mm, the nozzle must beinstalled further back. You will find a Delta Tool calculation program on our homepage at available for download free of charge. ØD Fig. Nozzle installed in a retracted position Within the framework of permissible processing parameters, the smallest possible gate diameter means: small gate diameter tool temperature processing temperature Reducing the gate diameter The gate diameter cannot be arbitrarily reduced. The smallest permissible diameter is dependent on the material used. Furthermore, the gate size is also influenced by the mold temperature and processing temperature. Fig. Reducing the gate diameter This is the point at which the material solidifies at last. Vacuoles under the gate Direct gating with a hot runner system can produce vacuoles under the gate. Remedy: Longer holding pressure time to compensate for shrinkage. Fig. Vacuoles under the gate Gate diameter for fibre reinforced materials The gate diameters for glass fibre reinforced materials or materials containing additives (flame retardants, heat stabilisers) 0.2 to 0.3 mm larger. The same applies to multi-tip nozzles. 1.4. 11 Subject to technical changes 7/12

Gating 0.5 At 250 C the hot runner nozzle extends 0.5 mm into the part if the nozzle is installed to the nominal length. Fig. Hot runner nozzle installed correctly Potential error sources Problem: - Higher vestige - No flow gap despite a larger gate Fig. Cylindrical part at the gate Problem: - The expanded nozzle closes the gate. Fig. Gate <1.2 mm - nozzle to be installed further back Problem: - No sufficient insulation gap - Higher temperature needed - Great temperature fluctuations - Stringing Fig. The forechamber contour not produced correctly 1.4. 12

Injection ØD L Correct injection into an intermediate gate In order to obtain defined separation, the aperture in the face surface of the intermediate gate Ød should be larger than ØD. This is particularly true for reinforced thermoplastics (engineering plastics). If possible, employ a catch pit in the intermediate gate. Ød 1 mm > ØD catch pits Fig. Injection into an intermediate gate advantageous Gating into an angled surface Direct gating into an angled surface never results in an optimal gate point with a small vestige. We therefore recommend gating into a surface at right angle to the nozzle axis. advantageous disadvantageous Fig. Gating into an angled surface 1.4. 20

Gating Tempering Reserve gating into a high gloss facing surface Sufficient cooling is recommended for the gate area, next to the nozzle and on the ejector side to dissipate the heat additionally induced by shear. Insert The cooling circuit control must be separated from the other tempering circuits. Tempering Fig. Reserve gating into a high gloss facing surface Film hinge Articles with a film hinge When gating a part with a film hinge, the gating point must be located away from the surface center opposite to the film hinge. The flow front may not come to a standstill during the filling process. Fig. Parts with a film hinge 1.4. 21 Subject to technical changes 7/12

Hot runner nozzle Z ±0.02 Fig. Nozzle length at room temperature Nozzle length at room temperature Our nozzle length is made to the size that already provides for ist length change when heated to 250 C. The nozzle tip will then extend by 0.5 mm into the cavity contour. Dimension Z (as measured at room temperature) is equal to: Z = L + 0.5 - l (250 ) l consequently depending on L itself. l is the temperature dependent longitudinal expansion of the hot runner nozzle. Standard 90 Increased angle 120 Attention! Provide for adequate wall thickness. Insulation gap Insulation gap Modification of fore chamber geometry Fore chamber geometry can be modified for special applications or difficult-to-process materials (e. g. V0-adjusted materials). To avoid mistakes, we recommend that you consult with our application engineers. Enlarging the angle to 120 The standard angle of 90 in the forechamber can be widened to 120. This will enlarge the insulation gap between the hot runner nozzle and the mold. The nozzle can be operated at a lower temperature so that thermally sensitive material will not be damaged. Fig. Modification of forechamber geometry Using a titanium sleeve over the nozzle shaft in combination with an angle of 120. The insulation gap between the hot runner nozzle and the mold also becomes larger and the heat transfer to the cavity plate is reduced. Titanium sleeve Insulation gap 120 Fig. Employment from a titanium sleeve 1.4. 30

Hot runner nozzle Reference values for screw sizes The centering flange and screws of single nozzles must absorb the emerging lift forces. Screws and centering flange are to be appropriately dimensioned and the pitch circle of the screws is to be kept as small as possible. Guide values for screw selection can taken from the table below. Tightening torque M A for producing the screw connection must afford sufficient pretensioning force F v so that the required initial tension is still present when under the influence of operating force (i. e. operating force of the hot runner nozzle). Pretensioning force F v should be a factor 2 to 4 greater than the anticipated operating force. Screws should be selected which are as long as possible. F = force p = injection pressure A = area of the nozzles shaft Ø Example: Hot runner nozzle: 5SET50 ( ØS = 22 mm) Injection pressure: 2000 bar (200 N/ mm 2) Number of screws: 4 Factor 2 Lift force on the hot runner nozzle: p D 2 ( mm) π A = 4 A = F = p (N/ mm 2) A ( mm 2) F = 200 N/ mm 2 380 mm2 F = F A = 76000 N F = 76000 ges 22 mm 2 π 4 A = 380 mm 2 N Tightening torque for hot runner nozzles Pretension F v and tightening tor-que M A, for screws with head beaning surfaces per DIN EN ISO 4762 and 4014. Shaft screws ( µ ges. = 0.125) Pretension F v = F v = F v per screw: F ges ( N) Number of screws 76000 N 4 F v = 38000 N per screw factor 2 Chosen screws in consideration of factor 2. 4 x M10-12.9 je 45 kn per scres Thread designation Regular type screw threads M8 M10 M12 M16 M20 M24 Maximum pretension Property class 10.9 12.9 24 38 56 105 165 235 28 45 65 122 190 275 F V in kn Fine pitch thread M8x 1 26 31 40 M10x1,25 41 43 77 M12x1,5 M16x1,5 M20x1,5 M24x2 59 114 188 265 69 134 220 310 Maximum tightening torque M in Nm A Property class 10.9 12.9 37 73 125 315 615 1050 132 340 680 1150 43 84 148 370 700 1250 46 90 155 390 800 1350 1.4. 31 Subject to technical changes 7/12

Hot runner nozzle Standard Fixed connections PE = earthed lead yellow-green N = neutral lead orange L = line lead black Blue = Minus PE = earthed lead bare wire Red = Plus Thermocouple ype L (FeCuNi) Standard Pluggable connections CMT, 230 VAC* Power receptacle PE = earthed lead yellow-green N = neutral lead blue L = ine lead brown CMLK Thermoplug Red = Plus PE = earthed lead bare wire Blue = Minus Thermocouple Type L (FeCuNi) * Volt Alternating Current Fig. Designation / correlation of cables 1.4. 32

Hot runner nozzle Thickfilm heaters for hot-runner nozzles BlueFlowGünther's new BlueFlow technology incorporates several advantages as compared to conventional heating methods: the heating elements are not only considerably smaller in diameter, they also allow a substantially better temperature distribution and accordingly, a quicker thermal response. BlueFlow Fixed connections BlueFlow min. 10 mm Further outstanding features are their high electric strength and resistance to moisture. All in all, these four features are important steps taken towards a more spacesaving, precise and energy-efficient hot runner design and, therefore, a more effective injection molding process. PE=earthed lead yellow-green N = neutral lead blue L = line lead brown Hot runner nozzle heater Heater are pressed into a brass body. The heater is fixed in place by the mechanical structure of the carrier body. The homogeneous brass body ensures optimal heat transfer from the heater to the material tube, showing a highly reproducible temperature pattern. Power and thermo connection up to 10 mm bent only once in this area. Minimum bending radius R8. Blue = Minus PE = earthed lead yellow-green Red = Plus BlueFlow Pluggable connections CMT 230 VAC* Power receptacle CMLK Thermocouple L=line lead brown N=neutral lead blue Blue = Minus PE=arthed lead yellow-green PE=earthed lead bare wire Red = Plus Thermocouple Type L (FeCuNi) * Volt Alternating Current Fig. Designation / correlation of cables 22 mm 18 mm Brass body with pressed-in heater BlueFlow Hot runner nozzle Fig. Hot runner nozzle heater 1.4. 33 Subject to technical changes 7/12

Hot runner nozzle High Quality. Blue. BlueFlow The BlueFlow hot runner nozzle sets new standards for quality and design of parts made of thermally sensitive plastics. This re-sults in better or even completely new application possibilities, depending on the application area in different sectors of industry. The thick film heater makes it possible to adjust the heating capacity to the exact power requirement in each single section over the entire nozzle length in order to reach a homogenous temperature. The plastic material in the material tube is hardly exposed to thermal stress, which means that the physical properties of the end product are obtainable even with thermally sensitive plastics and very small parts. FIg. Microfilter Example: Microfilter (automotive sector) Microfilter (outlet valve for an automotive application), injectionmolded in one process step from unreinforced PA66. This method has replaced the earlier procedure of insert-molding of an available metal or plastic mesh to obtain a ready-toinstall component. The resulting savings are dramatic: costs have decreased by 60-80%, depending on the product. Details: thread size 0.13; 1848 gaps with 0.07 x 0.07 mm. 2 Passage surface approx. 9 mm. Max. allowed flash is 4.5 µm. 1.4. 34

Hot runner nozzle Hot-runner nozzle OktaFlow for side multi-tip gatin under 90 without cold slug, in connection with a manifold or can be used as a single nozzle with heated adaptor.) Assembly of the star manifold Insert the star manifold and use 4 hexagon socket head cap screws M3x12 to fasten it to the sleeve-type heating. Assembly of support Insert the support and mount the lid from the parting line. Note: the lid must be solidly bonded to the insert. Assembly of the hot-runner nozzle Push the hot-runner nozzle (MT) in from the nozzle side! 1.4. 35 Subject to technical changes 9/12

Hot runner nozzle Without extended nozzle tip With extended nozzle tip Nozzle holding plate Extended nozzle tips in connection with the material It is often necessary to use several different nozzle lengths when gating a part. Extended nozzle tips allow sprueless molding of parts even in space constrained environments. L +0.02 L1 +0.02 L1 +0.02 Cavity plate Shimmed Inserted Nozzle holding plate L1 +0.02 L1 +0.02 Cavity plate Shim Fig. Use of nozzle with extended tip Side gating Under 90 without a cold slug in combination with a manifold. Gating should always be against the core. Always specify the material to be processed and the part weight when making inqiries. Also specify whether a part is to be gated with several tips, or if several parts are to be molded. Note: Slide out the inserts only horizontally! Fig. Side gating under 90 without a cold slug 1.4. 36

Hot runner nozzle Reference notes on disassembly of a multi-tip nozzle To avoid damaging nozzle tips, we suggest a mechanical construction which imposes a change in the way the nozzle is disassembled : 1. Loosen the wedge and the counter-pressure insert. 2. Push out the divided form inserts to the right and left over the nozzle tips to their limits. 3. Now pull out the form inserts downwards in the direction of the cavity. 4. Loosen the screw fastening for the suppressor and remove it 5. Now the nozzle can be taken up-wards. What should be observed in the construction phase: 1 To prevent jetting, inject against a core, for example. 2. The shear edge must amount to at least the injection gate diameter + 0.2 mm (see drawing). 3. There should not be any draft angle in the injection gate area (see drawing). Fig. Disassembly of a multi-tip nozzle 1.4. 37 Subject to technical changes 7/12

Valve gate technology Fig. Valve gate system Commissioning Before heating the nozzles and the manifold, switch on the mould temperature control. Heating the hot runner system: With the soft-start function the manifold is heated to about 100 C and held at this temperature for approximately 10 minutes. The nozzles and manifold must be heated evenly (ramp function). In any case, it is essential to prevent the nozzles reaching the processing temperature before the manifold does. Heating the manifold to the required temperature can take up to 20 minutes depending on the size and circumstances. Only when the hot runner system has reached production temperature, may the needle mechanism be put into operation, whereby it must be ensured too that the plastic is in molten form in the needle guide area. It might be necessary to extend the heating time for the nozzle by 5 10 minutes. With putting into operation for the first time, several injections may be necessary to fill the hot runner completely with plastic. Until all parts are filled completely, the cavities must be checked after every cycle for parts that have not been filled completely. Dwell time: To keep the thermal damage to the melt as low as possible, the idle time at production temperature should be adapted to the sensitivity of the material. As a rule, the dwell time can be up to 10 minutes depending on the type of plastic. Interruption in production When a process is interrupted, the hot runner temperature must be lowered (depending on the material and down-time by 100 150K). The needles must be in the closed position. Make sure the process temperature is reached again before activating the needles again. Set-up operation To prevent damage to the gate bores/valve needles from cold material in the needle guide, the valve needles may not be activated while the injection moulding machine is being set up or during the flushing-out process. If the melt is to be ejected through the open mould / hot runner, the needles must be opened during the injecting-through process and closed during the dosing phase. Switching off the hot runner When the hot runner system is being turned off, all control circuits can be turned off at the same time. To prevent the hot runner system being damaged by the build-up of heat, let the mould cooling run on at about 30 C for another 30 min. approximately. The valve gates should be in the closed position for this. Before starting disassembly, make sure the hot runner is switched off. To prevent damage to the needle guide/needle, the needles must be in the open position. Before putting the system into operation again, make sure the needles are in the closed position again. Needle actuation To reach a high needle speed, the valve for actuation (hydraulics pneumatics) must be designed to be as lare as possible. The connection tube dimensioning must be designed to suit the flow rate. The distance between the pressure generation and pressureconsumption (mould) should be as little as possible. (Needle closing time 20-40 ms/7-10 mm travel) Note! The first filling of the hydraulic cylinders should be done at a low speed or the cylinders should be vented. Connection values Electric Voltage 230 V~ System * max. permissible operating pressure in the hot-runner system 2000 bar * If special nozzles or other components with a pressure limit (less than 2000 bar) are fitted to systems or individual tools, this situation is documented in the height adjustment and on the type plate. Hydraulic Single valve- gate nozzle Lifting plate mechanism Sliding cam mechanism Pneumatic max. permissible operating pressure in the hot-runner system Single valve gate nozzle Single needle valve Lifting plate mechanism Sliding cam mechanism 40 40-60 40-60 8-10 8-10 8-10 8-10 8-10 bar bar bar bar bar bar bar bar 1.4. 40

Valve gate technology Insulation ring Steel piston ring, large Marking XXX Fixed power connection Steel piston ring, small Fixed thermo connection Marking XXX * Power receptacle CMT * Thermoplug CMLK Needle closing Needle opening * 5-6NEST = pluggable connection * 8-12NEST1 = fixed connection Fig. Single valve-gate nozzle 12NEST1 There are three 0.1-mm shims over / under the needle head. Caution! When assembling / dismantling the needle holder (A/F 10), care must be taken not to deform the steel piston rings. Use the flat of the piston! It is essential to put the metal O ring back in after replacing the disk package. The piston and/or the steel piston rings must be greased again before assembly (GÜNTHER recommends Klüber paste UH 196-402 [NSF registered]). Furthermore, it is essential to ensure that the steel piston rings have been inserted correctly. The rings have a marking (XXX) on the face surface, indicating the side that must point towards the pressurised side. Installation of the complete nozzle The cables for activating the needles are located at the bottom of the nozzle. Accordingly the centring ring can be produced as a bell. This measure makes it possible to reduce the height of the mould. Screw centring with at least 6x M10 (12.9) screws, with due consideration to lift forces. For an optimum thermal separation between the nozzle and the mould, use the (blue) insulation ring. Caution: Grind in the K dimension in compliance with the data in the chapter. 2.3 yellow page. Inlet/ outlet pipes for activating the needle It is preferable to use channels with diameters of 6 mm and a minimum length of 200 mm. The inlet and outlet lines must be placed in the cooled mould plate in order to prevent the medium overheating. If the mould temperatures exceed the thermal stress capability of the pneumatic valves, a separately cooled manifold must be installed. The mechanics of the needle drive and the valve gate nozzle are absolutely capable of withstanding high temperatures. Note on guarantee GÜNTHER guarantees nozzle type NEST1 only if they have been fitted or serviced on GÜNTHER premises or by a GÜNTHER specialist. GÜNTHER will not provide any guarantee for damage caused by the incorrect fitting of the steel piston ring operated nozzle type NEST by the pur-chaser, its representatives or contractors. The same applies to inappropriate or neglected maintenance. 1.4. 41 Subject to technical changes 7/12

Valve gate technology Electromagnet ME 10/UV75 The ME 10 bistable heavy-duty lifting magnet serves to actuate the valve gate needles in valve gate systems. Excellent for fully electric injection moulding machines and for clean room use. Single needle valve ENV Needle actuation in single and multiple systems. Sequential opening and closing of the needles. Special holes in the mould clamping plate allow the down-stroke depth of the valve gate to be adjusted individually from the outside. Maximum working temperature is 100 C. Pay attention to the balancing of the oil feed and oil outlet ducts as well as of the air feed and air outlet ducts. Note on guarantee GÜNTHER guarantees single needle valves only if they have been fitted or serviced on GÜNTHER premises or by a GÜNTHER specialist. GÜNTHER will not provide any guarantee for damage caused by the incorrect fitting of the O-rings in hydraulically/pneumatically operated single needle valves by the purchaser, its representatives or contractors. The same applies to inappropriate or neglected maintenance. Note: See operating instructions for details. Lifting plate mechanism ANEH The lifting mechanism is recommendable for a precisely simultaneous opening and closing of all needles. Special holes in the mould clamping plate allow the down-stroke depth of the valve needles to be adjusted individually from the outside. The maximum working temperature is 100 C. Sliding cam mechanism ANES For narrow cavity spacing a sliding cam mechanism is the preferred drive. Exact opening and closing of all needles. Special holes in the mould clamping plate allow the down-stroke depth of the valve gate to be adjusted individually from the outside. Maximum working temperature is 100 C. 1.4. 42

Valve gate technology Notes on valve needles The needle length is dependent on the nozzle length, type of actuation and manifold structure. The needles have a basic hardness of 64 HRC (HSS steel) and are coated. The needles are fitted with a cylindrical seal towards the cavity and are adjustable. The 2 mm Ø needle design for nozzles with material tube-ø 4 mm, threads M6x 0,5 gate-ø: 0,8 mm, 1,0 m, 1,2 mm, 1,4 mm, (1,6 mm). The 3 mm Ø needle design for nozzles with material tube- Ø 5, 6 mm, threads M8 x 0,5 gate Ø: 0,8mm, 1,0 mm, 1,2 mm, 1,4 mm. The 3 mm Ø needle design for nozzles with material tube- Ø 8 mm, threads M8 x 0,5 gate Ø: 2,0 mm, 2,5 mm. The 5 mm Ø needle design for nozzles with material tube- Ø 10-12 mm, threads M10 x 0,75 gate- Ø: 3,0 mm, 4,0 mm. Maintenance Sliding cam mechanismus -ANES- When fitting the sliding cam mechanism, use a hightemperature long-life grease to lubricate the movable parts. This allows the sliding cam mechanism to work without any problems even at higher temperatures over a long period of time. Make sure the mould temperature does not exceed 100 C in the area of the frame plate/ clamping plate. During maintenance the sliding cam mechanism must be checked for dirt and wear. Melts that have exuded from the manifold sealing because of the stroke movement of the needles must be removed. In older hot-runner systems the sliding cam mechanism can be relubricated through the ball impact holes (DIN 3410 Form F); in new systems the sliding cam mechanism can be relubricated without disassembly. Tools to disassembling the needle guide (piece of PM), see chapter 7. Thread tightening torque for needle adjustment Needle Ø Thread Tightening torque M A [Nm] Ø 2 mm M6 x 0,50 15 Ø 3 mm M8 x 0,50 30 Ø 5 mm M10 x 0,75 45 Typ NEP Typ NHP Fig. Sliding cam mechanism with externally accessible grease fittings Fig. Ball impact holes To ensure optimal greasing performance also at higher temperatures, avoid using different greases. We recommend the lubricating grease from Klueber Barrierta L55/2 high temperature long-life grease. The lubricating grease can be purchased either directly from the manufacturer or from us. Safety data sheets can be called up at www.klueber.com. Introduction: Lubrication after 150.000 shots or 1x weekly. Maintainance work (cleaning) must be done on the needle-driving mechanisms every 400.000 shots! This frequency depends greatly on the material to be processed or the application. If a thermoplastic elastomer (TPE) is being processed, it may be necessary to do maintenance work on the sliding cam after just approximately 200.000 shots. This also concerns polymers, in which the viscosity is greatly reduced by the shearing. 1.4. 43 Subject to technical changes 7/12

Hot runner systems / manifolds V2 Sign up at to start configuring your individual hot runner system with CADHOC V2 System Designer. You will save time and cut costs by having detailed information at an early phase of your project. Hot half on the basis of the 8-cavity H manifold 2-cavity straight manifold" and 4-cavity cross manifold" For mould size up 196x296 mm to 796x996 mm (depending on the manifold size and manifold design). Hot half as 2-plate system, incl. guide elements, cable duct, cooling etc. All system nozzles with a tip and an open nozzle piece can be used (Catalogue Chapter 2.1). Valve-gate systems with single needle valves for individual types of manifold. Straight manifold 1-cavity, 2-cavity und 4-cavity H manifold 4-cavity and 8-cavity, T manifold 2-cavity and Cross manifold 4-cavity with nozzles from our valve gate portfolio. Catalogue Chapter 2.3). 1.4. 50

Hot runner systems / manifolds View straight/frame version Position of power connections Note: Nozzles should always be surrounded by heater loops. Heater lines should be routed mirror-inverted (cold ends of the tube heaters compensate for one another). When possible, reserve an area for connectors where no material-carrying bore holes are located. For high temperature applications > 320 C external connectors are appropriate. Fig. View: straight version Fig. Internal heater connections Fig. External heater connections Frame plate / rail Edges absolutely burr-free Supporting plate / cavity plate Fig. View: f rame version Fig. Cable channel Not recommended Recommended Fig. Cable channel Fig. Cable channel 1.4. 51 Subject to technical changes 7/12

Hot runner systems / manifolds Air circulation Attachment : housing Insulating plate Clamping plate Fig. Optimal air circulation Distance bolts Connector housing On account of heat convection, do not mount the connector housing onto the mould directly. We recommend the use of sufficiently long spacer bolts. Manifold Frame structure Fig. Cross section of a mold - optimal air circulation High temperature application Special hot runner design is necessary for plastics with processing temperatures over 320 C. This includes full insulation, external heater connectors and high tempe-rature resistant thermo-couples. In the nozzle area it requires a fixed, high temperature resistant thermocouple connection, a hard metal tip (for reinforced polymers) as well as a high temperature pro-tective sleeve for cables. Fig. Manifold for high temperature application 1.4. 52

Hot runner systems / manifolds Titanium washer Screw M6, M8, M10, (12.9) depending on manifold design Nozzle type _MT, _TT Fig. Manifold with _TT nozzle type, screwed to the parting line Fig. Screw fastenings for _MT/_TT nozzles Note: Hot runner nozzles of the _MT/_TT type are not screwfastened to the manifold. The system is started with coldstate play. Please refer to the respective heat expansion table. In its cold state, the hot runner system has no positive seal between nozzles and manifold. Operating temperature must first be reached in order to seal the system. Please provide for adequate screw fixation of the clamping plate towards the cavity plate close enough to the manifold with at least 2x M10 per nozzle or, based on the length, 2x M10 per every 80 mm. We recommend connecting with screws of the 12.9 property class. Advantages: For high number of cavities and tight pitch spacing. Easy front mounting of the nozzles - the mold can remain on the machine for maintenance. Two fits provide a precise positioning to the pitch distance. Safety due to spatial and thermal separation of the connecting cable from the manifold. Protection against leakage by sealing the manifold from the cable channels om the cable channels. Please use a pry bar or a nozzle extractor tool to professionally disassemble the nozzle from the gate bushing and/or cavity plate. See chapter 8. 1.4. 53 Subject to technical changes 7/12

Hot runner systems / manifolds Manifold power calculation (230 V) Power Voltage Current Approximate resistance Watt Volt A values to be measured in Ohm [S] 2300 3680 1500 1400 1100 1000 750 500 630 500 400 250 600 (max.) 600 (max.) 230 230 230 230 230 230 230 230 230 230 230 230 5 24 10 16 6.5 6.1 4.8 4.4 3.3 2.8 2.2 1.8 1.4 1.1 125 (max.) 25 (max.) 23.0 14.375 35.4 37.7 47.9 52.3 69.1 82.1 104.5 127.8 164.3 209.1 0.1-0.2 0.2-0.4 P = U I R = U/I P = U 2 / R Example: P = (230 V) 2 / 23 Ohm P = 2300 W PE earthed lead Thermocouple cable Alternating current 230 V Red = plus Blue = minus Fig. Manifold - correlation of cables 1.4. 54

Hot runner systems / manifolds Assembly of the manifold 26 27 1 2 3 4 5 24 25 A 6 7 23 22 21 B C 8 9 20 10 STT SHT NMT NHF 11 19 19 12 18 17 16 15 14 13 Signs and symbols: 1 Surface mounted thermocouple, chap. 7 11 Nozzle length, chap.2 + 3 21 Manifold height 2 3 4 5 6 7 8 9 10 Bores in the clamping plate to fix the nozzle PE-ground cable connection, chap. 7 Connection elements, chap. 6 Pressure pads, chap. 8 Clamping plate Air circulation above and below depending on the position of the mould Manifold, chap. 4 Nozzle holding plate Cable channel 12 13 14 15 16 17 18 19 20 Nozzle protrusion Cylindrical pin to prevent twisting, chap. 4.1 Hot runner nozzle, chap. 2 + 3 Height temperature insulating plate, optional Support piece, chap. 8 Gate bushing, chap. 2.2 + 3.2 Tempering Cavity plate Height of the nozzle head 22 23 24 25 26 27 Installation height of the hotrunner without pressure pad Recess for the hot runner system in the tool Heat expansion gap dimension K, chap. 4.1 Pressure pad height Protection against leakage: The manifold area is sealed off from the cable ducts Melt direction element A B C Needle adjustment from outside Protected heating conductor connection in the manifold Needle guide and sealing in the manifold 1.4. 55 Subject to technical changes 7/12

Hot runner systems / manifolds Complete Hot Halves The hot half is delivered as a nozzleside mold half without cavity plates. The nozzle overhang over the supporting plate can be set individually. The height-matched hot runner is completely wired and functionally tested. This ready-to-install solution eliminates extensive design matching work and possible installation errors. Prior to delivery, hot halves are subjected to a functional test which is documented according to DIN EN ISO 9001:2000. Complete Hot Halves normally guarantee a smooth production start-up. Fig. Cross section of a mold Fig. Complete mold half Hot Half, valve gate system 1.4. 56

Service program Our comprehensive program of services is meant to provide you with the service you need, from consul-tation and layout for hot runner systems to practice-oriented seminars for users and designers. On the GÜNTHER website you will find many tools and programs to make your work easier. You can now configure your hot runner system individually via the GÜNTHER Internet platform. 3-D CAD data including negative volume and drawings are available for downloading for each hot runner system. To round this service off, price information (as a PDF file) is also provided. Once you have configured your individual hot runner system, you can select various data formats. The CADHOC V2 System Designer and the systems running in the background generate the required data. All files are then compressed and made available for downloading. You will be notified by e-mail a few minutes later. This e-mail will contain a link to the product data for the configured hot runner system. With its high functionality, the system is designed to suit the requirements of our customers, first of all designers of injection molds and sales personnel, to meet the desire for quicker availability of complete hot runner systems including negative volumes. Register once on our Internet platform and you can then start the CADHOC V2 system designer to configure your own individual hot-runner system. Advantages of the new CADHOC system-designers version 2: optimised calculation of the nozzle size extensive choice of types of plastic two different methods of configuration - application-specific by entering processing parameters - direct configuration without entering processing parameters shorter waiting periods during the configuration process 1.4. 60

Service program Reworking the 1.2 mm gate For gate diameters smaller than ØD = 1.2 mm, the nozzle must be installed further back from the gate. You will find a Delta Tool calculation program on our homepage at under the menu item Service available for download free of charge. Fig. Delta Tool calculation program Application database The application database is a program for selecting from design proposals and machine parameter data. Following the entry of simple search criteria for hot runner requirements and material compa-tibility, the program makes available a selection of systems which have already been implemented along with their results. You can also enter your own applications directly into the data-base. The application will be reviewed and subsequently released under the menu item Service. The registration is free of charge. Fig. Application database with many applications already implemented 1.4. 61 Subject to technical changes 7/12

Service program Download / catalog Under the menu item Catalog you will find all hot runner components with their relevant data available as a PDF file. The online catalog provides you with the newest version of the technical information. Here you can find GÜNTHER hot runner components with all the relevant information as a PDF file. Make use of extensive TM Acrobat Reader features, such as shortcuts, bookmarks and icons, for a comfortable and quick search for information! Fig. Online catalog Pressure drop / Filling analysis The melt channels are dimensioned by GÜNTHER on the basis of application-specific rheologic calculations, with pressure drop, shear and dwell time standing in the foreground. Our calculations can be expanded to include the filling analysis of plastic parts per Moldflow. This is particularly advisable when laying out family molds with different cavities. By performing this calcu-lation, we offer you support in determining an optimal gate position and demon-strate the flow front course for the ideal part filling along with anticipated air pockets and the course of the weld line. Fig. Filling analysis Fig. BlueFlow Energie cost comparsion 1.4. 62

Service program Seminars for users and designers Topics, such as layout, smooth running operation and professional maintenance of GÜNTHER hot runner systems, are handled in a comprehensive manner. Additional services in our program include performing injection molding experiments in our in-house labora- tory as well as conducting external seminars. Please look for dates and locations on our website under the menu item Seminars or ask by phone at +49 (0) 64 51-5008-0. Fig. Seminars for designers and users Webinar, what's that? Webinar is an acronym formed from the words web (world wide web) and seminar. In short, it is a seminar held over the Internet. Advantages for you: concise and specific information no travelling and overnight accommodation expenses, no loss of working days! See website 1.4. 63 Subject to technical changes 7/12