Hot Runner & Control Systems

®

HOT RUNNER & CONTROL SYSTEMS

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Table of Contents Hot Runner Systems

Hot Runner Systems

Temperature Control Systems SS TSP & TSP Plus

DME Hot Runner Technology......................................17-19 Stellar Micromolding....................................................28-33 Thermal Gate Hot Runner Systems Customer Commitment........................................................4 Terms and Conditions of Sale ............................................5 Sales and Ordering Information........................................6 Hot Runner Warranty ..........................................................7 Hot Runner Systems Overview...................................... 8-9 Custom Applications Engineered Hot Runner Systems Standard Global Manifold and Components .................12 Hot Runner Selection Guide.............................................11 Plastic Materials, Specifications/Bushing Selection ..13 Hot Runner Quote Request Form.....................................15

TSP (Touch Screen Panel) ........................................114-117 TSP Plus (Touch Screen Panel.................................118-119

Standard Pre-Engineered Hot Runner Systems

The Hot One Technology.............................................35-52 Meteor Hot Runner......................................................53-60

Hot Sprue Bushings D-MAX............................................................................63-69 Gate-Mate .....................................................................70-77 Straight-Shot ............................................................... 78-88 >High-Performance ....................................................79-80 >S-Series ...........................81 >E-Series .................... 82-83 >ER-Series ................. 84-85 >T-Series ...........................86 >TR-Series .........................87 >Replacement Parts ........88 Integrally Heated Sprue Bushings ...........................89-94

Hot Runner Services

Obsolete System Replacement Parts Gate-Mate...................................................................... 102 Cool One.....................................................................104-111 Moldflow........................................................................ 96-97 Moldflow Quote Request Form........................................98 Hot Runner Service Center........................................99-100

SVG Pneumatic Control Systems SVG Hydraulic Control Systems VCAP Air Valve Assemblies

164 166 168 16 8 16 9

Compact 4-Zone Hydraulic/Pneumatic Control

Single Zone Timer

Modular Components Deliver High Performance......112

Technical Support

170

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Hot Runner Systems

Index

Alternate Cable Configuration........................................ ...... 160 Alternate Cable Wiring Diagram.......................................... 162 Blank Panels, Fuses & Crimp Connectors............................. 135 Bushing Selection....................................................................14 Cable Storage Baskets...........................................................164 Cartridge Heaters.................................................................... 46 Control Systems.............................................................. ...... 113 D MAX High Performance Hot Sprue Bushings ..................... 63 Digital Current/Voltage Monitor........................................... 134 DSS Modules ........................................................................ 148

Plastic Materials and Specifications......................................13

Obsolete Hot Runner Replacement Parts........................ ..... 101 Cool One & Micro Cool One............................................ 104 Gate-Mate Nozzles...........................................................102 Gate Shell Insulators........................................................103

Replacement Parts (Temp Control) ....................................... 155

Sales and Ordering Information ............................................... 6 Selection Guide, Hot Runner Technology ............................... 11 Single & 2-Zone Controller Accessories ....................... 125-130 Single Zone Controllers ........................................................ 125 Single Zone High Power Controller & Accessories.............. 128 Single Zone Timer ................................................................. 171 Smart Series 15 AMP Mainframe Configurations....................................................................... 132 Smart Series 30 AMP Mainframe Configurations....................................................................... 133 SSM Modules ....................................................................... 146 Stellar Micromolding Hot Runner Systems............................ 28 Step-Down Transformer Kit .................................................. 135 Straight Shot™ Hot Sprue Bushings ...................................... 78 TAS Temperature Alarm/System Modules........................... 152 Technical Support Data (Temp Control) ................................ 172 Terminal Mounting Boxes ............................................. 144, 163 Terms and Conditions of Sale................................................... 5 Thermocouple Cables ........................................................... 139 Thermocouple Input Connectors........................................... 140 TSM Modules ....................................................................... 150 TSP Temperature Controllers ................................................ 114 TSP Plus Temperature Controllers ........................................ 118 Tubular Heaters, Flexible ........................................................ 41 Two Zone (2-Zone) Temperature Controllers ........................ 127 Typical System Configuration (Temp Control) ...................... 124 VCAP Air Valve Accessories ................................................. 170 Valve Gate Controls .............................................................. 166 Valve Gate Single Zone Timer...............................................171

Flexible Tubular Heaters ......................................................... 41 Floor Stand (Temp Control) ................................................... 135

Gate-Mate Hot Sprue Bushings......................................... .... 71 Global Manifolds .................................................................... 12

Hot One Components & Accessories ..................................... 35 Hot One Hot Runner Technology – Overview......................... 18 Hot Runner Modular Components ........................................ 112 Hot Runner Quote Request Form ........................................ 15 Hot Runner Services ............................................................... 96 Hot Runner Selection Guide ................................................... 10 Hot Runner Warranty ................................................................ 7 Hot Sprue Bushings, D-MAX High Performance .................... 65 Hot Sprue Bushings, E-Series Straight Shot .......................... 82 Hot Sprue Bushings, ER-Series Straight Shot........................ 84 Hot Sprue Bushings, High-Performance ................................. 79 Hot Sprue Bushings, Integrally Heated .................................. 89 Hot Sprue Bushings, Straight Shot Replacement .................. 88 Hot Sprue Bushings, S-Series Straight Shot.......................... 81 Hot Sprue Bushings, Straight Shot™ ..................................... 78 Hot Sprue Bushings, T-Series Straight Shot .......................... 86 Hot Sprue Bushings, TR-Series Straight Shot.........................87

Input Power Wiring Diagrams........................................ ...... 157 Integrally Heated Hot Sprue Bushings ................................... 89

Mainframe Connector Wiring............................................... 136 Meteor Hot Runner Systems .................................................. 53 Moldflow™ Services............................................................... 96 Mold Connector Pocket Layouts ........................................... 142 Mold Filling/Mold Cooling Analysis Form........................... 98 Mold Power Cables............................................................... 140 Mold Power Input Connectors .............................................. 140 Mold Thermocouple Connectors........................................... 141 Pre-Wired Combination Terminal Mounting Boxes.............. 144

Warranty Information................................................................ 7

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Customer Commitment Hot Runner Systems

SERVICES

CONTACT US

Applications Engineering Is there a hot runner application on your wish list that you don’t see here? DME can help. Our design and applications engineering group consists of professional engineers and experienced designers. Once you provide the information necessary for proper application design and analysis, the DME applications engineering team will go to work diligently analyzing, designing and manufacturing a hot runner system that will best suit your needs and requirements. Technical Service DME is proud to say that it is an industry model for technical service coverage and response. The DME technical service department covers the entire United States and Canada, with additional service representatives in Europe, Asia and throughout the world. Because DME knows you need assistance starting, operating, and maintaining hot runner systems it has made a great effort to strategically staff a Technical Service Department that is responsible for the success of D ME’s molding systems.

To take advantage of any or all of these services, or if you have any questions, problems, or ideas please call DME at: n 800-626-6653 (U.S.) n 800-387-6600 (Canada) Part prints or system design prints may be sent in the following ways:

n dme_appl_eng@dme.net n 248-544-5707 (U.S.) fax n 905-677-5280 (Canada) fax

DME offers you a wide range of services from component selection to on-site system installation. Our ever-growing list of services include the ability to:  n Analyze the best system to fit your needs n Assist in system design n Perform computerized system analysis and resin qualification before any metal is cut  n Marry your system to the mold base, plates and components required  n Provide quotations for and perform all of the special machining required n Assemble and wire the system  n Check mechanical fit of all components and perform electrical load testing n Assist with system start-up and maintenance All of which gives you ... more time to concentrate on cavities and cores!

FIND A REP

Field Sales and Customer Service When you need a knowledgeable person to help you order parts and components, DME has you covered. Our direct field sales force puts a local sales representative in your area. One who understands your business and can offer valuable assistance in helping you select the molding system best suited to your application and your budget. In addition, DME provides a customer service department that has been extensively trained on all of DME’s products and systems, making it easier for you to order and have your questions answered. We can provide you price and delivery information on all DME items quickly and accurately.

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Terms and Conditions of Sale Hot Runner Systems

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1. FOB POINT / PRICES: Products are sold FCA Madison Heights. Any taxes are in addition to the prices and may be invoiced later. 2. SHIPPING SCHEDULE: The shipping schedule is our current estimate of delivery dates and we agree to use reasonable efforts to comply with the schedule. 3. WARRANTY: (a) Any DME trademarked or tradenamed product or part thereof manufactured by or for us which, under normal operating conditions in the plant of the Buyer thereof, proves defective in material or workmanship, as determined by our inspection, within 12 months from the date of shipment will be replaced or repaired free of charge to Buyer. This warranty is contingent upon the following conditions: that we promptly receive notice of the defect; that Buyer establish that the product has been properly installed, maintained, and operated within the limits of related and normal usage as specified by us; and that, upon our request, Buyer will return to us at our expense the defective product or part thereof. (b) The terms of this warranty do not in any way extend to any product or part thereof which have a life, under normal usage, inherently shorter than 12 months. (c) The conditions of actual production in each end user’s plant vary considerably. Therefore, descriptions of the production or performance capabilities of any product or software materials are estimates only and are not warranted. 4. EXCLUSIONS OF WARRANTIES: THE WARRANTIES TO REPAIR OR REPLACE DEFECTIVE PRODUCTS OR PARTS AS SET FORTH IN PARAGRAPH 3, AND ANY ADDITIONAL WARRANTY EXPRESSLY STATED TO BE A WARRANTY AND SET FORTH IN WRITING AS PART OF THESE TERMS HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANT- ABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 5. LIMITATION OF REMEDIES AND LIABILITIES: UNDER NO CIRCUMSTANCES SHALL WE OR ANY AFFILIATE OF OURS HAVE ANY LIABILITY WHATSOEVER FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES HOWSOEVER CAUSED OR ARISING (INCLUDING CONTRACT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE), such as, but not limited to, loss of profit or revenue; loss of use of the product, part thereof; cost of capital; cost of replacement equipment; claims that the warranty failed of its essential purpose or claims resulting from contracts between Buyer, its customers and/or suppliers. Unless expressly provided for herein, in no event shall we or any affiliate of ours assume responsibility or liability for (a) penalties, penalty clauses or liquidated damages clauses of any description, (b) certifications or (c) indemnification of Buyer or others for costs, damages or expenses arising out of or related to the product or part thereof. 6. CANCELLATION: Unless otherwise agreed, Buyer may cancel all or any part of the order by written notice received by us before our completion of the order or applicable portion of the order. On receipt of such notice, all work on the order or part thereof canceled will be stopped as promptly as is reasonably possible. Buyer will then be invoiced for and will pay to us a cancellation charge. For completed items, the charge will be equal to their established prices. For items not completed, the charge will be equal to our full cost plus a premium in addition to a charge for any packing and storage and less a credit for the balance of the material as scrap. 7. PAYMENT TERMS: Payment is due in accordance with any applicable progress, advance or other agreed upon payment schedule, or, if no such schedule has been agreed to, upon Acceptance as specified in Paragraph 8, but in no event later than 30 days from the date of invoice. No cash discount is provided. If, in our judgment, Buyer’s financial condition changes, we may stop work until financial arrangements satisfactory to us are made. 8. ACCEPTANCE OF PRODUCT: Each such product shall be deemed to be accepted within seven days after delivery of the product to the Buyer, unless we receive written notification of rejection for cause from Buyer within the seven day period.

“Returned Goods”: No goods are returnable without prior approval, prepaid transportation and an issued RMA number. All items are subject to our inspection before credit will be allowed. NO GOODS ARE RETURNABLE LATER THAN THIRTY DAYS AFTER RECEIPT OF MERCHANDISE. 9. PATENT INDEMNITY: We shall defend any suit or proceeding brought against Buyer and pay all costs and damages awarded against Buyer provided that: (a) The suit or proceeding is based upon a claim that the product or part thereof is an infringement of any claim of a presently existing U.S. patent; (b) The claim of infringement is not based, directly or indirectly, upon (i) the manufacture, use, or sale of any product furnished by us which has been modified without our consent; or, (ii) the manufac- ture, use, or sale of any combination of a product furnished by us with products not furnished by us; or (iii) performance of a patented process using a product furnished by us or production thereby of a patented product; and, (c) We are notified promptly and given information and assistance (at our expense) and the authority to defend the suit or proceeding. We shall not be responsible hereunder for any settlement made without our written consent nor shall we be responsible for costs or expenses incurred without our written consent. If our product is adjudicated to be an infringement and its use in the U.S. by Buyer is enjoined, we shall, at our own expense, either: (i) procure for Buyer the right to continue using our product; (ii) replace it with a noninfringing product; (iii) modify it so it becomes noninfringing; (iv) remove the product or part thereof and refund Buyer’s net book value and transportation costs attributable to it. The foregoing states our entire liability with respect to any patent infringement by our products or any parts thereof. To the extent that our product or any part thereof is supplied according to specifica- tions and designs furnished by Buyer, Buyer agrees to indemnify us in the manner and to the extent set forth above insofar as the terms thereof are appropriate. 10.FORCE MAJEURE: We shall not be liable for any delay in perfor- mance or nonperformance which is due to war, fire, flood, acts of God, acts of third parties, acts of governmental authority or any agency or commission thereof, accident, breakdown of equipment, differences with employees or similar or dissimilar causes beyond our reasonable control, including but not limited to, those interfering with production, supply or transportation of products, raw materials or components or our ability to obtain, on terms we deem reason- able, material, labor, equipment or transportation. 11.ACCEPTANCE OF ORDERS: Buyer agrees that all orders, including any arising from our Proposal, shall include these terms and conditions only, notwithstanding any different or additional terms that may be embodied in Buyer’s order. All orders are subject to our acceptance and we reserve the right to reject orders as, in our sole judgement, mandated by business conditions. We reserve the right to not proceed with any order until all necessary information is received from Buyer. 12.MERGER CLAUSE: This Agreement entirely supersedes any prior oral representations, correspondence, proposal, quotation, or agreement. This writing constitutes the final and total expression of such agreement between the parties, and it is a complete and exclusive statement of the terms of that agreement. 13.ASSIGNMENT: Neither party may assign this Agreement without the written consent of the other party, except that we may assign this Agreement to a third party that acquires substantially all of our assets or we may assign the flow of funds arising out of this Agreement. 14.GOVERNING LAW: This Agreement shall be governed by and construed in accordance with the laws of the State of Michigan.

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Hot Runner Systems Sales and Ordering Information

U.S.A. TERMS AND CONDITIONS OF SALE: See previous page.

PHONE ORDERS – TOLL FREE: 800-626-6653. DME’s Customer Service Dept. operates Monday through Friday from 8 a.m. to 6 p.m. E.S.T. Calls can be made from anywhere in the continental U.S. and Puerto Rico (Puerto Rico: use “137” prefix instead of “1”). Our Customer Service Representatives will be happy to answer your questions on DME products or services, provide on-the-spot feedback on product availability and shipping details, or take any messages you wish relayed to your local DME sales, manufacturing or technical service representatives. MAIL ORDERS: If you prefer to order by mail, please address your order to: n DME Company, 29111 Stephenson Highway, Madison Heights, Michigan 48071-2330 ATTN: Customer Service Dept. FAX: You may fax your order to: • DME Customer Service • 248-544-5113 or 888-808-4363 CHECKS OR MONEY ORDERS: When paying invoices by check or money order, please make payable to DME Company. include remittance copy of invoice and mail to: • DME Company, Department Lock Box 774867, 4867 Solutions Center, Chicago, IL 60677-4008 WALK-IN ORDERS, PICK-UPS AND RETURNS: If desired, ordered products in stock at your nearest DME Service Center can be picked up rather than shipped. Walk-in orders at Service Center locations can also be processed while you wait. Products being returned for repair or exchange should be processed through Customer Service prior to being returned. SPECIAL MACHINING SERVICES: Prints for quotation on special machining work can be sent by EDI to dme_cad@dme.net or mailed to the Estimating Department of the DME manufacturing location nearest you. Call our toll-free number if desired to clarify location which serves your area. Estimating locations are: • 70 East Hillis Street, Youngwood, Pa 15697, FAX: 724-925-2424

• 117 Fairplains Street, Greenville, MI 48838, Tel. 616-754-4601, FAX: 616-225-3924 • 3275 Deziel Drive, Windsor, Ont N8W 5A5, Tel. 519-948-5001, FAX: 519-948-4652

Please add “DME Company” and “Attn: Estimating Dept.” to above addresses when mailing prints. To obtain prices and delivery on special mold base orders or to check status of special work in progress please contact Customer Service.

CANADA TERMS AND CONDITIONS OF SALE: See previous page.

PHONE ORDERS: Contact our Mississauga, Ontario office at 800-387-6600, FAX: 800-461-9965. MAIL ORDERS: Send to: DME Company, 6210 Northwest Drive, Mississauga, Ontario L4V 1J6. CHECK OR MONEY ORDERS: Make payable to DME Company. Include remittance copy of invoice and mail to Mississauga address above. WALK-IN ORDERS, PICK-UPS, RETURNS, AND SPECIAL MACHINING: Contact our Mississauga office.

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Hot Runner & Temperature Control Warranty Hot Runner Systems

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CONTACT US

DME Company 29111 Stephenson Highway, Madison Heights, MI 48071 Tel. 248/398-6000 n FAX 248/544-5113

DME Hot Runner Systems and Temperature Controllers are warranted pursuant to DME Company’s standard terms and conditions (see page 5) for the time periods set forth below. The warranty (i) covers items sold and shipped [supplied in accordance with orders placed by the customer with DME on or after JULY 1, 2003], (ii) applies only to the original DME customer and, (iii) is not transferable to subsequent owners of the product except as specifically set forth herein (see Transferability below for conditions). WARRANTY PERIODS APPLICABLETO SPECIFIED DME PRODUCTS; COVERAGE STARTS UPON DATE OF SHIPMENT: Item Coverage DME Hot One Hot Halves (plates designed, machined & assembled by DME, excluding Electrical Parts ) Plastic leakage, due to manufacturing defect, within hot runner plates covered for Two (2) years; excluding Gate Detail.

DME Stellar Hot Runner Hot Halves (plates designed, machined & assembled by DME, excluding Electrical Parts )

Plastic leakage, due to manufacturing defect, within hot runner plates covered for Two (2) years; excluding Gate Detail. Plastic leakage, due to manufacturing defect, within hot runner plates covered for One (1) years; excluding Gate Detail.

DME Smart One Valve Gate Hot Halves (plates designed, machined & assembled by DME, excluding Electrical Parts )

DME Hot One and Stellar & Smart One VG Manifold and Components (neither plates nor assembly supplied by DME, excluding Electrical Parts )

One (1) year

DME Electrical Parts (all heaters and thermocouples)

One (1) year

DME Mold Controls and Valve Gate Controls ( excluding Fuses & Triacs, Power Packs & Trolley as appropriate )

One (1) year - Pumping systems, Valves & Solenoids Two (2) years - Smart Series Mainframes & Modules TSP, TSP Plus & SVG Electronic Controllers

Replacement or repair will be made at the election of DME; implemented at a DME facility and/or by shipment of replacement parts to the customer for installation and/or return of defective parts to DME for repair. Transferability: This warranty may be transferred by the original DME Customer to a subsequent owner of the product if all of the following conditions exist: (i) the original DME Customer purchased the product for purposes of re-sale or other immediate transfer and DME was made aware of these purposes at the time of purchase in writing, (ii) within thirty (30) days from the date of invoice, DME is notified in writing of the transfer and provided with the name of the new owner (hereafter “Transferee”), the contact person of the Transferee and the Transferee’s address. Exclusions: • Normal wear of the system and components including, but not limited to: Nozzle Tips, Nozzle Seal Rings, and Electrical connectors • Damage to the critical seal-off areas on the manifold, nozzle bodies, or in the mating cavities or cavity inserts caused by improper assembly, operation, disassembly and maintenance • Wear or damage resulting from corrosion or processing of abrasive/aggressive resins • Damage due to failure to follow recommended operation and maintenance procedures specified in the DME Hot Runner Manual, Hot Runner Nameplate, Service Bulletins, User Manuals or failure to follow standard industry operation and maintenance procedure • Damage caused by abuse, neglect, and failure to adhere to DME instructions and operational recommendations • Damage caused by improper installation, operation and maintenance • Damage resulting from modifications to the product or component parts, abuse or neglect • Failure caused by modifications made to the product without the prior written approval of DME • Damage resulting from operation of products at injection pressures greater than 20,000 psi (1360 bar) on Hot One, Stellar & Smart One VG Systems;

unless specifically designed and manufactured for higher pressure applications in agreement with manufacturer • Damage or failure caused by the product’s inability to perform as a component of a system design not supplied by DME • Operator absence or operator error • Operator maintenance and training capability • Electrical interruptions

• Events beyond the control of DME • Errors or actions by a third party • Non-compliance with local laws, codes, ordinances or regulations codes or bylaws unless DME is informed of them by our customer at the time of order placement

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Hot Runner Systems

DME Hot Runner…

DME : Your essential resource for hot runner solutions

Whether your application requires best-in-class components or a turnkey hot-half system, DME has a hot runner solution that meets your needs.

DME: An Essential Resource for Hot Runner Productivity Moldmakers, molders and mold designers worldwide look to DME for essential hot runner solutions — whether that is a single, best-in-class component or a complete, fully functioning hot half system. Offering the industry’s broadest range of hot runner products and services as well as an unsurpassed knowledge and expertise, DME is committed to helping customers achieve maximum productivity, reliable operation, and better performance.

System Solutions DME offers a comprehensive family of hot runner systems built on our modular architecture making custom configuration easy and quick. Systems include: • Stellar ® Micromolding Systems engineered for tight pitch molding • The Hot One 250, 375 and 625 series

A wide range of DME nozzles allows versatility in system selection

Stellar Micromolding Nozzles pro vide application flexibility

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Hot Runner Systems

…from components and manifolds to turnkey hot halves

page content

Our goal is simple: to be an essential resource for your molding challenges. Every step of the way.

Specialized Systems As one of the world’s leading hot runner manufacturers, we recognize that some application challenges demand specialized solutions. Offerings include: • Stellar Manifold and Components • Stellar Hot Halves • Hot One Manifold and Components • Hot One Hot Halves

Knowledge That Gives You an Advantage

Service and Support to Keep You Productive DME provides essential support to keep your hot runner systems in-service. Our dedicated hot runner service center is staffed by trained, experienced technicians who support DME systems, as well as other brands, to provide help when and where you need it, every step of the way.

Our team of trained, experienced experts can help you with needs analysis, design, configuration, operation, and all the other services that enable you to focus on your core business. • Applications engineering • Moldflow analysis

SERVICE

Stellar & Hot One Systems are custom configur ed for your application

Moldflo w predictive analysis optimizes part design and lowers costs

DME Hot Runner Service Center provides total support for your hot runner system

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Your Design Molded plastic parts remain one of the key enablers to innovation of both consumer and industrial products. Lighter, stronger, smaller and more appealing products are possible by leveraging the versatility and performance of plastics. And DESIGN is critical to every aspect of the plastic part. Through DESIGN products can be differentiated in terms of their form, fit and function to deliver improved performance through the entire application life-cycle. DESIGN also allows for lower total costs allowing for high-speed, high-volume molding operations due to higher material prices, a need to reduce cycle time, reduce scrap rates, and increase overall productivity and costs to manufacture further improving the total value to the customer.

We work alongside you taking a holistic approach that helps ensure all of the project requirements are met wherever in the world they are required. We start by building a detailed understanding of your plastic part design and its intended application in use. Drawing on unrivalled breadth of capabilities we take an integrated approach to meet your needs combining our precis melt delivery systems, engineered components that enable the molding process, and mold cooling technologies that ensure part quality and appearance are achieved at the lowest cost possible. Our goal is to deliver the best possible plastic part at the lowest possible cost. This is DME’s MOLD TECHNOLOGY SOLUTION. Our Solution

Cool

Melt

Form

Form COoL

MELT

Pellet

Part

THERMAL (cooling) Management

Melt Delivery sys- tems

Engineered Components

Injection solutions

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Standard Global Manifold Hot Runner Systems

DME Global Manifolds and Components are standardized worldwide to ensure that even the smallest detail provides operational excellence regardless of where DME hot runner products are used. Whether you’re relying on a quick-delivery manifold or an applications-engineered, custom manifold, the DME Global Manifold Standard ensures optimal hot runner performance no matter where in the world it was built. Key Features of the DME Global Manifold Include: • Flexible tubular heaters • Locating rings that fit virtually any injection press platen hole diameters • Heated Manifold Extension Nozzles available • High-tolerance, press-fit heaters • Upper and center Manifold supports constructed of high-strength, low-heat conductive titanium that minimizes heat loss and maintains an even heat profile • J-type thermocouples are black-and-white, coinciding with the IEC 584-3 International Standard • Flow channel sizes range from 6mm to 16mm DME customers are assured that DME Manifold Systems are designed and built with a global standard that ensures efficient molding anywhere in the world. And, since replacement parts are identical worldwide, they are readily available wherever your mold is operating, not just where it was built. All DME nozzles, including, Stellar and the Hot One, perform flawlessly with the DME Global Manifold Standard.

Heated “MEN“ From Machine Nozzle to Manifold

Available in all balanced design layout patterns up to 24 nozzle drops*, including inline, X, Y, H, Double H & Multiple Level Systems. *Contact DME for Higher Cavitation MANIFOLD DESIGN, SPECIFICATION & TOLERANCE STANDARDS HARMONIZED FOR GLOBAL PRODUCT OFFERING AMERICAS – EUROPE – ASIA – AUSTRALIA / NEW ZEALAND – INDIA – AFRICA

U.S. 800-626-6653

 Canada 800-387-6600  store @milacron.com  www.dme.net

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Plastic Materials and Specifications

PLASTIC MATERIAL PROCESS CONDITIONS

PROCESS TEMPERATURE

MOLD TEMPERATURE

HOT RUNNER TEMPERATURE

DENSITY MELTING

SOLID DENSITY

STANDARD RESIN SYMBOL

MATERIAL

[g/cm 3 ] [Ibs/inch 3 ] [g/cm 3 ] [Ibs/inch 3 ]

[°C]

[°F]

[°C]

[°F]

[°C]

[°F]

SB

210 220 230 210 300

410 428 446 410 572

70 45 80 45 80

158 113 176 113 176

230 240 255 230 330

446 464 491 446 626

0.93 0.93 0.99 0.95 1.08

0.0366 1.02 0.0366 1.11 0.0358 1.08 0.0343 1.05 0.0390 1.20

0.0369 0.0401 0.0390 0.0379 0.0434

Styrene Butadiene

PUR SAN

Polyurethane

Styrene-acrylonitrile

PS PC

Polystyrene

Polycarbonate

PPO

260

500

80

176

300

572

0.99

0.0358 1.13

0.0408

Polyphenylene Oxide-Styrene

PE PP

200 225 330 300 265 220 255 240

392 437

25 40

77

225 245 370 330 290 250 280 265

437 473 698 626 554 482 536 509

0.74 0.73 1.13 1.53 1.44 0.98 1.09 0.78

0.0267 0.96 0.0264 0.91 0.0408 1.37 0.0553 1.70 0.0520 1.57 0.0354 1.14 0.0394 1.26 0.0282 0.90

0.0347 0.0329 0.0495 0.0614 0.0567 0.0412 0.0455 0.0325

Polyethylene Polypropylene

104 329 230 140 194 194

PEEK PPS PBT PA 6 PA 66

626 165 572 110

Polyether-etherketone Polyphenylene Sulfide

509 428 491 464

60 90 90 35

Polyebutylene Terephthalate

Polyamide 6 Polyamide 66

TPE

95

Thermal Plastic Elastomers

POM

180

356 100

212

200

392

1.16

0.0419 1.42

0.0513

Polyoxymethylene (Polyacetal)

PMMA

235

455

70

158

250

482

1.09

0.0394 1.18

0.0426

Polymethyl Methacrylate

ABS

225

437

70

158

250

482

0.95

0.0343 1.08

0.0390

Acrylonitrile Butadiene Styrene

NOTE: Temperature and density values shown above are general, and may not apply to your application. Please refer to proper processing data for the resin grade intended for your specific application. Failure to use temperature settings appropriate to the specific resin and resin grade intended for your application may result in poor part quality, or inability to produce acceptable molded parts.

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Bushing Selection

HOT SPRUE BUSHING TIP STYLE

For use where gate vestige is allowed. Provides low resistance to flow with excellent flow rates. Extended style provides additional stock for machining profiles or part contours.

SPRUE GATE TIP STANDARD / EXTENDED

Ideal for low vestige commodity and engineering grade resin applications. The Ring Gate features a sealed tip for efficient shut-off at the part surface. Available with standard or wear resistant needles. Extended style provides additional stock for machining profiles or part contours.

RING GATE TIP STANDARD / EXTENDED

Suitable for high viscosity resins, engineering plastics and applications requiring optimum gate cosmetics with minimal gate vestige. Available with standard or wear resistant needles.

POINT GATE TIP

BUSHING TIP AND PLASTIC MATERIAL COMPATIBILITY

THERMOPLASTIC RESIN TYPE

AMORPHOUS

SEMI-CRYSTALINE

NOZZLE

SPRUE GATE TIP STANDARD / EXTENDED

RING GATE TIP STANDARD / EXTENDED

POINT GATE TIP

Green Yellow Red

– Works well with this resin – Contact DME Engineering for guidance – Not recommended

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Hot Runner Quote Request Form Hot One Hot Runner Technology

EMAIL TO DMEUS_AE_QUOTE@MILACRON.COM OR FAX United States: 888-808-4363 • Canada: 800-461-9965 • International: 248-398-7394

ONLINE REQUEST FORM

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page content text Table of Contents

Hot Runner T echnology...........................................1. 7-19 The best solution for precision thermoplastic micromolding

Smart One Valve Gate Hot Runner System..........20-27 Cost efficient and capable, the DME SMART ONE gives you all you need in a melt delivery system at an economical price.

Stellar Micromolding Hot Runner Systems..........28-33 The best solution for precision thermoplastic micromolding

Hot One Nozzles......................................................34-60 A long-standing industry standard in user-friendliness and affordability

Components: Heaters & Thermocouples ......47-52 Custom-configured manifolds, manifold and component systems, and complete hot half assemblies for quick delivery

Meteor ® Hot Runner Systems.................................54-60 Custom-configured manifolds, manifold and component systems, and complete hot half assemblies for quick delivery

Hot Runner Technology

A LONG-STANDING INDUSTRY STANDARD IN USER-FRIENDLINESS AND AFFORDABILITY

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Features and Benefits Hot Runner Technology

Our ongoing customer-driven philosophy has fostered many new and innovative systems and components, allowing you to take advantage of more than seven decades of leadership in injection molding technology. DME’s Hot Runner Technology has become an industry standard in technology, user-friendliness, and affordability. Available in two styles – Manifold & Components and as a complete Hot Half System. Tubular Heated Systems Using exclusive, distributed wattage Tubular Heaters, the DME Hot Runner Systems can process many engineering grade resins. Tubular Heaters reduce the number of zones of heat required, providing the added benefit of lowering your temperature control costs.

DME’s Hot Runner Technology has become an industry standard in technology, user- friendliness, and affordability. Available in two styles – Manifold & Components and as a complete Hot Half System.

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text Nozzles Hot Runner Technology

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Each DME nozzle series has its own advantages and characteristics to meet your needs.

Stellar Nozzles

Point Gate

Sprue Gate

Nozzles The DME Hot One is accompanied by a nozzle offering that allows versatility in system selection to best suit the material and molded part configuration. DME offers different styles of nozzles: The “EHA” series, using square coil heaters and the “CIA” series , using replaceable, slip-on high performance heaters . Each nozzle series has its own characteristics and advantages. For example, the “EHA” series of nozzles can be used for many applications using commodity resins with low crystallinity. The “CIA” series, with high performance heaters developed exclusively for DME, can be used for all applications, especially engineering grade resins with a high degree of crystallinity.

“CIA”/”EHA” Nozzles

“EHA”/”CIA” Nozzle Tips

n Sprue Gate/Extended Sprue Gate – Used primarily in applications where gate vestige is not a concern. Offers minimal flow resistance and handles most resins very effectively. Extended style provides additional stock for machining of runner profiles or part contours.

n Point Gate – Used for applications needing optimum gate cosmetics, this tip can run a wide range of resins. It has two interchangeable needles, standard and wear resistant. The wear resistant needle is especially useful for abrasive or filled material applications.

n Full Body Point Gate – Used for low vestige, commodity grade resin applications. The Full Body Point Gate features a sealed tip for efficient shut- off at the parting line.

Ordering Options: Use this information and our design and machining guidelines to build your system, or take advantage of DME Applications Engineering services to help you select the system best suited to your requirements. Then, either order the steel and components to construct your system or let DME do all of the machining, assembly and wiring for you.

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Valve Gate Hot Runner System

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Smart One

SMART ONE VALVE GATE HOT RUNNER SYSTEM THE SMART WAY TO FILL

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Valve Gate Hot Runner System

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Smart One

CONTACT US

DME Hot Runner - SMART ONE C ost efficient and capable, the DME SMART ONE gives you all you need in a melt delivery system at an economical price.

Why the DME SMART ONE? • A Global offering from DME, providing a common design platform no matter where your molds are built • 5 different nozzles size to match your application requirements • A Valve Gate solution available as a Manifold & Components offering, or as a complete Hot Half, ready to interface with your cavity plate • Valve gate tip styles include Bodiless, Full Body and Full Body with Extended Sprue • Available with Pneumatic or Hydraulic cylinders • Actuation options include individual (sequential) or all open/all close • Cylinder design allows removal/setting of Valve Pins without system disassembly • Available for 2- to 32-drops, using a naturally-balanced manifold flow path design • Easily matched with DME Pneumatic or Hydraulic control systems • Your choice of temperature control connector options • Tips, retainers, heaters and thermocouples can be serviced while the system is in the machine for maximum up-time

• Spare thermocouples installed on all manifold zones • Replacement/spare part availability in North America • A value offering to provide a competitive edge over other manufacturers • Ideal for your lower cavitation, less-technical applications • Designed, Manufactured and Supported by DME North America Valve Gate • Good for superior gate cosmetics, sequential part filling and the elimination of trimming and secondary operations • Available in hydraulic & pneumatic actuation • For core thermoplastic resins and from small to large parts • Global manifold platform

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Valve Gate Hot Runner System

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Smart One Mold Technologies Package Solution The DME SMART ONE fits right into the complete package solutions offered by DME. Analysis, Hot Runner, Cooling, Mold Bases & Components, Temperature Control and Industrial Supplies. From start to finish, top to bottom... it can all be included .

Thermal Management Solutions Add off-the-shelf Conformal Cooling Working in perfect combination with the DME SMART ONE is DME’s Cooled Gate Bushings. These bushings are a thermal management solution that can be designed into your next project.

CONTACT US

Lifecycle Value Solution The DME SMART ONE is part of the DME complete lifecycle products and services package. DME understands that you need products and services that support you from the design stage, through development, execution and service through the life of the project.

SERVICE

Your Global Partner Have an tool from overseas?

No problem, DME SMART ONE valve gates are built on a common design platform that will fit, no matter where your mold is built.

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Valve Gate Hot Runner System

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Smart One

CONTACT US

Ø 6.00 Ø 30.00

Smart 12 Valve Gate Series Nozzle Sub-Assembly

1 NOZZLE HEATER WATTS

2 TC

3 TC RETAINER 2 PC.

4 SNAP RING (2-PCS)

A

60 70 80 90

PCPHT12060B PCPHT12070B PCPHT12080B PCPHT12090B PCPHT12100B PCPHT12110B PCPHT12120B PCPHT12130B

250 300 350 350 350 350 400 400

1

PNJTC10150A SMTCRC22 PSRSN12001A

2

100 110 120 130

A

3

4

Smart 15 Valve Gate Series Nozzle Sub-Assembly

Ø 8.00 Ø 36.00

1 NOZZLE HEATER WATTS

2 TC

3 TC RETAINER 2 PC

4 SNAP RING (2-PCS)

A

64 74 84 94

PCPHT15063B 300 PCPHT15073B 350 PCPHT15083B 400 PCPHT15093B 400 PCPHT15103B 400 PCPHT15113B 400 PCPHT15123B 450 PCPHT15133B 450 PCPHT15143B 450 PCPHT15153B 450

1

2

104 114 124 134 144 154

PNJTC10250A SMTCRC22 PSRSN15001A

A

3

4

Smart 19 Valve Gate Series Nozzle Sub-Assembly

3 TC RETAINER 2 PC

1 NOZZLE HEATER WATTS

2 TC

4 SNAP RING (2-PCS)

Ø 10.00 Ø 40.00

A

82 97

PCPHT19077B PCPHT19087B PCPHT19097B PCPHT19107B PCPHT19117B PCPHT19127B PCPHT19137B PCPHT19147B PCPHT19157B PCPHT19167B

400 450 550 700 800 850 850 900 950 950

112 127 142 157 172 187 202 217 232 247 262

1

PNJTC10250A SMTCRC23 PSRSN19001A

2

A

3

PCPHT19177B 1000 PCPHT19187B 1050 PCPHT19197B 1100

4

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Valve Gate Hot Runner System

4

Smart One

Smart 21 Valve Gate Series Nozzle Sub-Assembly

CONTACT US

3 TC RETAINER 2 PC.

4 SNAP RING (2-PCS)

1 NOZZLE HEATER PCPHT21082A PCPHT21097A PCPHT21112A PCPHT21127A PCPHT21142A PCPHT21157A PCPHT21172A PCPHT21187A PCPHT21202A PCPHT21217A PCPHT21232A PCPHT21247A PCPHT21262A

2 TC

A

WATTS

Ø 13.00 Ø 41.00

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650W 700W 750W 800W 850W 950W 950W 1000W 1000W 1050W 1050W 1100W 1100W

112 127 142 157 172 187 202 217 232 247 262

1

PNJTC10350A SMTCRC23 PSRSN21001A

2

A

3

4

Smart 24 Valve Gate Series Nozzle Sub-Assembly

3 TC RETAINER 2 PC.

1 NOZZLE HEATER WATTS

2 TC

1 SNAP RING (2-PCS)

Ø 16.00 Ø 45.00

A

82 97

PCPHT24082A 750 PCPHT24097A 850 PCPHT24112A 950 PCPHT24127A 1000 PCPHT24142A 1000 PCPHT24157A 1050 PCPHT24172A 1050 PCPHT24187A 1100 PCPHT24202A 1100 PCPHT24217A 1150 PCPHT24232A 1150 PCPHT24247A 1200 PCPHT24262A 1200

112 127 142 157 172 187 202 217 232 247 262

1

PNJTC10350A SMTCRC23 PSRSN24001B

2

A

3

4

Pneumatic & Hydraulic Cylinders

SERIES

D-DIA. REF.

SEAL KIT #

VALVE PIN TUNING PAD (Ø)

Smart 12

30 Series-A 30 Series-B

42mm 70mm

SM30ASK SM30BSK

PTPSC30025A (Ø11.5)

Smart 15

40 Series-A 40 Series-B

85mm 80mm

SM40ASK SM40BSK

PTPSC40025A (Ø12.0)

Smart 19

50 Series-A 50 Series-B

100mm 92mm

SM50ASK SM50BSK

PTPSC50025A (Ø14.0)

Smart 21

Tuning Pad resides under the valve pin head

65 Series-A

110mm

SM65ASK

PTPSC65025A (Ø16.0)

Smart 24

80 Series-A

128mm

SM80ASK

PTPSC80025A (Ø17.0)

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Valve Gate Hot Runner System

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Smart One

CONTACT US

Valve Pin Dimensions

Part Number

Ø D

Ø D1

L (mm)

Tuning Pad

P25VP40210A P25VP40260A P30VP40230A P30VP40280A P37VP40250A P37VP40280A P37VP40330A P57VP60270A P57VP60320A P57VP60370A P57VP60420A P57VP60450A P57VP80270A P57VP80320A P57VP80370A P57VP80420A P57VP80450A

210 260 230 280 250 280 330 270 320 370 420 450 270 320 370 420 450

2.5

PTPSC30025A

Ø D1

3

PTPSC40025A

4

3.7

PTPSC50025A

5.7

6

PTPSC65025A

7.7

8

PTPSC80025A

Ø D

Valve Pin Guide Bushings

Ø D

Systems

Part Number

D Dia.

D1 Dia.

SMART12

PGB121524

4

7

SMART15

PGB151927

4

8

SMART19

PGB191830

4

10

SMART21

PGB212034

6

13

PGB242335

8

16

SMART24

PGB242336

8

18

Ø D1

Pin Bushing Screws

Systems

Part Number

Thread

L

SMART12 SMART15 SMART19 SMART21 SMART24

PPCMF18015A

M18X1.5

15

PPCMF22013A

M22X1.5

13

PPCMF24015A PPCMF27015A

M24X2 M27X2

Thread

15

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