GÜNTHER Hot Runner Technology

Index
iT
Materials Page
3
Reference values for maximum throughput in cm /s 1.4. 2 + 3
Reference values for gate diameter 1.4. 4 + 5
Processing temperatures for common plastics 1.4. 6
Processing of POM, TPE, PP and shear-sensitive materials 1.4. 7
Gate point
Gate geometry, gate inspection 1.4. 10
Reworking the gate 1.4. 10
Gate diameters < 1,2 mm, reducing gate 1.4. 11
Vacuoles under the gate, gate for reinforced materials 1.4. 11
Potential error sources in the gate area 1.4. 12
Gating
Injection into an intermediate gate 1.4. 20
Gating into an angled surface 1.4. 20
Gating into a high gloss facing surface 1.4. 21
Part with a film hinge 1.4. 21
Hot runner nozzles

Nozzle length at room temperature, modified forechamber geometry, use of a titanium sleeve 1.4. 30
References values for screw sizes 1.4. 31
Designation/assignment of the cables 1.4. 32
BlueFlow product description 1.4. 33 + 34
OktaFlow assembly notes 1.4. 35
PektaFlow product description 1.4. 35
Extended nozzle tips, side gating 1.4. 36
Reference notes on a disassembly of a multi-tip nozzle 1.4. 37
Valve-gate technology
Commissioning of valve-gate system, operating pressure levels for drive mechanisms 1.4. 40
NEST single valve-gate nozzle assembly 1.4. 41
Drive mechanisms 1.4. 42
Notes on valve-gate needle / maintenance of the sliding cam mechanism 1.4. 43
Hot runner systems / manifolds

Manifolds 1.4. 50
Heater connections, straight / frame version 1.4. 51
Structural notices for air circulation and high-temperature applications 1.4. 52
Screw fastenings for _MT/_NT/_TT nozzles 1.4. 53
Manifold power calculation, correlation of cables 1.4. 54
Construction of the hot-runner system 1.4. 55
Complete mold halves hot halves 1.4. 56
Service program
CADHOC System-Designer 1.4. 60
Delta tool calculation program, application database 1.4. 61
Online-catalog, MoldCae/Moldflow analyse 1.4. 62
Seminars for users and designers 1.4. 63
www.guenther-hotrunner.com
1.4. 1
4/11 Subject to technical changes
iT 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 coun-
ter-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
Fig. Disassembly of a multi-tip nozzle 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).
1.4. 37
Subject to technical changes 4/11
Materials
iT
Reference values for maximum nozzle throughput per second The specified throughputs are re-
Nozzle length: 50/ 100 mm ference values. Considerable de-
viations for specific materials can-
not be excluded. We will be glad to
Low viscosity material: e. g. PA, PS, PP assist you with the selection of
channel .
120
Additional applications which have
100 already been implemented can be
Throughput in cm3/s
80 found in the application database on

our website
60 www.guenther-hotrunner.com
menu item: Application Database.
40
20
0
4 mm 5 mm 6 mm
Nozzle length 50 mm
Nozzle length 100 mm
Medium viscosity material: e. g. ABS, PPO
120
100
Throughput in cm3/s
80
60
40
20
0
4 mm 5 mm 6 mm
Nozzle length 50 mm
High viscosity material: e. g. Polycarbonate, Bayblend, Polysulfon
30
25
Throughput in cm3/s
20
15
10
5
0
4 mm 5 mm 6 mm
Nozzle length 50 mm
1.4. 2
iT Materials
The specified throughputs are Reference values for maximum nozzle throughput per second
reference values. Considerable Nozzle lengths: 60/ 100 mm
deviations for specific materials
cannot be excluded. We will be glad
to assist you with the selection of
channel .
Low viscosity material: e. g. PA, PS, PP
Additional applications which have
already been implemented can be 2500
found in the application database on 2250
our website 2000
www.guenther-hotrunner.com 1750
Throughput in cm3/s
menu item: Application Database. 1500

1250
1000
750
500
250
0
8 mm 10 mm 12 mm
Nozzle length 60 mm
Medium viscosity: e. g. ABS, PPO
2500
2000
Throughput in cm3/s
1500
1000
500
0
8 mm 10 mm 12 mm
Nozzle length 60 mm
High viscosity material: e. g. Polycarbonate, Bayblend,

Polysulphone
500
450
400
Throughput in cm3/s
350
300
250
200
150
100
50
0
8 mm 10 mm 12 mm
Nozzle length 60 mm
1.4. 3
Materials
iT
Determining the gate diameter for standard materials depending on Please note:
the part weight 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
Gate diameter
containing additives (flame retar-

dants, 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
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 1.2
D
0.8 0.8
D
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
Article weight g Article weight g
Material: PMMA Material: POM, PA 6, ABS
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 1.2
D
0.8
D
0.8
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
1.4. 4
iT Materials
Material: PBT Material: PA 6.6 (glas filled + 0.3 mm)
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 1.2
D
D
0.8 0.8
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
Material: PS Material: TPU, TPE
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 D 1.2
0.8
D
0.8
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
Material: PPO Material: SB, SAN
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 1.2
D
0.8 0.8
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
Material: PSU, PC Material: PP
2.8 2.8
mm
mm
2.4 2.4
2.0 2.0
1.6 1.6
1.2 1.2
D
D
0.8 0.8
0.4 0.4
0.1 1 3 5 8 10 100 1000 0.1 1 3 5 8 10 100 1000
Material: LCP
2.8
mm
2.4
2.0
1.6
1.2
D
0.8
0.4
0.1 0,5 1 3 5 8 10 100 1000
Article weight g
1.4. 5
Materials
iT
Processing window for common
Material Recommended Recommended plastics
processing temperature (C) WZ-temperatur (C)
PP 220 - 280 20 - 60
PE 220 - 280 20 - 60
PS 220 - 280 20 - 70
ABS 220 - 250 40 - 80
SAN 220 - 250 40 - 80
PA 6 240 - 250 40 - 60
PA 6.6 270 - 290 40 - 80
POM 205 - 215 60 - 120
PC 280 - 310 80 - 120
PMMA 220 - 250 40 - 90
PBT 245 - 270 60 - 80
ABS / PC 260 - 270 70 - 100
LCP* 300 - 345 80 - 120
PPS 310 - 340 140 - 145
PEEK 360 - 400 140 - 180
* depending on polymer-type
High temperature resistant

plastics
The performance pyramid High temperature resistant plastics
with processing temperatures
>300C:
PI PEK
High temperature resistant
plastics FP Liquid Crystal Polymer (LCP)
Polyphenylene sulphide (PPS)
Price / performance
LCP
(HDT > 150C) PES PEI
PAI
PPS Polyetherketone /
PAR PSU PA 46 PPA
Polyetheretherketone
Technical plastics PET (PEK/ PEEK)
PC
(HDT = 100 - 150C)
COC
PBT PA6.6 Polysulphone (PSU)
PPO POM Polyether-Imide (PEI) etc.
LFT
SAN ABS PMMA PP

Standard- PE-HD
plastics PS
SAN
PVC PE-LD
amorphous semy-crystalline
1.4. 6
iT Materials
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
D1
be used for nozzles with tip and for open nozzles. It must
D2 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
Fig. Gate design A and hot-runner nozzle with shear in the melt in the area of the injection gate is lower
nozzle piece version C than when a nozzle with tip is used.
Shear-sensitive materials
Gate design C
Single nozzles are mostly used when processing shear-
sensitive materials through an intermediate gate. The
gate design C is exclusively used for open nozzles with a
nozzle piece, version A.
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).
D2
D1
Fig. Gate design version C and hot-runner nozzle with

nozzle piece version A
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
55 reduced from 55 to 40.
2,5...3,5
This modified geometry must be ordered separately.
40
Fig.Tip geometry for polypropylene
1.4. 7
Gating
iT
Gating
The hot runner nozzles function is
essentially influenced by gate size
80 diameter D.
6,3
An enlargement of gate size must
H
d be done at an 80 angle. The edge
must be sharp to achieve clean
separation.
Note:
D The most frequented faults on
sharp-edged
commissioning a mould are due to
the incorrect design of the gate
geometry.
Fig. Gate geometry
Inspecting the gate

4,0
H [mm]
The correct position of the 80 angle

d= is inspected with a measuring ball.
4m
m
3,5
d=
3m
3,0 m
2,5
2,0
1,0 1,5 2,0 2,5 3,0

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
iT Gating
Reworking the gate

With gate diameters smaller than
D = 1.2 mm, the nozzle must
L + L + 0.02
beinstalled further back.
You will find a Delta Tool calculation
program on our homepage at
w w w. g u e n t h e r - h o t r u n n e r. c o m
available for download free of charge.
Fig. Nozzle installed in a retracted position
Reducing the gate diameter

The gate diameter cannot be
Within the framework of permissible processing arbitrarily reduced. The smallest
parameters, the smallest possible gate diameter means:
permissible diameter is dependent
on the material used.
tool temperature Furthermore, the gate size is also in-
small gate diameter fluenced by the mold temperature
and processing temperature.
processing temperature
Fig. Reducing the gate diameter
Vacuoles under the gate

Direct gating with a hot runner sys-
tem can produce vacuoles under the
gate.
This is the point at Remedy:
which the material Longer holding pressure time to
solidifies at last. 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 retar-
dants, heat stabilisers) 0.2 to 0.3 mm
larger. The same applies to multi-tip
nozzles.
1.4. 11
Gating
0.5
iT
At 250C 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: Problem:
- Higher vestige - The expanded nozzle closes the gate.
- No flow gap despite a larger gate
Fig. Cylindrical part at 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
iT
Correct injection into an interme-
diate gate
In order to obtain defined separation,
the aperture in the face surface of the
intermediate gate d should be
larger than D. This is particularly
true for reinforced thermoplastics
D (engineering plastics).
L
If possible, employ a catch pit in the
intermediate gate.
catch pits
d
1 mm > D
Fig. Injection into an intermediate gate
Gating into an angled surface

Direct gating into an angled surface
never results in an optimal gate point
with a small vestige. We therefore
advantageous recommend gating into a surface at
right angle to the nozzle axis.
advantageous
disadvantageous
Fig. Gating into an angled surface
1.4. 20
iT Gating
Reserve gating into a high gloss

Tempering 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.
The cooling circuit control must be

separated from the other tempering
Insert circuits.
Tempering
Fig. Reserve gating into a high gloss facing surface
Articles with a film hinge

When gating a part with a film hinge,
the gating point must be located
away from the surface center
Film hinge opposite to the film hinge. The flow
front may not come to a standstill
during the filling process. The film
hinge must be filled last.
Fig. Parts with a film hinge
1.4. 21
Hot runner nozzle
iT
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)
Z 0.02
is equal to:
Z = L + 0.5 - l (250)
l consequently depending on L
itself.
l is the temperature dependent
Fig. Nozzle length at room temperature longitudinal expansion of the
hot runner nozzle.
Modification of fore chamber

Standard
90 geometry
Fore chamber geometry can be
modified for special applications or
difficult-to-process materials (e. g.
V0-adjusted materials).
To avoid mistakes, we recom-
mend that you consult with our
application engineers.
Insulation gap
Enlarging the angle to 120
Increased angle The standard angle of 90 in the fore-
chamber can be widened to 120.
This will enlarge the insulation gap
120
between the hot runner nozzle and
the mold. The nozzle can be oper-
ated at a lower temperature so that
thermally sensitive material will not
be damaged.
Insulation gap
Attention!
Provide for adequate
wall thickness.
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
Reference values for screw sizes Example:

The centering flange and screws of Hot runner nozzle: 5SET50 (S = 22 mm)
single nozzles must absorb the Injection pressure: 2000 bar (200 N/ mm2)
emerging lift forces. Number of screws: 4
Screws and centering flange are to Reliability: 2-cavity
be appropriately dimensioned and
the pitch circle of the screws is to be Lift force on the hot runner nozzle:
kept as small as possible.
p F
=A
Guide values for screw selection can
taken from the table below. Tightening
torque MA for producing the screw D 2 (mm)
A =
connection must afford sufficient 4
pretensioning force Fv so that the
22 mm 2
required initial tension is still present A =
when under the influence of operating 4
force (i. e. operating force of the hot A = 380 mm 2
runner nozzle).
F = force F = p (N/ mm2) A (mm2)
Pretensioning force Fv should be a p = injection
factor 2 to 4 greater than the anti- pressure F = 200 N/ mm2 380 mm2
cipated operating force. Screws A = area of the
should be selected which are as nozzles shaft F = 76000 N
long as possible. Fges = 76000 N
Pretension Fv per screw:

Fges (N)
Fv = Sicherheit
Number of screws
76000 N
Fv = 2 (-fach)
4
Tightening torque for hot runner nozzles Fv = 38000 N per screw
Pretension Fv and tightening tor-que MA,
for screws with head beaning surfaces per Chosen screws in consideration of 2-cavity
DIN EN ISO 4762 and 4014. reliability.
Shaft screws ( ges. = 0.125) 4 x M10 - 12.9 je 45 kN per scres
Thread Maximum pretension FV in kN Maximum tightening torque MA in Nm

designation Property class Property class
10.9 12.9 10.9 12.9
Regular type
screw threads
M8 24 28 37 43
M10 38 45 73 84
M12 56 65 125 148
M16 105 122 315 370
M20 165 190 615 700
M24 235 275 1050 1250
Fine pitch
thread
M8x 1 26 31 40 46
M10x1,25 41 43 77 90
M12x1,5 59 69 132 155
M16x1,5 114 134 340 390
M20x1,5 188 220 680 800
M24x2 265 310 1150 1350
1.4. 31
Hot runner nozzle
iT
Power receptacle,
alternating 230 V
PE=earthed lead
N = Neutral lead
L = earthed lead
Thermoplug CMLK
Nozzle type:
- 8-10SET/DET Red = plus
- 5-12NEST
- 4-6SHT/DHT/NHT Blue = minus
- 8-16SLT/DLT Shield
- 8-12NLT
- 4-6SMT/DMT/NMT
Fig. Designation / correlation of cables
Power receptacle,
alternating 230 V
PE = earthed lead
N = Neutral lead
L = earthed lead
Thermoplug CMLK
Red = Plus
Blue = Minus
Nozzle type: Shield
- 4-6STT/DTT/NTT
- 4-6SMHT/DMHT
1.4. 32
Thickfilm heaters for hot-runner Further outstanding features are Hot runner nozzle heater
nozzles their high electric strength and Heater are pressed into a brass
BlueFlowGnther's new BlueFlow resistance to moisture. All in all, body. The heater is fixed in place by
technology incorporates several these four features are important the mechanical structure of the
advantages as compared to steps taken towards a more space- carrier body. The homogeneous
conventional heating methods: the saving, precise and energy-efficient brass body ensures optimal heat
heating elements are not only hot runner design and, therefore, a transfer from the heater to the
considerably smaller in diameter, more effective injection molding material tube, showing a highly
they also allow a substantially better process. reproducible temperature pattern.
temperature distribution and
accordingly, a quicker thermal
response.
Thermoplug CMLK
Shield
Blue = minus
Red = plus
Power receptacle,
alternating 230 V
Nozzle type:
- 5SEF/DEF PE=earthed lead
- SMF/DMF/NMF N = Neutral lead
L = earthed lead
18 mm
22 mm
Brass body with pressed-in heater BlueFlow Hot runner nozzle
Fig. Hot runner nozzle heater
1.4. 33
Hot runner nozzle
iT
High Quality. Blue. BlueFlow Example: Microfilter (automotive
The BlueFlow hot runner nozzle sector)
sets new standards for quality and Microfilter (outlet valve for an
design of parts made of thermally automotive application), injection-
sensitive plastics. This re-sults in molded in one process step from
better or even completely new unreinforced PA66. This method has
application possibilities, depending replaced the earlier procedure of
on the application area in different insert-molding of an available metal
sectors of industry. or plastic mesh to obtain a ready-to-
install component. The resulting
The thick film heater makes it FIg. Microfilter savings are dramatic: costs have
possible to adjust the heating ca- decreased by 60-80%, depending
pacity to the exact power requir- on the product.
ement in each single section over the
entire nozzle length in order to reach Details: thread size 0.13;
a homogenous temperature. 1848 gaps with 0.07 x 0.07 mm.
Passage surface approx. 9 mm2.
The plastic material in the material Max. allowed flash is 4.5 m.
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.
1.4. 34
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 Assembly of support Assembly of the hot-runner nozzle
Insert the star manifold and use 4 Insert the support and mount the lid Push the hot-runner nozzle (MT) in
hexagon socket head cap screws from the parting line. Note: the lid from the nozzle side!
M3x12 to fasten it to the sleeve-type must be solidly bonded to the insert.
heating.
Hot-runner nozzle PektaFlow

Number of tips: up to 24 tips, for side
multi-tip gating under 90 without
cold slug.
Be used as a single nozzle with
heated adaptor.
Hot-runner nozzle PektaFlow type PLT
are designed for challenging appli-
cations e.g. in medical technology
and packaging.
Direct injection onto the product
Divided inserts
Tips individually replaceable
Leading-edge area heated for
optimum temperature
development
Supported on floating bearings and
therefore independent of the ther
mal expansions
1.4. 35
Hot runner nozzle
iT
Without extended nozzle tip With extended nozzle tip 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
L +0.02
L1 +0.02
L1 +0.02
space constrained environments.
Shimmed Inserted
L1 +0.02
L1 +0.02
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 hori-
zontally!
Fig. Side gating under 90 without a cold slug
1.4. 36
Valve gate technology
iT
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
30C for another 30 minutes approximately. The valve
gate needles should be in the closed position here.
Before doing any disassembly, make sure the hot runner

is switched off. To prevent damage to the needle guide /
needle, the needles must be in the opened position.
Before putting the system into operation again, make
sure the needles are in the closed position again.
Connection values
Electric
Voltage 230 V~
System *
max. permissible operating
Fig. Valve gate system pressure in the hot-runner system 2000 bar
Commissioning the valve gate system *If special nozzles or other components with a pressure limit (less
than 2000 bar) are fitted to systems or individual tools, this situation
Before heating the nozzles and the manifold, switch on is documented in the height adjustment and on the type plate.
the mould temperature control. Hydraulic
Heating the hot-runner system: Single valve- gate nozzle 40 bar
- Heat the manifold with the controller unit's soft start
function. With the softstart function the manifold is Lifting plate mechanism 40-60 bar
heated to about 100C and held at this temperature Sliding cam mechanism 40-60 bar
for approximately 10 minutes.
- The nozzles and manifold must be heated evenly. Pneumatic
Heating the manifold to the target temperature can max. permissible operating
take up to 20 minutes. pressure in the hot-runner system 8 bar
The needle mechanism may be put into operation when Single valve gate nozzle mind. 8-10 bar
the hot-runner system reaches production temperature. Single needle valve 8 bar
The idle system must be held at production temperature Lifting plate mechanism 8-10 bar
for at least 10 minutes to ensure thermal stability. Sliding cam mechanism 8-10 bar
When putting into operation for the first time, several
injections may be necessary in order to fill the hot runner To attain the right needle speed (needle closing time 20-
completely with plastic. Until the parts are filled 40 ms / 7-10 mm travel), the valve must be designed to be
completely, the cavities must be checked after every large enough for the actuation (hydraulic/pneumatic).
cycle for parts that have not been filled completely. The connection hoses too must be dimensioned to suit
If the process is interrupted, the hot-runner temperature the flow volume.
must be lowered (depending on the material and The distance between the pressure generation and the
downtime by 100150C). The needles must be in the pressure consumption (mould) should be as small as
"closed" position. To prevent damage being caused to possible.
the gate bores / valve needles by cold material, the valve
needles may not be actuated when the injection Note!
moulding machine is being set up or during injection out The first filling of the hydraulic cylinders should be done
through the unit. If the melt is to be injected out through at a low speed or the cylinders should be deaerated.
the open mould / hot runner, the needles must be opened
during the injecting-through process and closed during
the dosing phase.
1.4. 40
iT Valve gate technology
Insulation ring
Steel piston ring, large
Marking XXX
Steel piston ring, small
Marking XXX
Power connection
Fixed thermo-
couple connection
Power connection
Needle closing
Fixed thermo-
couple Needle opening
Scew M10x1
Fig. Single valve-gate nozzle 12NEST

There are three 0.1-mm shims over / under the needle Inlet/ outlet pipes for activating the needle
head. It is preferable to use channels with diameters of 6 mm
Caution and a minimum length of 200 mm. The inlet and outlet
When assembling / dismantling the needle holder (A/F lines must be placed in the cooled mould plate in order to
10), care must be taken not to deform the steel piston prevent the medium overheating. If the mould
rings. Use the flat of the piston! It is essential to put the temperatures exceed the thermal stress capability of the
metal O ring back in after replacing the disk package. The pneumatic valves, a separately cooled manifold must be
piston and/or the steel piston rings must be greased installed. The mechanics of the needle drive and the
again before assembly (GNTHER recommends Klber valve gate nozzle are absolutely capable of withstanding
paste UH 196-402 [NSF registered]). high temperatures.
Furthermore, it is essential to ensure that the steel piston Note on guarantee
rings have been inserted correctly. The rings have a GNTHER guarantees nozzle type NEST only if they
marking (XXX) on the face surface, indicating the side have been fitted or serviced on GNTHER premises or
that must point towards the pressurised side. by a GNTHER specialist. GNTHER will not provide
Installation of the complete nozzle any guarantee for damage caused by the incorrect fitting
The cables for activating the needles are located at the of the steel piston ring operated nozzle type NEST by
bottom of the nozzle. Accordingly the centring ring can be the pur-chaser, its representatives or contractors.
produced as a bell. This measure makes it possible to The same applies to inappropriate or neglected
reduce the height of the mould. maintenance.
Screw centring with at least 4x M12 (10.9) 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.
1.4. 41
Valve gate technology
iT
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
GNTHER guarantees single needle valves only if they have been fitted or serviced on GNTHER premises or by a
GNTHER specialist. GNTHER 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 Sliding cam mechanism ANES

The lifting mechanism is recommendable for a precisely For narrow cavity spacing a sliding cam mechanism is the
simultaneous opening and closing of all needles. preferred drive.
Special holes in the mould clamping plate allow the Exact opening and closing of all needles.
down-stroke depth of the valve needles to be adjusted Special holes in the mould clamping plate allow the
individually from the outside. down-stroke depth of the valve gate to be adjusted
The maximum working temperature is 100 C. individually from the outside.
Maximum working temperature is 100 C.
1.4. 42
iT Valve gate technology
Notes on valve needles Maintenance

The needle length is dependent on the nozzle length, Sliding cam mechanismus -ANES-
type of actuation and manifold structure. The needles
have a basic hardness of 64 HRC (HSS steel) and are When fitting the sliding cam mechanism, use a high-
coated. The needles are fitted with a cylindrical seal temperature long-life grease to lubricate the movable
towards the cavity and are adjustable. parts. This allows the sliding cam mechanism to work
without any problems even at higher temperatures over a
The 2 mm needle design for nozzles with material long period of time. Make sure the mould temperature
tube- 4-6 mm, threads M6x 0,5 does not exceed 100 C in the area of the frame plate/
gate-: 0,8 mm, 1,0 m, 1,2 mm, 1,4 mm, (1,6 mm). clamping plate.
The 3 mm needle design for nozzles with material During maintenance the sliding cam mechanism must be
tube- 8 mm, threads M8 x 0,5 checked for dirt and wear. Melts that have exuded from
gate : 2,0 mm, 2,5 mm. the manifold sealing because of the stroke movement of
the needles must be removed. In older hot-runner
The 5 mm needle design for nozzles with material systems the sliding cam mechanism can be relubricated
tube- 10-12 mm, threads M10 x 0,75 through the ball impact holes (DIN 3410 Form F); in new
gate- : 3,0 mm, 4,0 mm. 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 Thread Tightening torque

MA [Nm]
2 mm M6 x 0,50 15
3 mm M8 x 0,50 30
5 mm M10 x 0,75 45 Fig. Fig.
Sliding cam mechanism Ball impact holes
with externally accessible
grease fittings
Type NEP
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
Type NHP 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
iT
V2
NEW: Sign up at www.guenther-hotrunner.com 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.
NEW: 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.
NEW: 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).
NEW: 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
iT 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 > 320C external
connectors are appropriate.
Fig. View: straight version

Fig. Internal heater Fig. External heater
connections connections
Frame plate / rail
Edges absolutely burr-free
Supporting plate /
cavity plate
Fig. Cable channel
Fig. View: frame version

Not recommended Recommended
Fig. Cable channel Fig. Cable channel
1.4. 51
iT
:
Attachment housing
Air circulation
Insulating plate
Clamping plate
Fig. Optimal air circulation Distance bolts
Manifold
Frame structure
Fig. Cross section of a mold - optimal air circulation
High temperature application

Special hot runner design is neces-
sary for plastics with processing
temperatures over 320C. This in-
cludes full insulation, external heater
connectors and high tempe-rature
resistant thermo-couples.
In the nozzle area it requires a fixed,

high temperature resistant thermo-
couple 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
Titanium washer
Screw M6,
M8, M10, (12.9)
depending on
manifold design
Nozzle type
_MT, _NT, _TT
Fig. Manifold with _TT nozzle type, screwed to the

parting line
Fig. Screw fastenings for _MT/_NT/_TT nozzles
Note: Advantages:
Hot runner nozzles of the _MT/_NT/_TT type are not For high number of cavities and tight pitch spacing
screw-fastened to the manifold. The system is started Easy front mounting of the nozzles -
with cold-state play. Please refer to the respective heat the mold can remain on the machine for maintenance
expansion table. In its cold state, the hot runner system Two fits provide a precise positioning to the pitch
has no positive seal between nozzles and manifold. distance
Operating temperature must first be reached in order to
Safety due to spatial and thermal separation of the
seal the system. Please provide for adequate screw
connecting cable from the manifold
fixation of the clamping plate towards the cavity plate
close enough to the manifold with at least 2x M10 per Protection against leakage by sealing the manifold
nozzle or, based on the length, 2x M10 per every 80 mm. from the cable channels om the cable channels
We recommend connecting with screws of the 12.9
property class.
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
iT
Manifold power calculation (230 V)
Power Voltage Current Approximate resistance

values to be measured in
Watt Volt A
Ohm [S]
2300 230 10 23.0

3680 230 16 14.375
1500 230 6.5 35.4
1400 230 6.1 37.7
1100 230 4.8 47.9
1000 230 4.4 52.3
750 230 3.3 69.1
500 230 2.8 82.1
630 230 2.2 104.5
500 230 1.8 127.8
400 230 1.4 164.3
250 230 1.1 209.1
600 (max.) 5 125 (max.) 0.1 - 0.2
600 (max.) 24 25 (max.) 0.2 - 0.4
P=UI Example:
R = U/I P = (230 V)2 / 23 Ohm
P = U2 / R P = 2300 W
PE earthed lead
Alternating current 230 V

Thermocouple
cable
Red = plus
Blue = minus
Fig. Manifold - correlation of cables
1.4. 54
Assembly of the manifold
1 2 3 4 5 6 7
24
9
22
10
23
21
11
SNT SMT SHT STT

20 12
19
11 12 10 18 17 16 15 14 13
Signs and symbols

1 PE-ground cabel connection, chap. 7 9 Manifold, chap. 4 18 Cylindrical pin to prevent twisting, chap. 4.1
2 Connection elements, chap. 6 10 Nozzle holding plate 19 Nozzle protrusion
3 Bores in the clamping plate 11 Cable channel 20 Nozzle lengt, chap. 2

to fix the nozzle
12 Cavity plate 21 Height of the nozzle head, chap. 2
4 Surface mounted thermocouple,
chap. 7 13 Hot runner nozzles, chap. 2 22 Manifold height
5 Pressure pads, chap. 8 14 High temperature insulating plate, optional 23 Installation height of the hotrunner
6 Heat expansion gap dimension K, 15 Gate bushing, chap. 2.2 24 Height of the pressure pad +
chap. 4.1 Heat expansion gap dimension K
16 Support piece, chap. 8
7 Clamping plate
17 Tempering
8 Air gap at the top and bottom
depending on tool position
1.4. 55
iT
Complete Hot Halves
The hot half is delivered as a nozzle-
side mold half without cavity plates.
The nozzle overhang over the sup-

porting 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
iT
Our comprehensive program of ser-
vices 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 GNTHER website you will

find many tools and programs to
make your work easier.
You can now configure your hot

runner system individually via the
GNTHER Internet platform. 3-D CAD
data including negative volume and
drawings are available for down-
loading 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 back-
ground 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. Register once on our Internet platform www.guenther-hotrunner.com and
you can then start the CADHOC V2 system designer to configure your own
This e-mail will contain a link to the individual hot-runner system.
product data for the configured hot
runner system.
Advantages of the new CADHOC system-designers version 2:
With its high functionality, the sys- optimised calculation of the nozzle size
tem is designed to suit the require- extensive choice of types of plastic
ments of our customers, first of all two different methods of configuration
designers of injection molds and - application-specific by entering processing parameters
sales personnel, to meet the desire - direct configuration without entering processing parameters
for quicker availability of complete shorter waiting periods during the configuration process
hot runner systems including nega-
tive volumes.
1.4. 60
iT Service program
Reworking the 1.2 mm gate

For gate diameters smaller than D
= 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
www.guenther-hotrunner.com under
the menu item Service available
for download free of charge.
Fig. Delta Tool calculation program
Application database
The application database is a pro-
gram for selecting from design pro-
posals 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 appli-
cations 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
Service program
iT
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 GNTHER 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 GNTHER on the basis of appli-
cation-specific rheologic calcu-
lations, with pressure drop, shear
and dwell time standing in the fore-
ground.
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
1.4. 62
iT Service program
Seminars for users and designers
Topics, such as layout, smooth

running operation and professional
maintenance of GNTHER hot runner
systems, are handled in a compre-
hensive 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
www.guenther-hotrunner.com 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 accom-
modation expenses,
no loss of working days!
See website
1.4. 63

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Index

Hot runner nozzles

Hot runner systems / manifolds

Reference notes on disassembly

80 found in the application database on

Medium viscosity material: e. g. ABS, PPO

High viscosity material: e. g. Polycarbonate, Bayblend, Polysulfon

menu item: Application Database. 1500

Medium viscosity: e. g. ABS, PPO

High viscosity material: e. g. Polycarbonate, Bayblend,

Gate diameter for fibre reinfor-ced

containing additives (flame retar-

Please contact us for all other types

Material: PC + ABS Material: PE

Material: PMMA Material: POM, PA 6, ABS

Material: PBT Material: PA 6.6 (glas filled + 0.3 mm)

Material: PS Material: TPU, TPE

Material: PPO Material: SB, SAN

Material: PSU, PC Material: PP

High temperature resistant

SAN ABS PMMA PP

Polyacetal (POM) and Thermo Plastic Elastomers (TPE)

It must be taken into account here that the injection gate

Fig. Gate design version C and hot-runner nozzle with

Parts made of Polypropylene (PP)

This modified geometry must be ordered separately.

Fig.Tip geometry for polypropylene

Inspecting the gate

The correct position of the 80 angle

1,0 1,5 2,0 2,5 3,0

Fig. Inspecting the gate

Reworking the gate

Fig. Reworking the gate

Reworking the gate

Fig. Nozzle installed in a retracted position

Reducing the gate diameter

Fig. Reducing the gate diameter

Vacuoles under the gate

At 250C the hot runner nozzle extends 0.5 mm into

Fig. Hot runner nozzle installed correctly

Potential error sources

Problem: - No sufficient insulation gap

Gating into an angled surface

Fig. Gating into an angled surface

Reserve gating into a high gloss

The cooling circuit control must be

Fig. Reserve gating into a high gloss facing surface

Articles with a film hinge

Fig. Parts with a film hinge

Modification of fore chamber

Using a titanium sleeve over the

Fig. Employment from a titanium sleeve

Reference values for screw sizes Example:

Pretension Fv per screw:

Thread Maximum pretension FV in kN Maximum tightening torque MA in Nm

Fig. Designation / correlation of cables

Fig. Designation / correlation of cables

Fig. Designation / correlation of cables

Brass body with pressed-in heater BlueFlow Hot runner nozzle

Fig. Hot runner nozzle heater

Hot-runner nozzle OktaFlow

Hot-runner nozzle PektaFlow

Fig. Use of nozzle with extended tip

Always specify the material to be