Husky HRPG en

Hot Runner
Product Guide
Version 5
Table of Contents
Page
1 General Hot Runner Information

1 Ultra Advantage
2 Hot Runner System
3 Nozzle Sizes
4 Melt Flow Index / Viscosity
5 Color Change Procedure
6 Hot Tip Nozzle Stacks
6 Key Advantages
7 Gate Quality Guidelines
8 Product Matrix
10 Gate Detail Dimensions
13 Pitch Spacing
15 Ultra 250 Hot Tip -Application Guidelines
19 Ultra 750 UP Hot Tip -Application Guidelines
21 Single Drops-Hot Sprue
22 Energy Savings Package (ESP) for Closures Hot Runners
23 Valve Gate Nozzle Stacks
23 Key Advantages
24 Gate Quality Guidelines
25 Valve Stem Actuation Options
26 Product Matrix
28 Gate Detail Dimensions
31 Pitch Spacing
37 Single Drops-Single Cavity Valve Gate
38 Ultra Helix™ Valve Gate
43 Valve Gate Air Circuit Recommendations and Machine Setup
44 Stack Hot Runners
44 Overview
45 Thermal Gate Consideration
46 Valve Gate Consideration
47 Split Sprue Bar
Table of Contents
Page
50 PRONTO®
50 Overview
51 Design for PRONTO®
58 FAQ
60 Ultra SideGate™
60 Overview
64 Ultra SideGate™-Application Guidelines
65 Ultra SideGate™ Angled
65 Ultra SideGate™ Inline
66 Specials
68 UltraSync™
68 Overview
68 Technology Comparison
70 UltraSync-E™
72 UltraSync™-H
73 UltraSync™-P
74 UltraSync-E™ with Altanium® Controller
77 UNIFY™
77 Overview
78 System Details
78 Installation Reference
80 Pitch Spacing
83 Stem Stroke
84 Bolted Manifold System
84 Overview
86 Installation Reference
89 Services
89 Flow Simulation
90 Refurbishment
92 General Altanium® Controller Information
92 Controllers Overview
94 Key Advantages
99 FTO (Finish to Order)
100 Dimensions
101 Operator Interface
101 Digital I/O Options
102 Delta3 and Matrix2 Hardware Overview
103 Advanced Features
Table of Contents
Page
106 H-Series Card

106 H-Series Card Configurations
107 H-Series Card Circuit Test Capabilities
109 H-Series Card Key Improvements
110 H-Series Card Reduced Footprint
111 H-Series Card Feature Comparison
113 Cables
113 Standard Cable Packages
116 Servo Control
116 Industry Trending Towards Electrification
117 Altanium® Servo Control Differentiation
118 Altanium® Servo Control Configurations
119 Altanium® Servo Control System Architecture
120 Altanium® Servo Control Screen Overview
124 Altanium® Servo Control Axes
125 Standard Motors and Actuators
126 Servo Motor and Actuator Feedback
127 Altanium® Servo Control Application Assessment
128 Altanium® Servo Control Motion Breakdown
129 Altanium® Servo Control Interface to Machine
130 Applications
130 Injection Molding Resin Grades
131 Gate Cooling
Ultra Advantage
UltraGuide® Wear Resistant Tips
General Hot Runner Information

• Reduced gate and stem wear • Improved longevity when
• Stem pre-aligned before gate processing abrasive materials
• Cylindrical shut-off
UltraSeal®
• Guaranteed leakproof operation
Wide Operating Window
• Less plate deflection
• Wide temperature ranges
• Preload nozzle to manifold without stringing or freeze-off
• Faster cycle times
• Robust seal-off
Ease of Maintenance
• Nozzle tips, thermocouples and
heaters are replaceable in the press
• Single O-ring operates in a cooled
backing plate for reduced
maintenance
Hot Runner Product Guide v 5.0 1

Hot Runner System
Electrical
Connector
Backing
Plate
Wire Clip
Manifold
Manifold T/C
Manifold
Bushing Air Line
Valve Stem Piston

Cylinder
Backup Pad
UltraSeal®
Locating
Ring
Manifold Plate
Sprue
Heater
Center Locating
Insulator
Sprue
Bushing
Nozzle Housing
Plate Cooling
Nozzle Heater
Tip Retainer Backup

Insulator Pad
Tip Insert
Manifold
Cavity Interface Heater
Tap
Drop Bolt
Guide Pin (Plate Bolt)
Plate
Alignment
Dowel
2 Hot Runner Product Guide v 5.0

Nozzle Sizes
L-Dim BL-Dim

L-Dim Range BL-Dim Range
Nozzle Size
Hot Tip Valve Gate Hot Tip Valve Gate
Ultra 1000
28- 300mm 29.3- 300mm 82 -320mm 82 -320mm

[1.10-11.81”] [1.15-11.81”] [3.22 - 12.59"] [3.22 - 12.59"]
Ultra 750 & Ultra Helix™ 750 (VG

only)
27.4- 290mm 27.4- 290mm 57 -305mm 64 -305mm

[1.08-11.41”] [1.08-11.41”] [2.24 - 12"] [2.51 - 12"]

only)
14–290mm 20 –290mm 70-305mm 85 -305mm

[0.55-11.41”] [0.78-11.41”] [2.75- 12"] [3.34 - 12"]

only)
17 –170mm 17–170mm 53 -185mm 53 -185mm

[0.6 - 6.69”] [0.6 -6.69 ”] [2.08 - 7.28"] [2.08 - 7.28"]
Ultra 250
13 –150mm 79- 165mm

N/A N/A
[0.51 -5.90 ”] [2.75- 6.49"]

Melt Flow Index / Viscosity
Resin Low Viscosity Medium Viscosity High Viscosity
ABS 14 1
CAP *
HDPE 68 1
LDPE 23 2
PC 25 5
PEI 18 2
PETG *
PMMA 24 1
PPA *
PPO 18 3
PS 40 2
PSU 20 5
PUR *
TPE *
PVC 20 3
SAN 27 4
TPO 41 2
LCP *
PA *
PBT *
PET *
POM 23 1
PP 53 2
PPS *
PBT/PC 15 5
PC/ABS 25 2
Bars represent typical Melt Flow Index ranges

* Resins with no numbers shown are not typically characterized with MFI values.

Color Change Procedure
Process:

Prepare the Machine
• Stop the machine and clean the material feed system
Ensure all traces of the original color are eliminated
• Purge the Barrel

• Use of a purge compound will reduce cleaning time
• Use natural (uncolored) resin if a purge compound is not suitable
• Use the new colored resin if neither of the above are suitable
Optimize color change process

• Increase the injection speed to the maximum value the system will allow
• Reduce the hold time and cooling time to the lowest levels possible
• Reduce barrel temperatures by 20°C (68°F) to 30°C (86°F)
• Increase manifold and sprue temperatures by 20°C (68°F) to 30°C (86°F)
• Increase nozzle tip temperatures by 20°C (68°F) to 30°C (86°F)
Run parts with new color

• After the color change is complete, return the temperatures on the Barrel and the
Hot Runner system to the standard processing temperatures
• Add new color to the material feed system if purge compound or natural
(uncolored) resin was used
• Adjust the injection speed to the standard parameter
• Start to produce parts with the new colored material
• Start production of new colored parts

Key Advantages
UltraSeal®
• 3 yr. guaranteed leakproof operation
• Pre-loads nozzle to manifold
• Minimizes plate deflection /bowing
Wide Operating Window

• Wide temperature ranges
without stringing or
freeze-off
• Faster cycle times
Wear Resistant Tip Inserts

• Optional wear resistant tip
for abrasive materials
Ease of Maintenance
• Tips, nozzle heaters & T/Cs
replaceable in the press
Hot Tip Nozzle Stacks

Gate Quality Guidelines

Factors Influencing Gate Quality
i. Tip style
ii. Tip position i
Tip / Gate iii. Tip land v ii

X
Variables iv. Gate diameter
iii
v. Gate land min 1-1.5X
iv vi
vi. Gate cooling
Flow balance
Manifold
Thermal balance
Variables
Melt channel sizing
Injection speed
Melt temperature
Processing
Mold temperature
Variables
Cooling time
Decompression
Performance Guidelines
Semi-Crystalline Materials
Vestige Height = 1/3 Gate Diameter
(POM, PA, PBT, PET, etc.)
Amorphous Materials
Vestige (PC, PS, ABS, PMMA, etc.)
Vestige Height = 1/2 Gate Diameter
Vestige Height=1/2 Gate Diameter or

Filled and reinforced materials
more
5% - 10% Occurrence: HDPE, POM
10% - 15% Occurrence: PA, LDPE
Stringing
15% - 20% Occurrence: PP, PS, PC, PMMA, ABS
General Guideline: Stringing can occur on any hot tip system

20% Occurrence with up to 3mm strings can be expected
Risk of stringing increases with faster cycle times

Product Matrix
Ultra 1000
Ultra 500
Ultra 250
Ultra 350
Ultra 750
Gating Style Application Overview
HT General purpose thermal gate.

Diverted Univerted Thruflow Suitable for most resins.
Three different tip styles
available depending on the P P P P P*
specific application (all share
common gate detail for each
nozzle series)
HT- X
(Extended) Extended thermal gate for
improved gate access.
Diverted Univerted Thruflow
Three different tip styles
available depending on the P P* P* P* X
a common gate detail for each
nozzle series)
HT-C Capped general purpose

(Cap) thermal gate. Typically applied
Diverted Univerted Thruflow on abrasive applications.
Offers simplified gate detail.
Three different tip styles X X P P P
available depending on the
a common gate detail for each
nozzle series)
HT-S6
Thermal gate for closure
applications.
X X X P X
Six hole tip to improve color
change for closure applications
TS
(Thermal Sprue)
Thermal sprue gate.
Typically used for Hot-to-cold

Standard Extra Stock applications.
Will mold sprue on the part.
X P P P P
Offers simplified gate
detail.
Extra Stock tip used for
contouring of tip
P P* X
Not all specific tip styles available
Standard Product Not Available
Contact Husky for more information

Product Matrix (continued)
Ultra 1000
Ultra 500
Ultra 250
Ultra 350
Ultra 750
Gating Style Application Overview

SG
(Ultra SideGate™)
Horizontal thermal gate.
Small parts, gate externally
X X X P X
on the side, generally small,
long and cylindrical
SG Angled
(Ultra SideGate™) Angled thermal gate.
on the side, generally small, X X X P X
SG Inline
(Ultra SideGate™) Horizontal or Angled
thermal gate.
X X X P X
on the side, generally small,
HT-UF
(UltraFlow®)
Mixing tip thermal gate.
Improved color change for X X X P X
PP and PE applications
UP
(Ultra Packaging)
Packaging thermal gate.
Used for high pressure, fast
X X X P X
cycle, packaging
applications.
UP-X
(Ultra Packaging Extended)
Packaging extended
thermal gate for improved
gate access. Used for high X X X P X
pressure, fast cycle,
packaging applications.
P X
Standard Product Not Available

Gate Detail Dimensions
Gate Detail Dimensions (mm [in])
Tip
Size A B C D E F Gate Detail
Style
A
HT-D B
Ultra 12.5 7.0 7.6 3.4
HT-U — —
250 [0.49”] [0.2756”] [0.30”] [0.13”] C
HT-T
D
AA
B
BB
Ultra HT-DX 12.5 7.0 20.1

— — — CE
250 HT-TX [0.49”] [0.2756”] [.79”]
AA
HT-D BB
Ultra 16.0 8.00 8.3 3.474
HT-U — —
350 [0.63”] [0.31”] [0.33”] [0.137"] C
HT-T
D
A
B
Ultra HT-DX 16.0 8.00 21.8 3.474
— —
350 HT-UX [0.63”] [0.31”] [.86“] [0.137"] C
D
A
B
Ultra 16.0 11.0 9.5 5.71 4.905 3
TS
350 [0.63”] [0.43”] [0.374”] [0.225"] [0.19"] [0.118"] D C
E F
AA
HT-D
Ultra 23.8 10.012 7.0 3.93
HT-U — — B
500 [0.94”] [0.394”] [0.28”] [0.155"]
HT-T D
D C
AA
Ultra 23.8 10.012 17.0 7.1
HT-DX — — BC
500 [0.94”] [0.394”]] [0.67”] [0.28"]
C E
AA
HT-DC BB
Ultra 23.8 14.00 6.40 3.25 9.005 1.50

HT-TC F
500 [0.94”] [0.551”] [0.252”] [0.128"] [0.354”] [0.059”] E
HT-UC
EC
D
C
A
A
Ultra 23.8 6.67 4.905 3.00

TS — —
500 [0.94”] [0.263"] [0.193”] [0.118”]
F
D
C
E
* Flexible measurement to be confirmed with original gate detail drawing

Additional gate sizes available upon review

Gate Detail Dimensions (continued)

Size Tip Style A* B C D E F G Gate Detail
A
A
HT-D B
B
Ultra HT-U 31.0 21.0 13.5 5.34 14.01 9.1

—
750 HT-T [1.22”] [0.83”] [0.531”] [0.210”] [0.5516”] [0.358”] CD
HT-UF G
D E
C
A
B
Ultra 31.0 21.0 25.0 5.34 13.80 21.10
HT-DX — C
750 [1.22”] [0.83”] [0.984”] [0.210"] [0.543”] [0.831”] D
D
E G
G
AA
HT-DC BB
Ultra 31.0 21.0 13.0 14.005 3.50

HT-TC — —
750 [1.22”] [0.83”] [0.512”] [0.5514”] [0.138”] F C
D
HT-UC
EC
AA
Ultra 31.0 8.5 9.005 4.2

TS — — —
750 [1.22”] [0.33”] [0.3545”] [0.165”] C
F E
AA
Ultra 31.0 19.06 26.0 11.28 BB
HT-S6 — — —
750 [1.22”] [0.7504”] [1.02”] [0.444"] CD
D
C
Ultra 16 7 6.38 4.234
SideGate — — — A B
750 [0.63’] [0.27”] [0.25”] [0.167"]
D
C
Ultra SideGate 16 7 8.38 5.134
— — — B
750 (Angled) [0.63’] [0.27”] [0.33”] [0.202”] A
D
C
Ultra SideGate 16 7 6.38 4.234
— — — A B
750 (Inline) [0.63’] [0.27”] [0.25”] [0.167"]
D
AA
Ultra
750 HT-D
31.0 19.06 26.0 11.28
— — —
BB
[1.22”] [0.750”] [1.02”] [0.444"] CD
UP
D
* Effective interfacing diameter on manifold plates is 35 mm [1.377"]

Gate Detail Dimensions (continued)

Tip
Size A* B C D E F Gate Detail
Style
AA
BB
Ultra
31.0 19.06 32.8 22.8
750 HT-DX — —
[1.22”] [0.750”] [1.29”] [0.9"] C
UP
DE
A
A
Ultra HT-D 42.0 18.010 13.0 6.30 BB
— —
1000 HT-T [1.65”] [0.709”] [0.51”] [0.248”]
D C C
AA
Ultra HT-DC 42.0 20.008 5.75
— — —
1000 HT-TC [1.66”] [0.787”] [0.226”]
FD EB
AA
Ultra 42.0 11.0 5.25
TS — — —
1000 [1.65”] [0.433”] [0.207”]
FD E
* Effective interfacing diameter on manifold plates is 35 mm [1.377”] (Ultra 750 only)


Pitch Spacing

Nozzle
Guidelines Min Pitch Layout
Size
Ultra
250
Minimum pitch dependent on melt channel size
and may require the use of a tight pitch manifold
bushing (Ultra 250 only)
R 31.8mm*
The sprue min radius is 31.8mm [1.25”] Y [1.25"]
The min drop-to-drop pitch is 18 mm [0.71”]

18mm
X and Y min distance must be greater than 45.0 [0.71"]
mm [1.77”]
Ultra
350
X 18mm
[0.71"]
The sprue min radius is 32.0 mm [1.26”]

R 32mm*
Ultra Y [1.26"]
The min drop-to-drop pitch is 25.4mm [1.00”]
500
X and Y min distances must be greater than 45.0
mm [1.77”]
25.4mm
[1"]
25.4mm
[1"]
* Plunger style sprue bushing requires additional spacing. Review required
• Pitch shown is minimum and is based on minimum melt channel sizing. Specific part, resin, and filling
requirements could dictate a larger pitch spacing requirement than shown
• Minimum distance between the outermost nozzle drop center to the outer side edge of the manifold
plate is 71mm [2.79”] (If reduced distance is required, contact Husky)
- For non-PRONTO® systems Husky review recommended for distance less than 100mm [3.93”]
• Minimum distance between the outermost nozzle drop center to the outer top and bottom edge of
the manifold plate is 96mm [3.77”]. (If reduced distance is required, contact Husky.)
• Systems greater than 16-drops layouts at minimum pitch spacing need to be reviewed by Husky
• Nozzles can be grouped in maximum clusters of 8 (except for Ultra 1000)
• Tighter pitch layouts may be available, contact Husky

Pitch Spacing
Nozzle
Guidelines Min Pitch Layout
Size
R 40.4mm*
[1.6"]
X
Ultra
750
The sprue min radius is 40.4 mm [1.60”]
The min drop-to-drop pitch is 44.5mm [1.75”] Y

For < 8 drops X and Y must be > 57.5 mm [2.26”] 44.5mm
[1.75"]
Ultra
750 UP
44.5mm
[1.75"]
61mm
[2.4"]
The sprue minimum radius is 50.0 mm [1.97”]

R 50mm*
Ultra
The min drop-to-drop pitch is 61mm [2.40”]
Y [1.97"]
1000
X and Y must be greater than 70.7 mm [2.80”]
X
• Minimum distance between the outermost nozzle drop center to the outer side edge of the manifold plate
is 71mm [2.79”] (If reduced distance is required, contact Husky)
• Minimum distance between the outermost nozzle drop center to the outer top and bottom edge of
the manifold plate is 96mm [3.77”]. (If reduced distance is required, contact Husky.)
• Systems greater than 16-drops layouts at minimum pitch spacing need to be reviewed by an Husky
• For Tip-to-Tip Spacing see Ultra SideGate™ section
(If Tip-to-Tip spacing is not a constraint for pitch spacing use Ultra 750 Thermal pitch spacing for Ultra Side-
Gate™)
• For UNIFY™ pitch spacing see UNIFY™ section

Ultra 250 Hot Tip -Application Guidelines
Max Throughput (g/sec.)

HT-D HT-T HT-U HT-DX HT-TX
Low 10 10 10 6 10
Viscosity Medium 4 4 4 2 4
High 1 1 1 1 1
Material Compatibility
HT-U
Resin HT-D HT-T STD WR HT-DX HT-TX Resin Structure
Abrasive
   P  
ABS P P P  A
¯ ¯
Color Change P ¯ ¯  ¯ ¯
LCP SC
  ¯ ¯  
PA P  SC
¯   
PA(33% GF) SC
  ¯ ¯  
PBT SC
  ¯ ¯  
PC P ¯ A
¯  ¯ 
PE P P P  P P SC
PET SC
  ¯ ¯  
PETG A
  ¯   
PMMA A
¯  ¯   
PP P P SC
¯ ¯  ¯
PPO(PPE+PS/PA) B
  ¯   
PS P P P  P P A
SAN P P P  A
¯ ¯
TPE P P  A
 ¯ 
TPUR P A
¯ ¯  ¯ 
P– Recommended ¯– Requires Review – Not Recommended

SC– Semi-Crystalline B– Blend A–Amorphous
• Independent temperature control is required for all Ultra 250 tips (group control is not supported)
• Minimum T = 140˚C [284˚F] (melt to mold temperature)
• HT-DX gating not acceptable for resins with MFI < 5
• HT-T and HT-TX gate diameter must be > or = 0.8mm [.03”]
• HT-U standard (STD) tips are not recommended if heat sensitive additives are used for very heat
sensitive resins

Ultra 350 Hot Tip -Application Guidelines
HT-D HT-T HT-U HT-DX HT-UX TS

Viscosity Low 15 15 15 15 15 15
Medium 8 8 8 8 8 8
High 3 3 3 3 3 3
HT-D Resin
Resin HT-T HT-U HT-DX HT-UX TS
Std. WR Structure
Abrasive
 ¯     
P ABS P ¯ ¯ ¯ ¯ P A
Color Change P P ¯ ¯ ¯  P
Flex. PVC
¯ ¯     ¯ A
¯ PA ¯  ¯   ¯ SC
PA (33% GF)  ¯      SC
PBT ¯ ¯  ¯   ¯ SC
PBT/PC ¯ ¯  ¯   ¯ B
PC
¯ ¯  ¯   ¯ A
PC/ABS ¯ ¯  ¯ ¯ ¯ ¯ B
PE P P P P ¯ ¯ P SC
PEI ¯     ¯ A
PET  ¯     ¯ SC
PETG ¯ ¯  ¯    A
PMMA ¯ ¯  ¯   ¯ A
POM ¯ ¯  ¯   ¯ SC
PP P P ¯ P ¯ ¯ P SC
PPO (PPE+PS/PA) ¯ ¯ ¯ ¯   ¯ A/SC
PS P P  P P P ¯ A
PSU  ¯     ¯ A
SAN P P  ¯ ¯ ¯ ¯ A
TPE P P  ¯ ¯ ¯ ¯ A
TPO P P  P ¯ ¯ ¯ A
TPUR P P ¯ ¯ ¯ ¯  A


Ultra 500 Hot Tip-Application Guidelines

HT-D HT-T HT-U HT-DX HT-DC TS
Viscosity Low 16 16 16 16 16 30
Medium 10 10 10 10 10 20
High 3 3 3 3 3 12
Resin HT-D HT-T HT-U HT-DX HT-DC TS Resin Structure
Abrasive P  P ¯ P P
ABS P  P P P P A
Color Change P P   P P
Flex. PVC ¯ ¯ ¯ ¯ ¯ ¯ A
PA P  P ¯ P ¯ SC
PA (33% GF) P  ¯  P ¯ SC
PBT ¯ ¯ ¯ ¯ ¯ ¯ SC
PBT/PC ¯  ¯ ¯ ¯ ¯ B
PC ¯  ¯  ¯ P A
PC/ABS P  P ¯ P P B
PE P P P P P P SC
PEI ¯ ¯ ¯ ¯ ¯ ¯ A
PETG     ¯  A
PMMA ¯  ¯ ¯ P ¯ A
POM ¯   ¯ ¯  SC
PP P ¯ P P P P SC
PPO (PPE+PS/PA) ¯ ¯ ¯ ¯ ¯ ¯ A/SC
PS P  P ¯ P ¯ A
PSU P  P ¯ ¯ ¯ A
SAN P  P ¯ ¯ ¯ SC
TPE P  P ¯ ¯ ¯ A
TPO P  P ¯ ¯ ¯ SC
TPUR ¯  ¯ ¯ ¯  SC

• Special purpose tip inserts required for process temperatures above 325°C [617°F] and resins with
an abrasive filler i.e. glass, mica, mineral, and carbon fiber
• Stainless Steel retainer required for process temperatures above 325°C [617°F]

Ultra 750 Hot Tip-Application Guidelines
HT-D HT-T HT-U HT-DX HT-DC TS HT-S6 HT-UF
Low 175 175 175 175 175 350 175 175
Viscosity
Medium 80 80 80 80 80 250 80 80
High 40 40 40 40 40 60 40 40
Structure
HT-D HT-T HT-U HT-DX HT-DC HT-UF
Resin
Resin STD WR STD WR STD WR STD WR STD WR TS HT-S6 STD WR
Abrasive  P  P  P  P  P P   
ABS P P P P P P P P P P P  P P A
Bev Closure ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ P ¯ ¯
CAB ¯ ¯       ¯ ¯ ¯    A
Color Change P P ¯ ¯     P P P P P P
Flex. PVC ¯ ¯         ¯    A
PA P P P P ¯ ¯   P P P  ¯ P SC
PBT ¯ ¯       ¯ ¯ P  ¯ ¯ SC
PBT/PC P P       ¯ ¯ ¯  ¯ ¯ SC
PC P P       P P P  ¯ ¯ A
PC/ABS P P P P ¯ ¯   P P P  ¯ ¯
PE P P P P P P P P P P ¯ ¯ P P SC
PEI ¯ ¯       ¯ ¯ ¯    A
PETG         ¯ ¯ ¯    A
PMMA P P ¯ ¯ P P P P P P P  ¯ ¯ A
POM P P P P     ¯ ¯ ¯  ¯ ¯ SC
PP P P ¯ ¯ P P ¯ ¯ P P P P P P
PPO P P P P P  A/SC
       
PPS ¯ ¯       ¯ ¯ ¯    SC
PS P P P P P P P P P P ¯ ¯ P P A
PSU ¯ ¯       ¯ ¯ ¯    A
SAN P P P P     P P ¯  P P A
TPE
P P P P P P P P P P ¯  P P A
TPO
P P P P ¯ ¯ ¯ ¯ P P ¯  P P A
TPUR P P ¯ ¯     P P   P P A

• Wear resistance is the preferred tip for abrasive and high temperatures above 325°C [617 °F]
• For Ultra SideGate™ information please see Ultra SideGate™ section

Ultra 750 UP-Application Guidelines

UP HT-D UP HT-DX
Low 300 300
Viscosity
Medium - -
High - -
Resin UP HT-D UP HT-DX Resin Structure
PE P P SC
PP P P SC
PS P P A
P – Recommended ¯ – Requires Review  – Not Recommended

SC – Semi-Crystalline B – Blend A – Amorphous
• High speed, high pressure packaging nozzle

• Uses 750 Series gate detail

Ultra 1000 -Application Guidelines
HT-D HT-T HT-DC TS
Low 350 350 350 750
Viscosity Medium 150 150 150 350
High 50 50 50 90
Resin
Resin HT-D HT-T HT-DC TS
Structure
Abrasive ¯ ¯ P P
ABS P  P ¯ A
Color Change   P P
PA P  P P SC
PA(GF) ¯ ¯ P P SC
PBT ¯ ¯ ¯ P SC
PBT/PC ¯  P P B
PC ¯  ¯ P A
PC/ABS ¯  P P B
PE P P ¯ P SC
PETG  ¯ ¯  A
PMMA ¯  ¯ P A
POM ¯  ¯ ¯ SC
PP P ¯ P P SC
PP (TALC) P ¯ ¯ ¯ SC
PPO(PPE+PS/PA) P ¯ ¯ ¯ A/SC
PS P  P P A
SAN P  P ¯ A
TPE/TPO ¯ ¯ ¯  A

• Wear resistant tips required for process temperature above 325°C [617°F] and resins with an
abrasive filler i.e. glass, mica, mineral, and carbon fiber

Single Drops-Hot Sprue
 25.75mm [1.01”]

Locating Ring
Band heater
Sprue bushing
Locating insulator
Nozzle housing
Nozzle heater
Nozzle tip insert
PL
Nozzle tip retainer
• Available in all sizes

BL
• Full range of thermal gating options
• Ideal for low volume or prototype
purposes
1
2
3
D3 D2 D1 4
• Installs direct into platen side of the ‘A’ side plates
D5 D4 • Relief bore depth “D1” mat vary to accommodate

standard nozzle housings
This dimension is dependent on the size of the nozzle
* Please note there is a longer lead time for XL dimensions
Max Max
Nozzle D1 Min Max Min Max
size
1 2 3 4 5 D2 D3 D4 D5 XL* XL*
Max PL PL BL BL
PL BL
Ultra 97.01mm 63mm 34.12mm 15.1mm 87mm 203mm 64mm 160mm

250
- - N/A N/A
[3.819"] [2.48"] [1.343"] [0.594"] [3.42"] [7.99"] [2.51"] [6.29"]
Ultra 97.01mm 63mm 40.52mm 15.1mm 58mm 214mm 34mm 170mm

350
- - N/A N/A
[3.819"] [2.48"] [1.595"] [0.594"] [2.28"] [8.42"] [1.33"] [6.69"]
Locating
Ring
Relief
Ultra (Dependent 97.01mm 63mm 40.52mm 27mm 16.8mm 5mm 15.1mm 3mm 2.5mm 55mm 170mm 300mm 31mm 130mm 270mm
500 on Locating [3.819"] [2.48"] [1.595"] [1.063"] [0.661”] [0.197"] [0.594"] [0.118"] [0.093"] [2.16"] [6.69"] [11.81"] [1.22"] [5.11"] [10.62]
Ring dia.
Selected)
Ultra 97.01mm 70mm 53.02mm 22.15mm 69mm 185mm 320mm 39mm 138mm 275mm
750
- -
[3.819"] [2.756"] [2.087"] [0.872"] [2.71"] [7.28"] [12.59"] [1.53"] [5.43"] [10.82"]
Ultra 97.01mm 70mm 58.02 17.93mm 97mm 233mm 71mm 190mm

1000
- - N/A N/A
[3.819"] [2.756"] [2.284"] [0.706"] [3.81"] [9.17"] [2.79"] [7.48"]

Energy Savings Package (ESP) for Closures Hot
Runners
Value
• Specifically designed for the closure market (MW, CSD, beverage closures in general,
overcaps usually molded with the HT-S6 nozzle)
• Help to reduce heat loss from largest sources of the hot runner resulting in energy savings
• Similar performance
• Key dimensional differences:
-- Nozzle bore relief increased to 37mm [1.45"] (Std 31mm[1.22"]) to have full benefit
of energy savings
-- Nozzle pitch increase to 50mm [1.96"] (Std 44.5mm [1.75"])
-- HR shut height increase by up to 16mm [0.62"]
-- L-dim:
• Up to 60mm [2.36"] (nozzle housing length 120mm [4.72"] max).
• Preferred value: L-dim 30mm or 40mm (nozzle housing length 90mm [3.54"]
and 100mm [3.93"] respectively)
Benefits
• Up to 30% energy savings over standard hot tip (HT-S6) applications
• Minimal impact on mold design (check possibility to increase heater bore relief to 37mm
[1.45"] in the gate insert)
• Similar processing window
• Similar heat up time
• Similar color change performance as standard
Features
6
1.) Low conduction nozzle insulator 10mm [0.39"] longer
housing typically required

2.) Modified nozzle housing
7 3.) Larger nozzle bore (37mm [1.45"]) Ø31mm [1.22"] std
1
4.) Increase clearance on gate insert
5.) Short UNH heater (30mm [1.18"]) 70mm [2.75"] std
3
6.) 14 mm [0.55"] height back-up pad 10mm [0.39"] std
2
7.) 7 mm [0.27"] bottom manifold clearance 5mm [0.19"] std
5
Standard ESP
HT-S6 HT-S6

Key Advantages
Ease of Maintenance
Valve Gate Nozzle Stacks

• O-ring replaceable without pulling valve stems
• Double Delta O-ring in cooled backing plate
doubles seal life
• Tips, nozzle heaters & T/Cs replaceable in the press
UltraSeal®
• 3 year guaranteed leakproof operation
• Pre-loads nozzle to manifold
• Minimizes plate deflection / bowing
UltraGuide®
• Valve stem pre-aligned before gate
• Reduced gate / stem wear
• Thermally conductive component for fast start-up
• Cylindrical (Plunger) shut-off for improved gate quality
Valve Gate Stem Shut-off Options
• 0˚ shut-off
• UltraGuide® technology pre-aligns stem to
Cylindrical gate, minimizing gate wear
(Plunger)
• Superior gate quality for non-abrasive resins
• Requires higher manufacturing tolerances
• 40˚ shut-off
• Gate geometry used to align valve stem
Taper
• Requires more strength in gate area to
avoid premature cracking
Plunger vs. Taper General Stem Shut-Off Guideline

Plunger
Description (Whenever possible Husky will use a Taper
plunger stem shut-off)
Gate Quality Expectations Best Good

Gate Quality vs. Cycle Time Gate Cycle
Mfg. Tolerance Requirements High Medium
Wall Thickness in Gate Area Thick Thin
Crack Development in Gate Area Unlikely Potential

Gate Quality Guidelines
Factors Influencing Gate Quality
Gate detail tolerances Shut-off Style
Gate wear
Gate cooling
Tip / Gate
Variables Shut-off style
Stem position / length
Gate diameter / land Taper Plunger
Flow balance
Manifold
Thermal balance
Variables
Melt channel sizing
Stem open/close
timing
Pneumatic pressure
Injection speed
Processing Melt temperature
Variables
Mold temperature
Cooling time
Decompression
Hold time
Performance Guidelines
Vestige Standard gate detail tolerance Vestige Height < 0.1mm**
Stem Stick- Cycle time > 5 seconds No sticking

ing
Cycle time < 5 seconds Contact Sales Support Husky for review
Contact Sales Support Husky for review
3M Cycles (est.)***
Gate Life Husky guidelines must be fol- Provide gate and concentricity measurements
lowed
Collect samples from first shots after start-up
** Vestige will vary based on the above factors, this value represents what would be considered a top performing,
optimized system
*** Gate life will vary based on the above factors, this value represents what would be considered a top performing,
optimized system

Valve Stem Actuation Options

Nozzle Sizes
Actuation Key points
Available
• Double Delta O-ring design for ease

of maintenance
Ultra 350
SX • Up to 200psi (13.8bar) air pressure may
Ultra 500
(Small be required for proper operation of SX
valve gated systems Ultra Helix™ 350
Pitch)
Ultra Helix™ 500
• Insufficient air pressure provided to SX
piston can lead to stems seizing, sticking,
and/or posting on the molded part
Ultra 350
Ultra 500
LX • Double Delta O-ring design for ease Ultra 750
(Standard) of maintenance Ultra Helix™ 350
Ultra Helix™ 500
Ultra Helix™ 750
Ultra 350
Ultra 500
EX (Large Ultra 750
of maintenance
Piston) Ultra Helix™ 350
• Used for high stem force applications
Ultra Helix™ 500
Ultra Helix™ 750

Ultra 1000 of maintenance Ultra 1000
• Pneumatic actuation
• Min drop-to-drop pitch= 18mm [0 .70”] Ultra 350

(U350) Ultra 500
UltraSync™ Ultra 750
• All standard valve gating styles
Plate
• Actuation drive designs Ultra Helix™ 350
Actuation
-- Electric (Servo Motor) – UltraSync-E™ Ultra Helix™ 500
-- Hydraulic – UltraSync™-H Ultra Helix™ 750
-- Pneumatic – UltraSync™-P
• Allows for easy access to back end valve

gate components
• O-rings, cylinder caps, pistons and stems
accessible in the press without removing
Air Plate backing plate All
• Limiting factor for tight pitch applications
• Individual drop airplate or multi-drop
airplates are available

Product Matrix
Ultra Ultra Ultra
Ultra Ultra Ultra Ultra
Application Helix Helix Helix
Gating Style 350 500 750 1000
Overview 350 500 750
T P T P T P T P T P T P T P
VG
General purpose valve

gate. Suitable for most P P P P P P P X X X X X X X
resins
VG-R (Retrofit)
General purpose valve
gate for retrofitting
into 750 Series VG
X X X X P P X X X X X X X X
gate details
VX General purpose valve

gate with gate shutoff
within the nozzle tip.
Typically P P P P P P P X X X X X X X
applied on abrasive
applications. Offers
simplified gate detail
VG-X (Extended)
Extended valve gate

for improved gate X X P P X X X X X X X X X X
access
VG-XX
(Double Extended)
Double extended
X X P P X X X X X X X X X X
valve gate for im-

proved gate access
VG-HP
(High Pressure) Single piece valve gate
nozzle tip and housing
for high pressure
applications. (Only for X X P P X X X X X X X X X X
Ultra 500)
Typically used for
Telecom
P X T P
Standard Product Not Available Taper Plunger

Product Matrix
Ultra Ultra Ultra

Ultra Ultra Ultra Ultra
Helix Helix Helix
Gating Style Application Overview 350 500 750 1000
350 500 750
T P T P T P T P T P T P T P
VX-HP
(High Pressure) Valve gate with gate
shutoff within the nozzle
tip. For high pressure
applications. Typically
X X X P X X X X X X X X X X
used for Telecom. Offers
simplified gate detail
VX-X Extended VX for

(Extended) increased gate access
and/or customization of
the contact land.
Typically applied on
X X X X X X P X X X X X X X
Automotive applications.
Offers simplified gate
detail
VX-X XS
(Extended Extra Stock)
Extended VX with extra
stock for increased gate
access and tip contour- X X X X X X P X X X X X X X
ing. Typically applied on
Automotive applications
VX-XS
(Extra Stock)
Extended VX with extra

stock tip for contouring
X X P X P P P X X X X X X X
VG-UF
(UltraFlow®)
Mixing tip valve gate.
Improved color change X X X X P P X X X X X X X X
for PP and PE applications
VR
(Ultra Helix™)
Excellent gate quality

with precise stem X X X X X X X X X P X P X P
alignment.
VG
(Ultra Helix™)
Excellent gate quality

with gate hole included X X X X X X X X X P X P X P
in tip
P X T P
Standard Product Not Available Taper Plunger


Std.
Tip
Size A B C D E F Gate Detail Gate
Style
Dia
A
A
Ultra 16.0 8.00 8.3 2.6

VG-P — — CC
350 [0.63”] [0.31”] [0.33”] [0.10”]* 1.0
D BB
B
[0.039”]
1.2
[0.047”]
AA 1.5
Ultra 16.0 8.00 8.3 3 BB [0.059”]
VG-T — —
350 [0.63”] [0.31”] [0.33”] [0.12”]* CC
D
A
Ultra 16.0 11.0 6.5 4.22 4.905 1.5 B
VX-P
350 [0.63”] [0.43”] [0.26”] [0.16”] [0.19”] [0.059"] D C
E F 1.5
A [0.059”]
Ultra 16.0 11.0 6.5 4.22 4.905 1.5 B

VX-T
350 [0.63”] [0.43”] [0.26”] [0.16”] [0.19”] [0.059"] D C
E F
A
Ultra 23.8 10.01 7.4 4.1
VG-P — —
500 [0.94”] [0.394”] [0.29”] [0.162”] CE
D B
AA
Ultra VG-T 23.8 10.01 7.4 4.1
— —
500 [0.94”] [0.394”] [0.29”] [0.162”] CE
D B 1.0mm
[0.039”]
A
1.2mm
Ultra 23.8 14.0 6.52 4.68 4.905 1.50 BB
[0.047]
VX
500 [0.94”] [0.55”] [0.257"] [0.184”] [0.193”] [0.059”] D
F
G
C 1.5mm
E [0.059]
A
A
1.8mm
[0.070”]
Ultra 23.8 12.01 17.4 7.48
VG-X — —
500 [0.94”] [0.472”] [0.69”] [0.294"]
D CE
BC
A
Ultra 23.8 12.01 22.4 7.48

VG-XX — — C
500 [0.94”] [0.472”] [0.88”] [0.294"]
D
B
C
* Flexible measurement to be confirmed with original gate detail drawing

Additional gate sizes available upon review


Std.
Tip
Size
Style
A* B C D E F G Gate Detail Gate
Dia
A A
Ultra VG-P 31.0 19.06 17.3 5.91

B
B
— — —
750 VG-UF(P) [1.22”] [0.7504”] [0.68”] [0.233”] C D
D
1.0mm
AA [0.039”]
Ultra VG-T 31.0 19.06 17.3 5.91 BB 1.2mm
— — — CD
750 VG-UF(T) [1.22”] [0.7504”] [0.68”] [0.233”] [0.047]
D 1.5mm
[0.059]
AA
Ultra VG-R (P) 31.0 19.06 25.0 11.28 1.8 mm
— — — BB
750 VG-R (T) [1.22”] [0.7504”] [0.98”] [0.444"] [0.070”]
CD
D 2.5mm
[0.098”]
AA
Ultra 31.0 24.7 7.5 9.005 2.00 BB
VX — —
750 [1.22”] [0.97”] [0.30”] [0.3545”] [0.078”] C
F
E
AA
VG BB
Ultra 42.0 25.415 15.61 7.32
(3 mm — — —
1000 [1.65”] [1.000”] [0.615”] [0.288”] CD
gate)
D
AA
BB 3mm
VG [0.118”]
Ultra 42.0 25.415 15.61 6.75
(5 mm — — — CD
1000 [1.65”] [1.000”] [0.615”] [0.266”]
gate) 5mm
D [0.197”]
AA
Ultra 42.0 14.00 3.95
VX — — — —
1000 [1.65”] [0.551”] [0.156”]
FE EB


Std.
Tip
Size
Style
A* B C D E F Gate Detail Gate
Dia
1.0
A
A
Ultra [0.039”]
16.0 8.00 8.3 2.6 1.2
Helix™ VR — — CC [0.047”]
[0.63”] [0.31”] [0.33”] [0.10”]
350 1.5
D BB B
[0.059”]
0.8
A [0.031”]
Ultra 1.0
16.0 11.0 6.5 4.22 1.5 B [0.039”]
Helix™ VG VAR 1.2
[0.63”] [0.43”] [0.26”] [0.16”] [0.059"] D C
350 [0.047”]
E F 1.5
[0.059”]
A 1.0mm
Ultra [0.039”]
23.8 10.01 7.4 4.1
Helix™ VR — —
[0.94”] [0.394”] [0.29”] [0.162”] CE 1.2mm
500
D B [0.047]
A 1.5mm
Ultra B [0.059]
23.8 14.0 6.52 4.68 1.50
B
Helix™ VG VAR
[0.94”] [0.55”] [0.257"] [0.184”] [0.059”] D 1.8mm
500
F
G
E C [0.070”]
A
A
1.0mm
Ultra B
B
[0.039”]
31.0 19.06 17.3 5.91
Helix™ VR — — 1.2mm
[1.22”] [0.7504”] [0.68”] [0.233”] C
750
D
[0.047]
D 1.5mm
A
A [0.059] 1.8
Ultra B
B
mm
31.0 24.7 7.5 1.50
Helix™ VG — VAR [0.070”]
[1.22”] [0.97”] [0.30”] [0.059”]] F C
750
2.5mm
E [0.098”]

Pitch Spacing
Valve Stem
Nozzle

Actuation Guidelines Min Pitch Layout
Size
Options
Ultra The sprue min radius is 45mm [1.77”]

350 X
The min drop-to-drop pitch is 25.4mm [1.00”]
X and Y must be greater than 62.6mm [2.47”]

Ultra
500 Husky to inform customer 200psi (13.8bar) air
pressure may be required for proper operation
Small Pitch of SX valve gated systems. Insufficient air R 45mm*
Valve Gate Y [1.77"]
Ultra pressure provided to SX piston can lead to
Helix™ (SX) stem actuation problems, sticking, and/or

posting on the molded part
350
Certain applications will require air pressure
greater than standard air pressure of 80-120psi 25.4mm**
Ultra [5.5-8.3bar] [1"] 25.4mm
[1"]
Helix™
500 ** Minimum channel size required for
minimum pitch
Ultra
350
50mm
Ultra [1.97"]
500
The sprue min radius is 50mm [1.97”]
Ultra
50mm
[1.97"]
750 X and Y must be greater than 71mm [2.80”]
Ultra Standard The min drop-to-drop pitch is 50mm [1.97”] Y R 50mm*

[1.97"]
Helix™ Valve Gate
EMI requires X and Y to be greater than 110mm
350 (LX) [4.33”] to accommodate air plates.
Ultra * * EMI requires 78mm [3.07”] pitch around the X

Helix™ sprue bushing to accommodate air plates.
500
Ultra
Helix™
750
• Minimum distance between the outermost nozzle drop center to the outer top and bottom edge of the
manifold plate is 96mm [3.77”] (If reduced distance is required, contact Husky)

Pitch Spacing
Valve Stem
Nozzle
Actuation Guidelines Min Pitch Layout
Size
Options
Ultra 350
59mm
[2.32"]
Ultra 500
59mm
[2.32"]
Ultra 750
Ultra R 65mm
Large Piston The min drop-to-drop pitch is 59mm [2.32”] Y
Helix™ [2.56"]
Valve Gate
350 X and Y must be greater than 92mm [3.622”]
(EX)
Ultra
Taper valve stems are not recommended
Helix™ X
500
Ultra
Helix™
750
75mm
[2.95"]

Ultra Valve Gate Y R 72mm
1000 (No Airplate) [2.83"]

X
121mm R 115mm
[4.76"] [4.53"]
Ultra Valve Gate
1000 (Airplate) Y
X
• Minimum distance between the outermost nozzle drop center to the outer top and bottom edge of the
manifold plate is 96mm [3.77”] (If reduced distance is required, contact Husky)

Ultra 350 Valve Gate -Application Guidelines

SCVG VG VX
Low 20 20 20
Viscosity
Medium 12 12 12
High 5 5 5
Resin SCVG VG VX Resin
Structure
Abrasive ¯ ¯ P
ABS P P ¯ A
Color Change P P P
Flex. PVC ¯ ¯  A
PA ¯ ¯ P SC
PA (33% GF) ¯ ¯ P SC
PBT ¯ ¯ ¯ SC
PBT/PC ¯ ¯ ¯ B
PC P P ¯ A
PC/ABS ¯ ¯ ¯ B
PE P P  SC
PEI ¯ ¯ ¯ A
PET ¯ ¯ ¯ SC
PETG ¯ ¯ ¯ A
PMMA P P ¯ A
POM ¯ ¯  SC
PP P P ¯ SC
PPO (PPE+PS/PA) ¯ ¯ ¯ A/SC
PS P P  A
PSU ¯ ¯ ¯ A
SAN ¯ ¯ ¯ A
TPE P P  A
TPO P P  A
TPUR ¯ ¯  A

• Recommended minimum air pressure is 6.8 bar [100 psi]

• For Ultra Helix™ information please see Ultra Helix™ section in Valve Gate Nozzle Stacks section

Ultra 500 Valve Gate-Application Guidelines
SCVG VG VX VG-X VG-XX VG-HP
Low 20 20 20 20 20 35
Viscosity
Medium 12 12 12 12 12 -
High 10 10 10 10 10 6
Resin SCVG VG VX VG-X VG-XX VG-HP Resin Structure
Abrasive ¯  P   
ABS P P  ¯  P A
Color Change P P P   
Flex. PVC ¯ ¯     A
PA P P P   P SC
PA (33% GF) ¯  ¯   P SC
PA (50% GF)      ¯ SC
PBT ¯ ¯ ¯    SC
PBT/PC ¯ ¯     B
PC P P    P A
PC/ABS P P    P B
PC/TPE      P
PE P P ¯ ¯ ¯  SC
PEI  ¯ ¯    A
PET ¯ ¯ ¯    SC
PETG ¯ ¯     A
PMMA ¯ P  ¯  P A
POM ¯ ¯ ¯    SC
PP P P ¯ ¯ ¯  SC
PPO (PPE+PS/PA) ¯ ¯     A/SC
PS P P     A
PSU  ¯ ¯    A
SAN ¯ ¯     SC
TPE P P ¯    A
TPO P P ¯    SC
TPUR ¯ ¯     SC

• Recommended minimum air pressure is 6.8 bar [100psi]


Ultra 750 Valve Gate-Application Guidelines

SCVG VG VX VG-R VG-UF
Low 250 250 250 250 175
Viscosity
Medium 150 150 150 150 80
High 50 50 50 50 40
Resin VG VX VG-R VG-UF Resin Structure
Abrasive  P  
ABS P P ¯ ¯ A
CAB ¯    A
Color Change P P  
Flex. PVC ¯    A
PA P P   SC
PBT P ¯   SC
PBT/PC ¯ ¯   B
PC ¯ P ¯  A
PC/ABS P ¯   B
PE P ¯ ¯ ¯ SC
PEI  ¯   A
PET ¯  ¯  SC
PETG ¯ ¯ ¯  A
PMMA P    A
POM ¯ ¯   SC
PP P ¯ ¯ ¯ SC
PPO(PPE+PS/PA) ¯ ¯   A/SC
PPS ¯ ¯   SC
PS P  P ¯ A
PSU ¯ ¯   A
SAN P P   A
TPE ¯ ¯ ¯ ¯ A
TPO ¯ ¯ ¯ ¯ A
TPUR ¯ ¯   A
SC – Semi-Crystalline B– Blend A– Amorphous
• Recommended minimum air pressure is 6.8 bar [100psi]


Ultra 1000 -Application Guidelines
VG VX VX-X
Low 450 450 450
Viscosity
Medium 200 200 200
High 80 80 80
Resin
Resin VG VX VX-X
Structure
Abrasive ¯ P P
ABS P P P A
Color Change P P P
PA ¯ P P SC
PA(GF) ¯ P P SC
PBT P P P SC
PBT/PC P P P B
PC P P P A
PC/ABS P P P B
PE P P ¯ SC
PETG ¯   A
PMMA P P P A
POM ¯ ¯ ¯ SC
PP P P P SC
PP (TALC) P P P SC
PPO(PPE+PS/PA) P P P A/SC
PS P P P A
SAN P P P A
TPE/TPO P ¯ ¯ A

• Wear resistant tips required for process temperature above 325°C [617°F] and resins with an abrasive
filler i.e. glass, mica, mineral, and carbon fiber
• Recommended minimum air pressure is 6.8 bar [100 psi]

Single Drops
Single Cavity Valve Gate (SCVG)

Sprue bushing • Ideal for low volume or prototype purposes
• Available in Ultra 350, 500, 750 and 1000
Extruder pad • Available in Ultra Helix™ 350, 500 and 750
Sprue body • Full range of valve gating options
heater • Temperature rating of 3500C [6620F] at a
Sprue body mold cooling temperature of 750C [1670F]
(This temperature rating may be higher or lower
Locating ring depending on the mold cooling temperature.
Reverse taper This temperature rating may also be less depending
on specific nozzle tip; reference nozzle tip temperature
PL stem
ratings.)
Air plate • Max. Pressure is 1792 bar [26k psi]
Nozzle heater • Stem Stroke added 7.3mm [0.29”]
BL 5-20mm
[0.2-0.8"] 12-15mm Cylinder
[0.5-0.6"] NOTE for SCVG:
Nozzle tip
• Preventative maintenance is required
at 500K cycles
1 • Disassembly, clean resin deposits, seals
inspection, inspect valve stem reverse
taper seat and stem assembly for any
2 noticeable wear
• All seals (static and dynamic) need to
D1 be replaced every one million cycles
D2
• Installs direct into platen side of the ‘A’ side plates
4
3
This dimension is dependent on the size of the nozzle
Max
Nozzle Min Max Min Max Max Std Max XL* Max Std
1 2 3 4 Min PL Min BL XL *
size D1 D1 D2 D2 PL PL BL
BL
Ultra 150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 95mm 244mm 25mm 165mm
N/A N/A
350 [5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [3.74"] [9.60"] [0.98"] [6.49"]
Ultra 150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 92mm 200mm 330mm 22mm 121mm 260mm
500 [5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [3.62"] [7.87"] [12.99"] [0.86"] [4.76"] [10.23"]
Ultra 150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 108mm 215mm 335mm 39mm 138mm 265mm
750 [5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [4.25"] [8.46"] [13.18"] [1.53"] [5.43"] [10.43"]
Ultra 170mm 134mm 130.04mm 70mm 12.25mm 21.85mm 87.55mm 97.15mm 125mm 245mm 37mm 157mm
N/A N/A
1000 [6.693"] [5.28"] [5.120"] [2.756"] [0.482"] [0.86"] [3.447"] [3.825"] [4.92"] [9.64"] [1.45"] [6.18"]
Ultra
150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 95mm 244mm 25mm 165mm
Helix™ N/A N/A
[5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [3.74"] [9.60"] [0.98"] [6.49"]
350
Ultra
150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 92mm 200mm 330mm 22mm 121mm 260mm
Helix™
[5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [3.62"] [7.87"] [12.99"] [0.86"] [4.76"] [10.23"]
500
Ultra
150.0mm 108.0mm 104.04mm 50mm 12.28mm 21.85mm 69.5mm 79.07mm 108mm 215mm 335mm 39mm 138mm 265mm
Helix™
[5.906"] [4.25"] [4.096"] [1.969"] [0.483"] [0.86"] [2.736"] [3.113"] [4.25"] [8.46"] [13.18"] [1.53"] [5.43"] [10.43"]
750
* Please note there is a longer lead time for XL dimensions

Ultra Helix™ Valve Gate
New Valve Gate Technology
• Combination of technologies that provides better gate vestige quality than any
existing technology
• Husky provides a new gate finishing service that is required to achieve industry’s
best gate quality
-- Higher precision capabilities than traditional gate finishing processes
Ultra Helix™ VR
Feature Benefit
Eliminates tolerance stack ups from tip
Single piece nozzle assembly
to housing
Improved valve stem alignment with

Continuous guidance
the gate
Better control of temperature in gate
Nozzle heater closer to the gate
area
Integrated seal ring More robust nozzle seal interface
Retrofitable with existing cold halves
Fits current Ultra gate detail
without requiring rework

Ultra Helix™ Valve Gate
New Valve Gate Technology

Ultra Helix™ VG
Feature Benefit
Superior gate quality with no
All critical gate geometry contained
Complicated gate orifice finishing
within tip
required
Stem guide integral with gate Eliminates multiple tolerance stack ups
Highly wear resistant tip materials Significantly improved gate life
60% less heat loss to mold Minimizes thermal defects in gate area
Small footprint enables tip to fit on a
3.0 mm OD of VG tip*
wide range of parts
Gate is restored to new condition with
Simplified mold maintenance
tip replacement
* 3.0 mm tip is with a 1.0 mm gate orifice. OD increases linearly with gate size above 100 min seal dia. 30mm

Ultra Helix™ 350 Valve Gate-Application Guidelines
VG VR
Low 20 20
Viscosity
Medium 12 12
High 5 5
Resin VG VR Resin
Structure
Abrasive
¯ ¯
ABS
P P A
Color Change P P
Corrosive ¯ ¯
Metallic or
Perlcent Pigments ¯ ¯
PA¯ P SC
PBT¯ ¯ SC
PC ¯ ¯ A
PC/ABS ¯ ¯ B
PE P P SC
PMMA ¯ ¯ A
POM P P SC
PP ¯ P SC
PS P P A
SAN ¯ ¯ A
TPE P P A
TPO P P A
TPU A
¯ ¯


VG VR
Low 20 20
Viscosity
Medium 12 12
High 10 10
Resin VG VR Resin
Structure
Abrasive ¯ ¯
ABS P P A
Color Change P ¯
Corrosive ¯ ¯
Metallic or
PA P P SC
PBT ¯ ¯ SC
PC ¯ P A
PC/ABS ¯ P B
PE P P SC
PMMA P P A
POM P P SC
PP P P SC
PS P P A
SAN ¯ ¯ A
TPE P P A
TPO P P A
TPU ¯ ¯ A

VG VR
Low 250 250
Viscosity
Medium 150 150
High 50 50
Resin VG VR Resin
Structure
Abrasive ¯ ¯
ABS P P A
Color Change P ¯
Corrsive ¯ ¯
Metallic or
PA P P SC
PBT P P SC
PC ¯ P A
PC/ABS ¯ P B
PE P P SC
PMMA P P A
POM P P SC
PP P P SC
PS P P A
SAN P P A
TPE P P A
TPO P P A
TPU ¯ ¯ A

Valve Gate Air Circuit Recommendations
and Machine Setup

These are recommendations only; they are to get the best possible performance out of a
pneumatically actuated valve gated Husky Hot Runner
• No more than 36 cavities/nozzles per air circuit
• Air supply should be clear and dry at a pressure between 80-120 psi [550-830 kPa]
- For thinwall parts and engineering resins the pressure should be between
100-120 psi [690-830 kPa]
•A four-way air solenoid should be on the machine for every air circuit in the hot runner
-- Example: If Hot Runner has four separate air circuits, the machine should have four
separate air solenoids controlling the four air circuits
• Quick exhaust valves should be installed on both air lines to increase the speed at
which the stems open and close
• For air circuits with less than 24 cavities/nozzles, the air solenoids must have a
minimum Cv valve of 1.5. If the air circuit is greater than or equal to 24 cavities/
nozzles, then the machine solenoid must have a minimum Cv value of 3.0
(Standard Husky Machine value has Cv of 1.5)
• If using a solenoid that has a Cv less than 3.5, regardless of number of cavities/
nozzles a quick exhaust should be installed
• The flow rate of air coming out of each machine solenoid should be at a minimum of
0.625 standard cubic feet per minute (scfm) per drop. This should be measured with
air flowing though all of the solenoids on the machine at the same time
• Air hoses running from the machine solenoids to the Hot Runner should have an
internal diameter no smaller than 9.525mm [3/8”], and no larger than 19.05mm [¾”]
• Air hoses should be as short as possible with a maximum length of 1.83m [6'], and
should all be the same length
• 13.8bar [200psi] air pressure may be required for proper operation of SX valve gated
systems
• Insufficient air pressure provided to SX piston can lead to stems seizing, sticking,
and/or posting on the molded part
• Use a Husky Air Kit for optimal performance

Overview
Husky offers 2 level stack manifold systems and hot runners. A 2 level stack mold
will nearly double the output per machine of a single face mold. Husky’s experience
gained in building over 3000 stack hot runners assures that all aspects of integrating
the hot runner into the mold will be taken into account during design.
• In addition to 2 level stack systems; Husky has successfully built many 3 level and
4 level systems
Moving Side Stationary Side

Cavity Plate Cavity Plate Machine Tie Bars
Sprue Hot Runner

Mold Bar Length
Opening Mold
Stroke Shut Height
Standard Sprue Bar
Standard sprue bars are solid sprue

extensions that connect the hot runner with
the machine nozzle.
Split Sprue Bar
Split sprue bars allow free access to the

Stack Hot Runners
molding surface without obstruction.
Back-to-Back Valve Gate
Back-to-Back valve gates are available with

standard and split sprue bars.

Thermal Gate Consideration
Available for:
Stack Hot Runners

Ultra 250, Ultra 350, Ultra 500, Ultra 750, Ultra 750 UP and Ultra 1000
For all thermal gating methods, the nozzles can be positioned back-to-back
or staggered
Stationary
Machine
Platen
Clamp Injection
Side Side
Heat
Sprue Bar Shield
Anti-Drool
Bushing
Minimum shutheights for stack systems will vary based on the requirements of the
application. Please consult Husky to determine the minimum shutheight for your
application

Valve Gate Consideration
Available for:
Ultra 350, 500, 750, 1000; as well as Ultra Helix™ 350, 500 and 750
In order to accommodate customer requirements Ultra VG nozzles can be
positioned back-to-back using a 3 plate hot runner design
Stack Hot Runners
Back-to-Back
X
Minimum shutheights for stack systems will vary based on the requirements of the
application. Please consult Husky to determine the minimum shutheight for your
application
Husky can provide offset stack valve gates as an option to address parts requiring
this gating location or to provide a reduced shutheight . For further details and
options please consult Husky

Split Sprue Bar
Stack Hot Runners

Two standard throughput options are available, “Medium” and “Large”.
Husky’s personnel can assist in the selection of the proper throughput option for
your system.
The Large Split Sprue Bar is available in an Offset configuration only
System
Description Sizes available Section View
Type
The Split Sprue Bar

is located on the
centerline of the Medium 2068 bar
Inline mold and is directly [30k psi]
fed by the machine
nozzle
An offset system
allows the Split
Medium
Sprue Bar unit to be
(Transfer manifold)
positioned freely in
2068 bar [30k psi]
the mold frame. A
Offset transfer manifold
Large
routes the feed
(Transfer manifold)
from the machine
1861 bar [27psi]
nozzle to the Split
Sprue Bar unit
Section View 204mm [8.0"]
 73mm [2.87"]  138mm [5.44"]

Hole through platens
Hole through mold plates
 127.4mm [5.0"]
Minimum Shutheight
• Medium Split Sprue Bar = 200mm [7.87”]
• Large Split Sprue Bar = 216mm [8.50”]

Split Sprue Bar
General Molder Considerations
Operating a Split Sprue Bar, the molder might observe some performance
differences compared to a Conventional Sprue Bar. For certain applications, this
could include an expected temperature overshoot at the split line of the Split Sprue
Bar , caused by shear.
Husky recommends
• The end user to stock at least one of each custom items. Husky will quote the
parts that are recommended to have on-hand
• That each Split Sprue Bar valve stem gets controlled by a separate air circuit in
order to shut the center section stem first (after machine decompression) and
then the stationary side one, 0.2 seconds later
• To lap each Split Sprue Bar stem to the corresponding tip for a very good fit. This
is done on new systems before leaving Husky
• To reduce the carriage pressure as much as possible during mold open, while
still maintaining a positive seal. This eliminates the additional stress on the molds
stationary half
• The inlet diameter of the machine injection nozzle to be 14.29mm [0.56 in].
This applies only for or inline split sprue bars
• To adjust the mold protection to compensate / overcome the additional load of
approximately 1,000 lbf (4,448 Newton) that will be generated during the last one
millimeter of mold closing stroke
Additional molder and moldmaker information is available from Husky
Area Detail Action When
Main Sprue and Locating Ring Weekly
Inspect for visible
damages; remove and clean resin Daily for the first week of
Split Sprue Bar Split Line deposits operation, then extended steps
(to establish timing)
Daily for the first week of

Inspect interface for
operation, then extended steps
Split Sprue Bar potential weepage and clean up
(to establish timing)
General
Sliding Bushing and Nozzle
Clean bushing and visually
Base 2M Cycles or 12 Months
inspect for damages
Stack Hot Runners
Replace Sliding Bushing and

4M Cycles
Inspect Nozzle Base
Wedge Collars Replace Wedge Collars 4M Cycles
Inspect for potential

2M Cycles or 12 Months
weepage and clean up
Replace Piston Seals, O and C

Sprue Body 2M Cycles
rings
Stationary Side
Clean Stem and visually inspect
Split Sprue Bar 2M Cycles or 12 Months
for damages
Clean Stem and visually inspect

Split Sprue Bar Nozzle Tip for damages
Husky Refurbishment 4M Cycles or 37 Months

Split Sprue Bar
Preventive Maintenance - Hot Runner & Split Sprue Bar
Stack Hot Runners

Area Detail Action When
Clean and visually inspect for
damages
Center Section
Split Sprue Bar Valve Stem S/A
Split Sprue Bar Replace Piston Seals 2M Cycles
Inspect for visible damage Weekly

Connector Inserts Measure heater resistance,
Electrical
and isolation resistance and ground
Interface 2M Cycles or 12 Months
Connector Hoods wire connection of all heating
elements
Visually inspect for damages;

Nozzle Tip, Tip Insulator, clean resin deposits at 2M Cycles or 12 Months
Nozzle Front Nozzle Heater and sealing interface
Thermocouple
Inspect for potential weepage
General 2M Cycles or 12 Months
and clean up
Clean and visually inspect for

damages
Valve Stem S/A
Replace Piston Seals 2M Cycles

Pocket Manifold
Clean weepage holes 2M Cycles or 12 Months
Back-up Pad
Visually inspect 2M Cycles or 12 Months
C-Rings Replace After each back-up pad removal
Visually inspect and Grease After each latch over

Guide Pins
• The PM intervals are an initial recommendation of Husky, based on other

applications, utilizing the same hardware
• The application itself (resin, pressures, temperatures, …) and the processing
environment do significantly impact the final cleaning or replacement cycle for a
Molding System

PRONTO® Overview
Benefits
Faster Delivery*
• Reduction in lead times**
Easy to Order
• PRONTO® Section in Hot Runner Product Guide
-- Readily available information
No Compromise in Quality
• Optimized melt channels
-- Leak proof warranty
Lower Price*
• 15% to 20% price reduction
Features
Optimized Processing
• Ultra 250, 350, 500, 750, 1000 as well as Ultra Helix™ 350, 500, 750
• Melt channels customized for each application
Flexible Pitch
• 1-32 drop manifold and hot runner systems (1-4 drops for Ultra 1000)
• 17 different manifold layouts
• Even profile for every application
• Balanced manifold layouts with level changes and thermally validated heater
design ensure optimized processing for all applications
Configurable plates
• Flexible plate size
• Customer specified guide pin and interface taps
• Multiple clamping options including DME and oversized backing plate
* Applications requiring custom components will not be given PRONTO® lead time
or price
** Leadtime reduction not applicable for Ultra Helix™, PRONTO® applies to pricing only
PRONTO

Design for PRONTO®
5 step process for PRONTO® eligibility
PRONTO
1. Nozzle Length
2. Sprue Clearance
3. Pitch spacing Nozzle Gate Min-L Max-L Ext-L*
U250 HT 17 [.66"] 170 [6.60”] -
4. Plate Sizes HT/
U350 17 [.66"] 170 [2.75"] -
VG
5. Configurable system options VG 20 [.78"] 230 [9.05"] 290 [11.41"]
U500
HT 14 [.55"] 230 [9.05"] 290 [11.41"]
VG 27.4 [1.08"] 180 [7.08"] 290 [11.41"]
U750
HT 27.4 [1.08"] 230 [9.05"] 290 [11.41"]
VG 29.3 [1.15"] 250 [9.84"] 300 [11.81"]
U1000
HT 28[1.10"] 300 [11.81"] -
UH350 VG 17 [.66"] 170 [2.75"] -
UH500 VG 20 [.78”] 230 [9.05"] 290 [11.41"]
Step 1—Nozzle Length UH750 VG 27.4 [1.08"] 180 [7.08"] 290 [11.41"]
• Must fall within range of

min/max
• Any increment within range
-- Same for VG/HT
Nozzle Gate Min BL Max BL Ext-BL*
* Longer lead time U250 HT 53 [2.08”] 185 [7.28”] -
HT/
U350 53 [2.08"] 185 [7.28"] -
VG
VG 85 [3.34"] 245 [9.64"] 305 [12"]
U500
HT 70 [2.75"] 245 [9.64"] 305 [12"]
VG 64 [2.51"] 195 [7.67"] 305 [12"]
U750
HT 57 [2.24"] 245 [9.64"] 305 [12"]
VG 82 [3.22"] 270 [10.62"] 320 [12.59"]
U1000
HT 82 [3.22"] 320 [12.64"] -
UH350 VG 53 [2.08"] 185 [7.28"] -
UH500 VG 85 [3.34"] 245 [9.64"] 305 [12"]
UH750 VG 64 [2.51"] 195 [7.67"] 305 [12"]
Ma
Step 2—Sprue Clearance xD
ro
p Max Drop
Min Drop Min Drop
• Minimum distance from inner
drop to sprue (Min Drop)
• Allows for standard design/components
• Maximum manifold size (Max Drop) Gate Nozzle Min Drop Max Drop
U250
-- Distance from outer most drop to sprue U350
31.8 [1.25”] 300 [11.8”]
Hot Tip U500 32 [1.26”]

U750 40.4 [1.59”] 500 [19.7”]
** Air Plate out of scope for U1000 PRONTO® U1000 50 [1.97”]
U350 SX- 45 [1.77”]
300 [11.8”]
U500 LX- 50 [1.96”]
LX- 50 [1.96”]
U750 400 [15.7”]
EX- 65 [2.55”]
Valve
U1000 72 [2.83”]** 500 [19.7”]
Gate
UH350 SX- 45 [1.77”]
300 [11.8”]
UH500 LX- 50 [1.96”]
LX- 50 [1.96”]
UH750 400 [15.7”]
EX- 65 [2.55”]

Design for PRONTO®
Step 3—Pitch Spacing Gate Nozzle Min Pitch
Ultra 250 18 [.71"]
• Same spacing requirements as our custom systems Ultra 350 18 [.71"]
Hot
• Dependent on nozzle size and gating style Tip
Ultra 500 25.4 [1"]
Ultra 750 44.5 [1.75"]
-- Allows for standard design/ components Ultra1000 61 [2.4"]
Ultra 350
Ultra 500 SX 25.4 [1"]
Ultra Helix™ 350 LX 50 [1.96"]
Valve
Ultra Helix™ 500
Gate
Ultra 750 LX 50 [1.96"]
Ultra Helix™ 750 EX 59 [2.33"]
= Ultra 1000 PRONTO® only available in these
Ultra1000 75 [2.95"]
layouts and only available up-to 4-drops
Min
Pitch Min
Min Pitch
Pitch
Min
Pitch
Min
Pitch
1l* 2I* 2T* 4H*
Min
Pitch Min
Min Pitch
Pitch
Min Min
Min Min Pitch
Pitch Pitch Pitch
4I* 4Z* 6 (2x3) 8 (2x4)
Min Min Min

Pitch Pitch Pitch
Min
Min Pitch
Pitch Min
PRONTO
Min Pitch Min

Pitch Pitch
8 (2x4)Z 12 (2x6)** 12 (3x4)** 16 (2x8)**

** For systems 12 -drops and above pitch spacings (vertical and horizontal) must be equal. [Spacing
across the sprue (0,0) may vary] i.e. as shown

Design for PRONTO®
Step 3—Pitch Spacing (Continued)
PRONTO
Min Min
Pitch Pitch
Min Min
Min Pitch
Pitch Pitch
Min
Pitch Min Min Min
Min Pitch Pitch
Pitch Pitch
16 (4x4)** 24 (2x12)** 24 (3x8)** 24 (6x4)** 32 (4x8)**

across the sprue (0,0) may vary] i.e. as shown
* Pitch Flexibility
Pitch locations for 1 and 2 drop PRONTO® systems are fully flexible and can be rotated about the
injection point.
49.22mm [1.93”]
49.22mm [1.93”]
58.32mm [2.29”]
64.36mm [2.53”]
64.36mm [2.53”]
58.32mm [2.29”]
95.43mm [3.75”] 62.54mm [2.46”]
47.91mm [1.88”] 32.95mm [1.29”]
47.91mm [1.88”]
32.95mm [1.29”]
95.43mm [3.75”] 62.54mm [2.46”]
Pitch location for 4 Drop PRONTO® systems is available in both symmetrical and asymmetrical
configurations. Asymmetrical layouts still require injection to be located at the center of the mold.
As seen in the example, drop locations must feature the same dimensions in two different
quadrants. For example the inner drops are both located at (58.32, 47.91) and the outer drops are
both located at (64.36, 95.43)

Design for PRONTO®
Step 3—Pitch Spacing (Continued)
across the sprue (0,0) may vary] i.e. as shown May vary*
X X
Y
* May vary - See sprue clearance (Step 2)
Y
May vary*
Y
Step 4—Plate Sizing

• Confirm plate sizes are within the maximum available width and height
• Check that all drop locations fit within the “area available for drops”
(leaving adequate open space at the edge of the plates)
96mm
[3.77]
Area available
for drops
PRONTO
96mm
[3.77”]
71mm 71mm
[2.79”] [2.79”]
Maximum Plate Width : 1200mm [47.3”]

Maximum Plate Height : 1500mm [61.0”]

Design for PRONTO®
Step 5—Configurable Options DME- Style Clamping
PRONTO
Top Top
• Clamping Options
-- Benefits Op Op
• Easy specification
• Predictable design
Clamp Thickness
-- Features Metric
A
Imperial
B
Metric Imperial Metric
C (min)
Imperial
• Industry standard clamping Standard 22.2mm

Optional
0.87" 16mm 0.62"
Customer to specify
23.8mm 0.93"
• Choice of clamping thickness

Over Size Backing Plate
Top Top
Op Op
Backing Plate Backing Plate
Manifold Plate Manifold Plate

Width Width
• Electrical Options
-- Requirements
• Top Locations
• Choose from standard
connector offering
Electrical Configurations
Pins Latches Supplier
6
16
Double DME
24
or Lapp
25
Single Harting
32
48
• Guide Pins and Interface Options

-- Guide Pins
• DME/Hasco
• Any size, location, qty
-- Interface Options
• Metric/Imperial
• Any size, location, qty

Design for PRONTO®
Step 5—Configurable Options (Continued)
• Utility Locations
-- Water
-- Air
WATER
and/or
AIR
WATER
and/or
AIR
PRONTO
Available Fittings
DME Festo Hasco Parker Staubli
Air P P P P P
Water P P P P

Design for PRONTO®
Step 5—Configurable Options-Custom Cutouts
PRONTO
• Installations:
-- Back-up cutouts
-- Latch cutouts
-- Cutouts for bolting
• Requirements:
-- Manufacturing tolerance +/- 0.2 mm

PRONTO® – FAQ
Q: What items are allowable in PRONTO® systems:
A: • Customized plate cutouts with manufacturing tolerances +/-0.2 mm

--If drop to plate edge is at the min, cut-outs should be reviewed by Husky,
plate thickness might be increased by depth of cutouts
• There are no limits in number of cut-outs, but should be enough space for
wire groves and if cut-outs are not in the corners, it should be reviewed by
Husky
• Sequential Valve Gate limited to 4 drop Hot Runner systems

--Must be reviewed by Husky, additional circuits and limited space would be
constrain to install other standard features
• Customized items like locating ring, sprue bushing at an additional cost and
lead time checked with Husky
• Corrosive/high pressure/high temp application at an additional cost and

increased lead time
• Different nozzle length are allowable for PRONTO®. Moldflow may be

required with 2 different L-dims
• Powertech Box installation

PRONTO

PRONTO® – FAQ
Q: Which items do not fit within PRONTO®?
PRONTO
A: The following items do not fit into PRONTO® but may be available through our
custom systems:
- Special shut-off geometry (angle, diameter, tolerances)

- Contoured gate (HT or VG)
- Special gate insert design or gate manufacturing request from customer
except Ultra Helix™
- Interface taps from backing plate to customer mold, because it leads to
customized design of hot runner
- Offset injection location, because it might lead to unbalanced system and
custom design
- Reverse taper stem, customized manifold bushings
- Customer circuits in Hot Runner plates
- Thru-holes
- Modified gate land, gate bubble or customized nozzle tip are allowable
after review by Husky
If your application requires any of these items please contact Husky to inquire
about our custom hot runner

Overview
Typical target applications and typical markets
• Part which are small, long, open ended at both ends
• Typical part size range: 0.2 to 10.0 grams (depending viscosity and injection time)
• When core pins restrict access for conventional gating
• For cold runner elimination
• Medical market: pipette tips, syringe barrels, infusion-transfusion components tube
connectors, luer, luer lock
• Closure market: specialty closures, flip top caps
• Technical market: small technical components (check resin compatibility)
Flexibility and Part Quality

• Flexibility: 1, 2 or 4 tips per nozzle
• Design flexibility in the cooling placement (possible around long parts)
• No split cavity required, no witness line
• Gate quality:
-- Typically < 0.05mm
-- Resin dependant (Consult Husky for critical gate quality application)
Ultra SideGate™ Order Guidelines

• See Material Compatibility & Throughput per gate chart
• Gate diameter – 0.70mm [0.027”], 0.8mm [0.031”], and 0.9mm [0.034”] based on application
• Gate diameter – 0.6mm [0.023”], for gate diameter available, based on application and
gate diameter guidelines
• Standard pitch spacing (tip-to-tip): 55mm [2.16”], others see specials section
• Gate cooling: mandatory review of cooling design by Husky
• Additional mold maker information available from Husky
Ultra SideGate

Overview
Principle
Ultra SideGate
• Better part quality (no witness
• Tip independent from the nozzle housing; always aligned with line from cavity split)
-- Less scrape
the gate -- Less mold maintenance
• Simple integration without cavity split and easy gate detail cost
manufacturing • Lower cavity insert cost
• Small footprint – more cavities
• Tip sealing obtained with a spring load in smaller mold size
• 1, 2 or 4 cavity per nozzle
• No special start up
procedure required
(no temperature boost)
Tip assembly, features and benefits • No need for special controller
• Reduce risk of cavity loss or
1. Ceramic insulation – wide process window short shot
2. Low conduction seal ring – wide process window • Spring seal prevent accidental
3. High conduction tip body – wide process window plastic leak
• Seal longevity prevent plastic
4. Anti-tilting fingers – ensures leak-proof operation leakage and avoid downtime
5. Wear resistant ring – preserve seal surface
6. Spring seal – prevent plastic leak – cold start protection
Nozzle
Expansion
6
5
1
4
3

Overview
Maintenance
• Easy maintenance from the split line into the press
• Full benefit of the ease of maintenance when tool
design allow to pull gate insert from the split line
• Blank tip available to neutralize cavities individually
• Gate contamination cleaning in less
than 30 minutes from stop to start
• Tip, TC, heater change from split line
• Faster and easier than most competitors
• Direct gating on geometries

Gate quality typically gated by cold
runner
• Direct thermal gating • Eliminate cold runner
• Commodity and technical
• Gate sheared off during mold opening resins
• Excellent gate quality
Balance
• Typical balance performance 75% to 95% depending on resin, part weight
• Improved balance tip for PP: up to 95% @ 90% short shot including random
block copolymer PP
• Consult Husky for details
Tip-to-Tip Pitch Spacing
L-dim: 46.5-196.5mm
[1.897-7.736"]
Ultra SideGate
55mm
[2.17”]
.66 m
.66 m
.66 m
[1 .24m
[1 .24m
[1 .24m
]
]
]
3”
3”
3”
42
42
42
SG-1 SG-2 SG-4

1 Cavity per drop 2 Cavity per drop 4 Cavity per drop

Overview
Gate Detail Consideration
Ultra SideGate
• Minimum steel thickness
Correct Incorrect
1.5mm Min
[0.05”]
• Gate location on the part
Correct Incorrect
Min. 1X
Recom. 1.5X
Gate diameter

Ultra SideGate™-Application Guidelines
Max Throughput per gate (g/sec.)
SG-1 SG-2 SG-4
Low 10 10 10
Viscosity
Medium 4 4 4
High 1 1 1
Resin SG HT-T SG HT-U Resin Structure
Abrasive  
ABS P ¯ A
COC P ¯ A
Color Change ¯ ¯
COP P ¯ A
Flex. PVC ¯ ¯ A
MABS P ¯ A
PA ¯ ¯ SC
PBT ¯ ¯ SC
PBT/PC   B
PC P ¯ A
PC/ABS ¯ ¯ B
PCTG, PCTA P ¯ A
PE P ¯ SC
PEI   A
PET   SC
PETG   A
PMMA P P A
POM  P SC
PP ¯ P SC
PPO   A/SC
PPS   SC
PS P ¯ A
PSU   A
SAN P ¯ A
SBC (K-Resin) P ¯ A
TPE  ¯* A
Ultra SideGate
TPO  ¯* A
TPUR  ¯* A

SC– Semi-Crystalline B – Blend A– Amorphous
• All gate cooling layouts must be reviewed by Husky prior to machining

• In case of color change, HT-U should be preferred when resin is compatible
*-Good process window consult Husky to review gate quality achievable

Ultra SideGate™ Angled
Angled tip:
Ultra SideGate
-- Improve access on part closer to the parting line
-- Reduce the offset of the split line
-- Consult Husky for details
L-Dim
17mm
~14mm
[0.66"]
~[0.55"]
1mm min
[0.03"] min
Ultra SideGate™ Inline

Inline Configuration:
-- Smaller mold base with tight part spacing
-- Split cavities not required for hot runner integration
-- Consult Husky for details
55 or 63mm* Gate-to-gate dimension

[2.16 or 2.48”]
A 18mm or 25mm*
[0.7” or 0.98”]
A+B
Drop-to-drop B 18mm min
[0.7” ]
dimension
* For other dimensions

please consult Application
Engineering

Specials
• Custom tip length (CAUTION, standard 55mm [2.16"] should always be preferred)
-- Gate to gate distance from 55mm [2.16"] to 63mm [2.48"] continuously
-- Blank in place for gate distance from 55mm to 63mm (2 weeks lead time)
-- HT-T and HT-U
-- May require adjustment of nozzle tip temperature set point and possible impact on short
shot balance 55 16-
[2
-6 2.4
.
3m 8"
m ]
90°
• Tighter nozzle pitch

-- Smaller than 44.5mm [1.75"] standard value
-- If cavity size allows for it
-- Minimum 35mm [1.37"] with non-standard nozzle spring pack and nozzle housing
-- Longer lead time
44.5mm
[1.75"]
35mm
[1.37"]
44.5mm
[1.75"] 35mm
[1.37"]
Ultra SideGate
44.5mm 35mm
[1.75"] [1.37"]
Standard nozzle pitch Special tight nozzle pitch

(min. value shown) (min. value shown)

Specials
• Special layouts
Ultra SideGate
-- Requires non-standard nozzle housings (other configuration than SG1, SG2 @ 180° or SG4)
-- Example shows SG2 @ 90°, in a square configuration
-- Like for SG1, opposite side of the tips to be supported with a dummy spacer – to be
considered for the mold construction
-- Longer lead time
Square configuration – to minimize

core shifting in critical applications
(If core shifting cannot be
addressed with part / mold design)

Overview
Benefits 27.9mm
[1.1"]
18mm
[0.709"]
• 100% synchronized valve stem movement

-- Stems are connected to an actuation plate
• Improved shot to shot and cavity to cavity 18mm
consistency [0.709"]
• Minimum drop to drop pitch spacing

(18mm, [0.709”]) with no sacrifice of closing
force
• Simple installation and maintenance 27.9mm
[1.1"]
• Increased process control with plate
R 39.5mm
position [1.56"]
sensing option
Minimum pitch spacing shown

Ultra 350 VG UX
Features
• Electric, pneumatic, and hydraulic actuation options
• Pitch spacing is the same for all three actuation methods
• Available for Ultra 350, 500, 750 and Ultra Helix™ 350, 500, 750 nozzles with
the same gating options as individual pneumatic actuation
Features Individual Plate Actuated

Constant stem force – SX, LX, EX X P
Close pitch availability 18mm [0.70”] X P
EX stem force P P
In-machine maintenance and stem removal P P
Automatic gate protection X P
UltraSync
Clean room environment acceptance P P

Extended gate and component life X P
Energy savings X P
Sequential Gating P X
Cold start protection X P
Stem Shut-off —Taper or Plunger Both Plunger only

UltraSync™ — Technology Comparison
UltraSync
Description Hydraulic Pneumatic Electrical
Repeatable shot-to-shot consistency P P P
Constant stem force P P P
Close pitch availability 18mm [0.70”] P P P
In-machine maintenance and stem removal P P P
Clean room environment acceptance X P P
Valve stem protrusion control X X P
Valve stem velocity profiling X X P
Extended gate and component life X X P
Energy savings P X P
Altanium® controller integration X X P
Minimum shutheight (Increase over individual VG) P P P
Minimal or no change to plate size (HxW) P P X

UltraSync-E™
Benefits
• Up to a 5X extension of gate and stem longevity
-- Motion control minimizes the force exerted on stem and gate orifice when
valve stems close
• Improved initial gate vestige quality and quality over time
• Closed loop control of stem motion, force, and position
• Cleanest valve gate technology Servo
available Motor
• Reduced energy consumption
• Lowest total cost of ownership Coupling
compared to any VG technology
Bearings
Ball Screw
Cam
Cam Follower
Manifold Backing Plate
Valve Stem Actuation Plate

Locating
Ring
Hot Runner
Manifold
Ultra VG Nozzle Stack
Features
• Requires an Altanium® controller
-- Important molder information on connecting
controller to the IMM is available from
UltraSync
Husky
• Fewer moving parts compared to any other VG technology
• In press lubrication
• Valve stem protrusion adjustability
• Stem pull back before the mold opens
• Shut height increase of 35-50mm [1.35”-1.97”]

UltraSync-E™
UltraSync
E
B C
UltraSync-E™ Plate And Space Requirements

Dimension Description 2-64 Drops 72-128 Drops
Top row of drops to edge of 100mm 100mm
A
manifold plate [3.93”] [3.93”]
Outer column of drops to side 125mm* 160mm
B
edge of manifold plate [4.92”] [6.29”]
Bottom row of drops to edge of 100mm 100mm
C
manifold plate [3.93”] [3.93”]
815-900mm 1165mm
D Minimum assembly height
[32”-35.4”] [45.8”]
300mm 408mm
E Minimum assembly width
[11.8”] [16”]
* With clamp slots only. Direct bolting or additional cut outs require review

UltraSync™-H
Benefits
• Plate size similar to individual VG
• Minimal shutheight increase over individual pneumatic VG, as low as 20mm [0.79”]
• Only requires one hydraulic core function from the IMM
Center Plate
Backing Plate
Hydraulic
Cylinder
Manifold
Plate
Guiding Elements
Back-up pad
Actuation Plate
Valve Stem
Head Assembly
(Shear Pin or Spring
Loaded Decoupling)
Valve Stem
Features
• No separate controller is required. The customer needs to have one hydraulic core function
or one hydraulic valve gate function available (one outlet for opening and one outlet for
closing)
• UltraSync™ H is not recommended for customers that do not have experience managing
hydraulic fluid in their molding areas
• Uses more robust (leak resistant) hydraulic cylinders than the original design
UltraSync

UltraSync™-P
UltraSync
Benefits
• Same set-up and operation as individual VG system including air flow and pressure
requirements
• Clean room compatibility
• Only requires one pneumatic valve gate
• Easy cylinder seal replacement without HR disassembly
Guiding
Elements
Backing Plate
Manifold
Plate
Center Plate
Pneumatic
Cylinder
Actuation Plate
Valve Stem
Head Assembly
(Shear Pin or Split Ring
Decoupling)
Features
• No separate controller is required
• Air functions the same as individual VG actuation
• Multiple sized cylinders are available for more pitch flexibility
• Increased shut height compared to individual VG 30-50mm [1.18”-1.96”]

UltraSync-E™ with Altanium® Controller
Delta3 All in one Integrated Matrix2
Servo and HR Control
(Also available in standalone
UltraSync-E™ Configurations)
• Matrix2 and Delta3 UltraSync-E™ controllers are available in two configurations:

-- Standalone = UltraSync-E™ control only
-- Integrated = Hot Runner Temperature + UltraSync-E™ control
• Delta3 and Matrix2 supports the following:

-- UltraSync-E™ control for low cavity hot runners (<=64 drops) in the integrated and standalone
configurations
• Matrix2 only supports the following:

-- UltraSync-E™ control for high cavity hot runners (>64 drops) in the integrated and standalone
configurations
-- Dual UltraSync-E™ control (Control for both UltraSync-E™ systems are integrated into the
Matrix2 HMI) for stack systems or other designs that require two UltraSync-E™ hot runners for
the same mold. Available in the integrated and standalone configurations
Benefits of Integrated Temperature and Servo Control
• Simple setup, control and monitoring using a single screen instead of two
• Less floor space – only one control unit required
• Cost savings – only one interface required
• Valve stem position, force and speed control
• Valve stem control parameters are saved to a mold setup for easy recall
• Integrated damage protection – if temperatures are not at setpoint, stem motion is prohibited
• Process data logging – open/close time, open/close position and peak open/ close force
Controller Interface with Machine
• Interface signals are provided via a supplied cable that connects to the controller with color
codes flying leads on the IMM end
• The following signals are required for stem operation:
• Integrated Temperature + UltraSync-E™ Control
-- E-Stop of IMM
-- IMM Safety Gates Closed
-- Open Valve Stems
-- Close Valve Stems (If configured)
• Standalone UltraSync-E™ Control
UltraSync
-- E-Stop of IMM
-- IMM Safety Gates Closed
-- External At-Temperature
-- Open Valve Stems
-- Close Valve Stems (If configured)
• Available Process Outside Limits output to the IMM – cable to be purchased separately
• Bench mode connector plug available for operation without IMM interface

Controller Valve Stem Operation Screen
UltraSync
• All screens provide access to the following:
-- Control Mode Buttons: Manual, Disable and Auto controls
-- Command Buttons: Close, open and calibrate controls
-- Status Field: Displays current active command and plate position
Home Screen
Displays indicators for all ready conditions and position, force and fault statuses as well as the
manual controls for open and close and calibration
Opening Profile Screen
Used for configuring and plotting the speed and force profiles for the stem opening motion
• Two available steps for opening
• Position and speed settings for each step

Controller Valve Stem Operation Screen
Closing Profile Screen
Used for configuring and plotting the speed and force profiles for the stem closing motion
-- Three available steps for closing
-- Position and speed settings for each step
-- Settings for closing hold force
Setup Screen
UltraSync
Used to set the At-temp soak time, Relax force limit, Relax delay time, behavior after calibration,
and configuring values for At-Position and Position Alarm Window monitoring functions as well
as accessing other screens for configuring engaged mode commands and conditions for signals
used for permitting calibration or disengaging, configuring the maintenance position on Gen 1
systems, setting up the stem pullback position and selecting the number of cavities and motor
type.

Overview
Ideal for Automotive parts
• One step installation
UNIFY
• Easy maintenance: one step removal from the mold
• Leak-proof UltraSeal® technology
• Available with new hydraulic or pneumatic valve stem actuator
• Dedicated and independent connector plates for water, oil or air, and electric wires
• Electrical-water-oil or air connectors can be installed to meet
customer requirements
• Nozzles are positioned to perfectly fit the mold seat
• One piece manifold system
• No need to heat the system during installation
• No need to align nozzle with seat
• Reduced risk of damage to the tips during installation
Back Front
• Customized, rigid services frame:

-- Matches the manifold and mold layout
-- Easy handling of the system during installation and maintenance
-- Connector plates rigidly fixed to the frame
System Details
• Actuator: easy to install and maintain
• Integrated cooling lines for hydraulic actuation
• Keyed stem and piston
• Easy to remove: allows fast access to stem without
exposing hydraulic oil

System Details
Hose Path
Electrical
Wire
Path
• Leak-proof retaining system • Standard clips for wire and hose:

• Husky standard nozzle stack -- Easy to replace
• Proven performance • Independent paths for wire and hoses:
-- easy to maintain separately
Installation Reference
A
Nozzle Gate
Actuation A B C D E BL Dim
Size Style
104mm
B Ultra
[4.09”] 45-80mm
35mm 25mm 77- 315mm
VG Hydraulic W/2mm [1.77-
1000 [1.37”] [0.98”] [3.03 -12.4”]
[.07”] 3.17”]
Shim
45-80mm
Ultra 84.5mm 35mm 25mm 77- 315mm
VG Pneumatic [1.77-
1000 [3.32”] [1.37”] [0.98”] [3.03 -12.4”]
3.17”]
45-80mm
Ultra 18mm 27mm 25mm 77- 315mm
HT None [1.77-
1000 [0.70”] [1.06”] [0.98”] [3.03 -12.4”]
C 3.17”]
104mm
Ultra 750
[4.09”] 40-80mm
Ultra Hydraulic 31mm 17mm 48- 300mm
VG 5mm W/2mm [1.57-
Helix (Lg) [1.22”] [0.66”] [1.61 -11.8”]
[0.19”] [.07”] 3.17”]
D 750
Shim
89.2mm
Ultra 750
E [3.51”] 40-80mm
Ultra Hydraulic 31mm 17mm 48- 300mm
VG W/1.5mm [1.57-
Helix (Sm) [1.22”] [0.66”] [1.61 -11.8”]
[.06”] 3.17”]
750
Shim
UNIFY
40-80mm
82mm 31mm 17mm 48- 300mm
Ultra 750 VG Pneumatic [1.57-
[3.22”] [1.22”] [0.66”] [1.61 -11.8”]
BL 3.17”]
40-80mm
14mm 25mm 17mm 51- 300mm
Ultra 750 HT None [1.57-
[0.55”] [0.98”] [0.66”] [2.0-11.8”]
3.17”]

Manifold Leg
UNIFY
A
B
D
C
Gating
Nozzle Size Actuation A B C D
Style
90mm 67mm 80mm 105mm
Ultra 1000 VG Hydraulic
[3.54”] [2.63”] [3.14”] [4.13”]
Ultra 1000 VG Pneumatic
[3.54”] [2.63”] [3.14”] [4.13”]
Ultra 1000 HT None
[3.54”] [2.63”] [3.14”] [4.13”]
Ultra 750 90mm 67mm 64mm 86mm
VG Hydraulic (Lg)
Ultra Helix™ 750 [3.54”] [2.63”] [2.51”] [3.38”]
Ultra 750 75mm 53mm 64mm 86mm
VG Hydraulic (Sm)
Ultra Helix™ 750 [2.95”] [2.09”] [2.51”] [3.38”]
74mm 55mm 64mm 86mm
[2.91”] [2.16”] [2.51”] [3.38”]
50mm 67mm 54mm 76mm
Ultra 750 HT None
[1.96”] [2.63”] [2.12”] [2.99”]

Pitch Spacing
• If drop to edge-of-plate distance is less than 150mm [6”], contact Husky to
review – alternate method of routing wires and hoses may need to be
implemented.
Less than 150mm [6”]
Examples of HT systems that required alternate method of wire management:

UNIFY

Pitch Spacing
UNIFY
Nozzle Gating
Actuation Min Pitch Layout
Size Style
R 108mm
[4.25”]
117mm
[4.61”]
Ultra
HT None
1000
R 108mm
[4.25”]
74mm
[2.91”]
Ultra
HT None
750
117mm R 108mm
[4.61”] [4.25”]
Ultra
VG Hydraulic
1000

Pitch Spacing
Nozzle Gating
Size Style
114mm R 101mm
[4.49”] [4”]
Ultra Hydraulic
VG
750 (Large)
ø 185mm 100mm
[7.28”] [3.94”]
Ultra Hydraulic
VG
750 (Small)
R 108mm
117mm [4.25”]
[4.61”]
Ultra
VG Pneumatic
1000
UNIFY

Pitch Spacing
UNIFY
Nozzle Gating
Size Style
R 95mm
[3.74”]
96mm
[3.78”]
Ultra
VG Pneumatic
750
Stem Stroke
Large Small Large Small Small
Hydraulic Hydraulic Pneumatic Pneumatic Hydraulic
Short Stroke
13.6mm 12.4mm 13.6mm 12.4mm 7.4mm
Stem Stroke
[0.53”] [0.48”] [0.53”] [0.48”] [0.29”]

Overview
Perfect to mold parts with optical or high aesthetic requirements
• Ideal for Automotive Lighting applications
• Angled manifold to place the Nozzle in the best gating position for the part
• Lucent™ includes UltraSeal® technology with a 3 years leak-proof warranty
• Easy installation: manifolds are bolted directly on the cavity
• Independent actuators available in Pneumatic and Hydraulic versions
• Easy access and maintenance
Easy Maintenance, simple Actuator Removal

• Full access to the stem
• Do not require to uninstall the system from plates / mold
Bolted Manifold System

Overview
Main Technical Features

1. Specialized steel and proprietary coating to avoid polycarbonate degradation
2. New shoulder designed to minimize the thermal losses
3. Jacket heaters easy to replace
4. Nozzle tip design with four different material combinations leads to

best thermal insulation and the lowest dissipation with the mold

C D
Gating
Nozzle Size Actuation Stroke A B C D
Style
13.8mm 96mm 67mm 58mm 85mm

Ultra1000 VG Hydraulic
[0.54”] [3.78”] [2.64”] [2.28”] [3.35”]
13.8mm 96mm 67mm 58mm 85mm

Ultra1000 VG Pneumatic
[0.54”] [3.78”] [2.64”] [2.28”] [3.35”]
96mm 58mm 85mm

Ultra 1000 HT None None None
[3.78”] [2.28”] [3.35”]
13.8mm 93mm 67mm 54mm 80mm

Ultra 750 VG Large Hydraulic
[0.54”] [3.66”] [2.64”] [2.13”] [3.15”]
12.42mm 80mm 53mm 54mm 80mm

Ultra 750 VG Small Hydraulic
[0.48”] [3.15”] [2.09”] [2.13”] [3.15”]
Small Hydraulic 7.42mm (APP) 92mm 53mm 54mm 80mm

Ultra 750 VG
(Short Stroke, APP) [0.29”] [3.62”] [2.09”] [2.13”] [3.15”]
12.42mm 80mm 55mm 54mm 80mm

[0.48”] [3.15”] [2.17”] [2.13”] [3.15”]
76mm 54mm 80mm

Ultra 750 HT None None None
[2.99”] [2.13”] [3.15”]

Min 97mm
°Max 45deg [3.81”]

A
C
D
U1
00
U7
E 6”] ”]
0
BL
[2.3
50
m [7.87
65 5- 1 m
0 m
[2. 400m .74”]
n6 mm
-40 5.7
65 5- 15
Mi x 200
5
[2.
-
0m 4”]
Ma
5
Nozzle Gating
Actuation Stroke A B C D
Size Style
103.5mm
[4.07”]
13.8mm 26.5mm
Ultra1000 VG Hydraulic W/1.5mm
[0.54”] [1.04”]
[0.06”]
Shim
45-60mm
13.8mm 84.5mm 26.5mm
Ultra1000 VG Pneumatic [1.77-2.36”]
[0.54”] [3.32”] [1.04”]
18mm 18.75mm
Ultra 1000 HT None None
[0.70”] [0.74”]
103.5mm
[4.07”]
13.8mm 22.623mm
Ultra 750 VG Large Hydraulic W/1.5mm
[0.54”] [0.89”]
[0.06”]
5mm Shim
[0.19”] 89mm
[3.5”]
12.42mm 22.623mm
Ultra 750 VG Small Hydraulic W/1.5mm
[0.48”] [0.89”]
[0.06”]
Shim
79mm 40-60mm
Small Hydraulic [3.11”] [1.57-2.36”]
7.42mm (APP) 22.623mm
Ultra 750 VG (Short Stroke, W/1.5mm
[0.29”] [0.89”]
APP) [0.06”]
Shim
12.42mm 82mm 22.623mm

[0.48”] [3.22”] [0.89”]
14mm 16.623mm
Ultra 750 HT None None
[0.55”] [0.65”]

A B
D C
Nozzle Size A B C D
120mm 38.5mm 77mm 95mm

Ultra 1000
[4.72”] [1.51”] [3.03”] [3.74”]
120mm 32.5mm 65mm 90mm

Ultra 750
[4.72”] [1.27”] [2.55”] [3.54”]
20
Nozzle Size Actuation C D

84.6mm 90mm
Pneumatic
[3.33”] [3.54”]
Ultra 1000
103.4mm 109mm
Hydraulic
[4.07”] [4.29”]
82.2mm 88mm
Pneumatic
[3.21”] [3.46”]
103.4mm 109mm
Hydraulic
[4.07”] [4.29”]
Ultra 750
89.2mm 95mm
Small Hydraulic
[3.51”] [3.74”]
79.2mm 85mm
Hydraulic Short Stroke (APP)
[3.11”] [3.34”]

Flow Simulation
Flow Simulation Service Capabilities
Consulting Services
Services
Husky’s Flow Simulation Center (FSC) offers a full range of flow simulation consulting
services to evaluate the filling, packing and cooling phases of the injection molding process
and predict part warpage upon ejection.
See the Capabilities chart for a complete listing of our offerings. A customized report of the
provided service will be supplied to the customer.
MPA MPI
(Basic fill analyst) (Advanced fill services)
Cavity Pressure X X
System Pressure X
Identify Filling Issues X
Air Trap Location X
Air Trap Elimination X
Weld Line X
Weld Line Elimination X
Hot Runner Balancing X
Gate Location Optimization X
Clamp Tonnage Prediction X
Cooling Optimization X
Warpage Prediction X
Material Selection/Optimization X
Injection Time Evaluation X X
Sequential Gating X
Wall Thickness Optimization X
Cold Runner Optimization X
Packing Phase Simulation X
Cooling Phase Simulation X
Core Deflection X
• MPA is intended for fast validation of a model during part design

-- Results are best suited for part with low to medium complexity
• MPI is intended for optimization of the part and mold

-- Provides significantly more detailed results
-- Addresses complex part designs

Refurbishment
Hot Tip
6 1 3-4
Maintenance Task
Months Year Years
Clean and visually inspect nozzle tip insert, tip retainer seal-off
diameter, and tip insulator P
Clean and visually inspect sprue bushing P
Perform a meter check on all electrical against the provided
electrical schematic P
Remove manifold backing plate; Visually inspect for plastic leakage P
Remove water fittings and check for corrosion deposits within
channels; Analyze water if necessary P
Clean and visually inspect locating ring P
Inspect manifold heater and heater insulation P
Remove manifolds and nozzle stacks from plates;
Clean and inspect melt channels. P
Replace center locating insulator, nozzle disc springs, and back up
P
Services
pads
Replace nozzle tip inserts, tip retainers, and tip insulators P
Remove sprue bushing;
Clean melt channel and rework spherical radius P
Replace sprue heater and thermocouple P

Refurbishment
Valve Gate
Services
6 1 3-4
Maintenance Task
Months Year Years
Clean and visually inspect nozzle tip retainer, tip insulator, and valve
stem P
Clean and visually inspect sprue bushing P
Perform a meter check on electrical components;
Verify electrical readings to electrical schematic P
Remove manifold backing plate; Clean plastic leakage around valve
gate back up pad/ manifold surface P
Remove valve gate cylinder and piston assembly;
Clean and visually inspect air sealing surfaces P
Clean and inspect valve gate piston;
Replace valve gate piston seal P
Remove water fittings and check for corrosion deposits within
channels; P
Analyze water if necessary
Clean and visually inspect locating ring P
Inspect manifold heater and heater insulation P
Remove manifolds and nozzle stacks from plates;
Clean and inspect melt channels. P
Replace center locating insulator, nozzle disc spring, and back-up pad P
Replace nozzle tip retainer, tip insulator, and valve stem P
Remove sprue bushing;
Clean melt channel and rework spherical radius P
Replace sprue heater and thermocouple P

Controllers Overview
Altanium® Operator Interfaces
Neo2* Delta3** Matrix2***
1-48 Zones 1-128 Zones 1-255 Zones
• Full featured • Full featured HR temperature • Full featured HR

hot runner and optional UltraSync-E™ temperature w/
temperature control optional integrated
control UltraSync-E™ and Mold
• Optimized for 24-96 Cavity
Servo control
• Optimized for Applications
2-16 Cavity • Optimized for >96
• 12” Color Touchscreen
Applications Cavity Applications
• 6” Color • 19” Color Touchscreen
Touchscreen
Altanium® Cards and Mainframes

• Interchangeable Across
H-Series Control all Configurations
Cards • 4z 5A, 2z 16A and 1z
30A
General Controller Information
• Small Foot Print with

Neo2 Compact Integrated Interface
Mainframes
• Up to 42z
• Standard and Custom

Free Standing Configurations
Mainframes
• Up to 255z
*Neo2 can be retrofitted to existing 1-48 zone controllers (X, C, CX & A)

**Delta3 can be retrofitted to existing 1-128 zone controllers (X, C & CX only)
***Matrix2 can be retrofitted to existing 1-254 zone controllers (X, C & CX only)
All controllers have a 5 year warranty; this includes the interface, cards and mainframe.
Cards are in the process of being switched over from green to red

Controllers Overview
Systematic Elimination of Process Variability

• Good temperature control helps molders to reduce scrap rates
Fill Balance Gate Quality Part Finish

Stringing or crowning
Inconsistent part weight Resin degradation leading
resulting in unacceptable
and dimensional stability to black specs and streaking
parts
• Altanium® is a building block within an injection molding system that eliminates

one process variable by accurately controlling the temperature of the melt in the
hot runner system
• By utilizing an Altanium®, users can achieve better melt stream management
which contributes to a more capable system producing higher yields
Greater Accuracy and Repeatability

• Optimal temperature control is determined by three major influences:
-- Input signal quality
-- Control algorithm precision
-- Power output speed and uniformity
• Altanium® employs Active Reasoning Technology (ART) to ensure that each of
these elements are accounted for during the control process:
Input Signal Control Algorithm Power Output

HRC High immunity to >15M control 10ms or less
electrical noise combinations modulation rate
1000 samples per sec.
MOLD Temperature Heating Element

Sensor

Key Advantages
ART-Active Reasoning Technology
ART delivers tighter control & less variability utilizing the following methods:
ART Advantage Altanium® Others
+15M Control Combinations:
ART differentiates itself by

having over 15 million control
combinations available so it is
able to generate a parameter
set to precisely fit each zone’s
unique thermal response
characteristics without having
to rely on preset defaults
based on heater Greater range of control Control algorithm is limited in its
classifications (e.g. tips, algorithms to adjust to the ability to adapt to the different
manifolds and sprues) specific thermodynamic thermodynamic conditions in
conditions in gate area gate area
10ms or Less Modulation Rate:

Once the optimal control Gaps = No Power to Heater
<10ms
algorithm is calculated, ART <250ms <500ms
utilizes a modulation method
that provides a uniform flow
of power at a rate of 10 mil-
liseconds or less, which greatly
reduces the time when no en-
ergy is being delivered to the
heater, resulting in minimal
deviations in temperature Phase Angle modulation Large gaps in power output result
minimizes gaps in power output in oscillations in temperature
to heaters to under 10ms over time
1000 Samples per Second:

Same Signal Different Signal

Using a thermocouple
oversampling technique the
integrity of the temperature
signal is ensured by taking a
temperature measurement
every 1 millisecond. This al-
lows the algorithm to execute
power changes based on the
most accurate data Oversampling ensures the Under sampled temperature
temperature signal is reproduced signal is reproduced at a different
at the same frequency frequency
~100% Immunity to Electrical
Noise:
Additionally, the reliability of
the temperature signal is
preserved through a
thermocouple circuit design
that provides a high degree of
immunity to electrical noise,
regardless of the hot runner
design or processing Isolation ensures noise on the line Lack of isolation allows noise on
environment does not distort the temperature the line to distort the temperature
signal signal

Key Advantages
ART-Active Reasoning Technology (Continued)

Actual testing showed ART allowed processing setpoint to be reduced by 13°C [55.4 °F]
2730C [5230F]
Material Processing
Processing Window with 2600C [5000F]
Manufacture Recommend Process Setpoint
Window ART 130C [55.40F]
247.250C [477.050F]
2470C [4760F]
246.250C [475.250F]
2460C [474.80F]
Time
*Results from lab tests on several resin and applications, individual customers may experience different results
• Benefit
-- More accurate and repeatable control with minimal cavity-to-cavity and shot-to-shot variability
contributing to better part quality and process stability
-- Reduced process temperatures resulting in lower energy cost & faster cycles
-- Eliminates potential risk associated with electromagnetic interference emitted by servo motor
systems found in electric molding machines
Easy to use
• Testing has shown that Altanium® improves operational efficiency by 30%
55
50
45
40
35 *Results from head to
Time (M)
30 head comparison tests,

25 individual customers
20
may experience differ-
ent results
15
10
5
0
Competitor A Competitor B Competitor C Competitor D Altanium®
Set-up Time Heat-up Time Stabilization Time
• Benefit
-- Flat screen navigation and color coding provide an intuitive interface that shortens the
learning curve for new users
-- Automatic setup storage and recall ensures the same processing parameters are used for
a mold without operator intervention
-- Multilingual interface increased user adoption regardless of what region the controller is
operating

Key Advantages
Phase Angle and Zero-Cross Power Modulation
• Altanium® provides the ability to switch between Phase Angle and Zero Cross power
control for each zone
-- Phase Angle: Uniform flow of power reducing time that no energy is being
supplied to the heater and ability to limit applied voltage
-- Zero Cross: Switches at 0V eliminating electrical noise that can disturb sensitive
equipment on or adjacent to the controller supply lines
Phase Angle: Fast, uniform power delivery
Zero Cross: Noise free power modulation
• Benefit
-- Optimized power delivery to heaters based on the conditions under which the
controller is operating and the heaters thermal response
-- Provides optimal method for extending heater life by applying low voltage to
evaporate moisture trapped in the heater body
Wet Heater Low Voltage Bake-out
Phase Angle Result

Voltage is Heat is applied evenly and
120V Peak
constantly gradually evaporating moisture
falling while reducing arcing
Voltage is applied
for short duration
Zero Cross Result

Heat is applied abruptly and for
340V Peak Voltage is applied
for long duration long durations contributing to
arcing and premature failure
Voltage is
rising

Key Advantages
Automated Mold Diagnostics

• Altanium® is capable of real-time current and voltage
measurements providing the ability to test for and
identify issues associated with the following items:
-- Supply voltage and current delivery to each heater
-- Thermal response and correct electrical wiring
-- Open, reversed or pinched thermocouples
-- KWH usage per mold
-- Resistance and Wattage measurement for each heater
-- Zone to zone thermal analysis
• Benefit
-- Faster and more accurate diagnosis of mold
problems, reducing down time
-- Accurate accounting of power usage and associated cost, better cost per part
calculations
-- Soft rewiring of miswired molds, increasing up-time
Plastic Leak and Heater Failure Detection

• The real-time power deviation monitoring feature provides early warning
detection of resin leaks or heater failure in the mold
• As plastic fills the nozzle bore, it will increase the heat losses
to the gate insert and can affect the thermocouple
connection in the nozzle body.
• Additionally, a plastic leak in the manifold pocket can bridge
the air gap and pull heat away from the manifold
• Both of these conditions will result in a sharp increase in duty
cycle to maintain setpoint
• The Altanium® monitors these variations in real-time and
triggers an alarm to alert the user of a possible leak in the
mold
Single Heater Zone

• Some hot runner designs include zones that bridge heaters
in parallel controlled by a single thermocouple
Heater #1 Heater #2
• If one of these heaters were to fail, it would be difficult to
detect the specific location of the problem
Heaters Bridged Thermocouple • Additionally, the functional heater would run hotter to
in Parallel Junction compensate for the loss of the second heater and overheat
the steel and degrade the resin
• The Altanium® monitors these variations in real-time and
triggers an alarm to alert the user of a possible heater failure
in the mold
• Benefit
-- Mold Leak detection, decreased down-time and operating costs
-- Heater failure detection, address issue before part quality is compromised

Key Advantages
Reliable and Economical to Own
• System reliability is maximized by the integrated card design that minimizes
discrete connections and components
Processing
Power Supply
Thermocouple Inputs
Earth Leakage
External Heat Detection
Sink
One Connection Per
Power Switching Card
Dual Leg Switching
Current Measurement
(Located on the back of the board)
Cards are in the process of being switched over from green to red
Mitigate Risk of Mold Damage and Resin Degradation

• Closed-loop digital interlocks protect the molding process by reducing the need
for operator dependent actions
Injection Molding Machine

Altanium® (IMM)
At -Temp
PCM
R. Standby
-- AT-Temperature Output to IMM:

Connects to a signal in the IMM to prevent injecting into a cold hot runner
before the mold has reached processing temperature
-- PCM Output to IMM:

Connects to a signal in the IMM to stop it from cycling if the controller stops
heating the mold
-- Remote Standby Input from IMM:

Connects to a cyclical signal from the IMM to automatically lower the
temperature of the hot runner system to prevent resin degradation in the mold
if the IMM stops cycling

FTO (Finish to Order)
Mainframe Option

Choices Power Choices
Connector Card (Mobile stands
(w/integrated Input Cable Choices
Choices Choices and integrated
operator Choices digital I/O
interface only) package)
Husky (2L-1L)
Neo2 Husky standard

6 zone (24P-2L)
Husky (2L-2L) Neo2
6 Zone
200-240V H-cards DME standard

3Phase 16 amp (25P-1L)
(2 Zone)
Neo2 380-415V DME standard Neo2

12 Zone 3Phase (25P-1L) 12 Zone
Harting 16P
(2L-2L)
HAN E only
(380-415V only)
HL-cards
16 amp
Harting 16P (2 Zone) Neo2
standard (16P-2L) Harting 16P 24 Zone
Neo2 HAN E only (2L-lL)
24 Zone (380-415V only) HAN E only
(380-415V only)
FTO Lead-Time
• All FTO controller configurations have a 2 week lead-time from receipt of a clean order
-- Lead-time is subject to maximum quantity limitations for large orders (+5)
• The regions covered by this program are:
-- North America (2 weeks- Milton, VT)
-- Latin America – Excluding Brazil (3 weeks- Milton,VT)
-- EMEA (2 weeks- Dudelange, Luxembourg)
-- Asia (2 weeks- Shenzhen, China)

Dimensions
Neo2
Model
Height (H) Width (W) Depth (D)
Name
394mm 191mm 254mm
C3-1
[15.5”] [7.5”] [10”]
394mm 305mm [12”] 254mm
C6-1 Neo2 Side view
[15.5”] [10”] 24 zone 24 zone
635mm 305mm [12”] 254mm
C6-2
[25”] [10”]
Neo2 Neo2 Side View

6 zone 12 zone 6/12 zone
W D
Freestanding
Model Name Height (H) Width (W) Depth (D)
Legacy C12 304mm [12”] 254mm [10”] 228mm [9”]
1 Stack (4 Total Bays) 1244mm [49”] 457mm [18”] 558mm [22”]

1 Stack 2 Stack 3 Stack 4 Stack
Legacy
C12
D
W

Digital I/O Options
Signal
Interface Function Description
Type
Operator Interface
Remote Standby Places all zones that have a Remote Standby setpoint into Remote
All
Input Standby mode (Lower setpoint) whenever this input signal gets activated
Remote Boost Places all zones that have a Remote Boost setpoint into Remote Boost
All
Input mode (Higher setpoint) whenever this input signal is activated
Places the system in start mode whenever this signal is remotely

Remote Start
All activated. This state will remain until the STOP key is selected or Remote
Input
Stop is activated
Places the system in stop mode whenever this signal is activated. This
Remote Stop state will remain until the START key is selected or Remote Start is
All activated
Digital Input Input
(From IMM) NOTE: The system cannot be started when this input is active
Places all zones that have a Manual Boost setpoint into Manual Boost
Manual Boost mode (Higher setpoint) whenever this input signal is activated
All
Input NOTE: This is the same as if an operator touched the boost key in the operator
interface
Forces a warning message “Mold Cooling Lines are not Enabled” on the
screen until the signal has been deactivated. This signal is intended to
Delta3/ Cooling Lines Not come from a thermolator
Matrix2 Enabled Input
NOTE: Anytime the thermolator is turned off (Input signal active), the warn-
ing message will be displayed
Activated ONLY when all zones are above the Under Temperature alarm
At Temperature
All limit. This state will remain until any zone drops below the Under
Output
Temperature alarm limit or the controller is put in stop mode
Activated when an Abort condition occurs, and the zone's PCM setting is
PCM Relay
All set to System is set to System. This state will remain until the alarm condi-
Output
tion is CLEARED or RESET
Alarm Relay Activated when any Alarm or Abort condition occurs. This state will
All
Output remain until the alarm condition is CLEARED or RESET
Remote Standby
All Activated when controller has received the Remote Standby signal
Output
Activated ONLY when all zones with a Remote Boost setpoint are above
their under temperature alarm limit while in BOOST mode. This state will
remain until any zone drops below its under temperature alarm limit or
At Boost Temp
All the controller is put into Stop mode
Output
NOTE: If any or all zones go above the over temperature alarm limit the state
will remain
Digital Activated whenever the START button is pressed. This state will remain
All Run Light Output
Output until the system is placed in STOP mode
(To IMM)
Max Temp Error
All Activated when any zone exceeds the Over Maximum Temperature limit
Output
Activated when all temperatures are greater than the Mold Cooling
Mold Cooling Enabled Limit
All
Enabled Output NOTE: All temperatures must be equal to or lower than the Mold Cooling Ena-
bled Limit before the signal is deactivated once the system is in STOP mode
Activated ONLY when all zones with a Remote Standby setpoint are
above their under temperature alarm limit while in Standby mode. This
At Standby state will remain until any zone drops below its under temperature alarm
All Temperature limit or the controller is put into Stop mode
Output
NOTE: If any or all zones go above the over temperature alarm limit the state
will remain
Comm Error Activated if the controller stops communicating with any of the Control
All
Output Cards. This state will remain until communications are restored
Delta3/ Process Outside Activated if any critical process parameter violates its threshold setting
Matrix2 Limits Output NOTE: The threshold setting is located in the Process Limits screen

Delta3 and Matrix2 Hardware Overview
Integrated
Delta3 Alarm Beacon
Integrated
Touch Monitor
Integrated
Computer
Enclosure
Matrix2 Integrated
Alarm Beacon
Modular
Computer
Modular Enclosure
Touch Monitor
Integrated
Cable
Hanger
Delta3 Matrix2
Item Matrix2 Advantage
Screen 37% greater screen area for

304.8mm [12”] 482.6mm [19”]
Size displaying more data on a single page
Operator Interface
3X faster processor increases screen

AMD G-Series Intel Core i5
Processor switching speeds and
1.65GHz 2.70GHz
overall GUI performance
100GB 320GB 69% more data storage for images,

Drive Size
(SSD) (HDD) documents and mold files

Advanced Features
Easy to Use, Integrated Control Screens
Operator Interface
• Temperature, UltraSync-E™ and Servo Control screens integrated into a single
operator interface
Servo Control UltraSync-E™ Control
Home Screen
All screens are

accessible with a
single button press
Temperature Control Common Functionality
• By utilizing a scalable software platform Delta3 and Matrix2 have the capability
to grow with customers needs with minimal investment

Advanced Features
Monitor the Process from any Location
• Remote Monitoring Dashboard Application
-- Dashboard interface connects to multiple controllers over a network for
real-time monitoring of the following:
• Controller status – Running, stopped, etc…
• Process temperatures for each zone
• All user changes to individual control zones
-- Accessible from any web browser enabled device that supports Internet
Explorer 9, Chrome, Firefox or Safari
Can be viewed locally by

personnel from a workstation
OR
Online allowing off-site personnel

to monitor process remotely
Dashboard Applications Interface
Main Overview Screen
Event Log
Operator Interface
Zone Details Screen

Advanced Features
Get a Complete Picture of the Process
Operator Interface
• Shotscope NX Process Monitoring System Integration
-- Link directly to the Shotscope NX process monitoring system
-- Pull and monitor process data for the mold from the controller
-- Provides a more complete picture of the overall process by collecting mold and
machine data
Complete Picture of Process
UltraSync-E™ Gen2 Servo Control

• UltraSync-E™ Gen 2 functionality integrated directly into the Delta3 and Matrix2
interface
-- Stem velocity profiling and recall
-- Stem position and pull back adjustability
-- Stem force adjustability
-- Process data recording
• Available in standalone and integrated configurations
-- Standalone: UltraSync-E™ control only
-- Integrated: Combined UltraSync-E™ and hot runner temperature control
• Matrix2 supports UltraSync-E™ control for high cavity hot runners (>64 drops)
and dual UltraSync-E™ control (Control for both UltraSync-E™ systems are
integrated into the Matrix2 HMI) for stack systems or other designs that require
two UltraSync-E™ hot runners for the same mold
UltraSync-E™ + HR UltraSync-E™ + HR
Control w/Delta3 Control w/Matrix2
All in one Integrated

Servo and HR Control
(Also available in standalone
UltraSync-E™ Configurations)

H-Series Card Configurations
4z Card (5A) 2z Card (16A) 1z Card (30A)
HL-Series
Cards include markers that

denote the number of
supported zones
4z Card (5A) 2z Card (16A) 1z Card (30A)
H-Series
Please note that cards are in the process of being switched over from green to red
• Available zone configurations:

-- 4 zones @ 5A each (Optimized for tip zones)
-- 2 zones @ 16A each (Optimized for manifold zones)
-- 1 zone @ 30A each (Optimized for high wattage manifold zones)
• Models:
-- HL-Series
• Equivalent to ICC2 XL-Series, economical solution w/voltage but no current or
ground fault measurement
-- H-Series
• Equivalent to ICC2 X-Series,full-featured with current, ground fault and
voltage measurement
• Backplane
-- Accepts any combination of H/HL-Series cards
• Max zones per backplane: 24z (6 x 4z card)
H-Series Card
-- Phase balanced design

• Power is better distributed across slots to reduce input supply requirements
-- Not compatible with ICC2 cards
• Different keying and spacing on connector
• Communication and addressing structure is different
-- Same physical size and mounting as ICC2 backplane
• Possible to retrofit ICC2 mainframe for use with H-Series cards

H-Series Card Circuit Test Capabilities
• On startup, H-Series cards perform a heater circuit test on each zone simultaneously before
H-Series Card
full power is applied to minimize risk of damage to the controller or hot runner system
• This test is critical for detecting the following heater circuit faults:
-- Leakage: A low current short to ground that typically occurs when moisture is ab
sorbed by a heater’s insulation material
-- Power to Thermocouple: Occurs when a cable plugged into the thermocouple
connector on the mold is attached to the power output of the controller
-- Short Circuit: Occurs when current travels along an unintended path as the result of a
wiring error across the heater outputs, a pair of frayed conductors or a pinched wire
-- Open Circuit: Occurs when a conductor is broken or comes loose and no current flows
through the circuit it is associated with
-- Wrong Heater: This is a case when the heater exceeds the capacity of the zone it is
connected to in the controller. The system can be configured to automatically set the
Power Limit level
This test provides in under 17 seconds an automated comprehensive diagnostics of all zones
in the mold each time the controller is started reducing the need for conducting more time
consuming sequential thermocouple and heater checks and operator dependant actions.
H-Series Card — Circuit Diagram
Legend:
IT = Amperage Current
Sensor
IL = Leakage Current Sensor
E = Voltage sensor
Circuit Test Test Description Example Fault
Low level leakage

check, wet heater
bake-out evalua-
tion and power to
Level 1
thermocouple fault
assessment

H-Series Card Circuit Test Capabilities
Circuit Test Test Description Example Fault
Leakage check and

short circuit
Level 2
evaluation of
triac-side faults
Short Across Short Triac Side Triac Side
Source Triac Side Load Pulled Source
before Pinched out and Pulled out
heater Shorted and Shorted
Leakage check and

short circuit
Level 3
evaluation of
relay-side faults Short Relay Relay Side Relay Side
Side Pinched Load Pulled Source Pulled
out and out and
Shorted Shorted
3840W 4320W
Line-to-line check for
Level 4
over-sized heaters
H-Series Card

H-Series Card Key Improvements
H-Series Card
H-Series cards 4z Card (5A per Zone)
1 Independent mechanical relays
for each zone
-- Allows both legs to be isolated
when zone is turned off in run
mode
2 Differential current measurement
per zone
-- Improved ground fault and
short circuit detection
3 Redesigned voltage and current

measurement circuits
-- More accurate voltage and
current readings
4 Upgraded processor and CANbus

transceiver
-- More robust communications

with HMI
5 Better resolution on ADC and CJC

sensor reposition
-- More accurate thermocouple
measurement
Current
Measurement
on Backside 6 Fully isolated T/C channels
-- Greater immunity to electrical
noise
Please note that cards are in the process of being switched over
7 Fast acting short circuit
from green to red
detection built into
processor *
-- Detect short and open circuit
before fuse clears
* Effectiveness determined by the con-

figuration of the supply voltage / region
where operating
** Effectiveness determined by the length

of thermocouple wire in hot runner
system
• Benefit
-- Better troubleshooting and fault mitigation capabilities
• Detect a greater range of fault conditions by measuring both current and earth leakage
• Detect a short and stop power output before the fuse clears using the fast
acting short circuit detection function*
• Detect when power is applied to a thermocouple circuit in hot runner and stop power
before any damage occurs to the thermocouple wire housing**

H-Series Card Reduced Footprint
Mix 2z + 4z Cards All 2z Cards
• 8z and 10z configuration with mix of 2z + 4z cards (6 & 8 Drop HR):

-- Reduces footprint by 38%
H-Series Card
• Benefit
-- Reduce controller footprint by as much as 64% when using a combination of 4
and 2 zone cards
-- Smaller footprint equates to less space used in the molding cell allowing more
room for other equipment or operations

H-Series Card Feature Comparison
Functions / Cards
H-Series Card
Benefit
Features HL H
Integrated design
Allows for a lower internal operating temperature which extends
with external heat
sink
P P the working life of the cards
Provides accurate and repeatable temperature control that

Active Reasoning
Technology (ART) P P minimizes the deviation from setpoint allowing the opportunity
to reduce cycle times and energy consumption
Integrated all-in-one Minimizes discrete connections and components which increases
design P P reliability and reduces maintenance costs
Allows both heater legs to be isolated when zone is turned off
Safety relay on
non-switched leg P P and system is in run mode preventing shock or shorts to ground
when servicing the mold
4 zones per card @ Higher zone density reduces the overall foot print of the
5A each P P controller by as much as 25% saving valuable floor space
2 zones per card @ Maximizes flexibility to run different molds regardless of the tip/
16A each P P manifold wiring scheme
Optional 1 zone card Ability to accommodate high current manifold zones commonly
@ 30A P P used in automotive applications
Run with grounded Isolated thermocouple inputs provide the flexibility to run any
or ungrounded
thermocouples
P P mold without risk of electrical noise interfering with the
temperature measurement
Thermocouple Allows automatic on-the-fly recovery of failed thermocouples
slaving (auto and
manual)
P P based on following the power output of a similar zone,
eliminating any downtime
Zero-Cross or Phase
Uniform flow of power reducing time that no energy is being
Angle power output
control
P P supplied to the heater and ability to limit applied voltage
Card Reduced number of components to stock and maintain

interchangeability P P contributes to lower maintenance costs
Automated mold Quickly and accurately diagnose issues in the mold without the
diagnostics P P need for additional tools, limiting down-time and costs
On screen board Identifies the exact location of failed cards and components, such
diagnostics (Delta3
and Matrix2 only)
P P as a fuse or switching device, reducing down time and
maintenance costs
Power deviation
Real-time power deviation monitoring provides early warning
alarm for plastic leak
detection
P P detection of resin leaks or heater failure in the mold
5 year warranty Warranty covers the cards, mainframe and operator interface
(standard ~ including
interface)
P P regardless of the configuration
Softstart even Contributes to longer component life, reduced material

thermal expansion
on heat up
P P degradation due to excessive residency time and maximizes
energy efficiency

H-Series Card Feature Comparison
Cards
Functions /
Benefit
Features HL H
Provides optimal method for extending heater life by applying

Multi-cycle wet-
heater bake-out P P low voltage to evaporate moisture trapped in the heater’s
insulation material
Real-time voltage Helps in diagnosing heating issues in the mold and problems
measurement P P associated with the mains supply to the controller
Real-time amperage Helps in diagnosing problems in the mold, calculating power
measurement - P consumption and preemptive heater failure
Real-time wattage
Helps in diagnosing problems in the mold, determining heater
and ohm
calculations
- P size for replacement and calculating power consumption
Real-time ground Helps to detect ground faults and other types of shorts in the
fault
measurement
- P mold that single leg current measurement is not capable of
finding
Detects shorts in the mold and opens the circuit before the fuse
Fast acting short
circuit detection - P clears providing cost and time savings associated with replacing
blown fuses
HL-Series 4z 5A Card H-Series 4z 5A Card

H-Series Card

Standard Cable Packages
Cables
Husky Standard Power and Thermocouple Cables
Power: 24M – 2L/24F – 1L | T/C: 24F – 2L/24M – 1L
Reference Image Controller Wiring
Controller Connectors Female Male
Zone T/C (+) T/C (-)
Power Power
T/C White Red
1 1 13 1 13
2 2 14 2 14
PWR 3 3 15 3 15
4 4 16 4 16
5 5 17 5 17
Cable Connectors
6 6 18 6 18
7 7 19 7 19
8 8 20 8 20
9 9 21 9 21
T/C-Mold PWR-Mold
10 10 22 10 22
PWR - Controller T/C - Controller

11 11 23 11 23
12 12 24 12 24
Husky Standard Power and Thermocouple Cables

Power: 24M – 2L/24F – 2L | T/C: 24F – 2L/24M – 2L

Power Power
T/C White Red
1 1 13 1 13
2 2 14 2 14
PWR
3 3 15 3 15
4 4 16 4 16
5 5 17 5 17
Cable Connectors
6 6 18 6 18
7 7 19 7 19
8 8 20 8 20
9 9 21 9 21
10 10 22 10 22
PWR - Controller
PWR-Mold T/C-Mold
T/C - Controller 11 11 23 11 23
12 12 24 12 24

DME Standard Power and Thermocouple Cables

Power: 25M – 1L/25F – 1L | T/C: 25F – 1L/24F – 1L
T/C Power Power
White Red
1 1A 2A 1 13
2 3A 4A 2 14
PWR
3 5A 6A 3 15
4 7A 8A 4 16
5 2B 3B 5 17
Cable Connectors
6 4B 5B 6 18
7 6B 7B 7 19
8 1C 2C 8 20
9 3C 4C 9 21
10 5C 6C 10 22
T/C-Mold PWR-Mold 11 7C 8C 11 23
T/C - Controller PWR - Controller
12 9A 9C 12 24
Harting Standard Power and Thermocouple Cables

Power: 16M – 2L/16F – 1L | T/C: 16F – 2L/16M – 1L (HAN-E)
Controller Connectors (HAN-E) Female Male
Zone
T/C (+) T/C (-)
Power Power
White Red
T/C
1 1 9 1 9
PWR 2 2 10 2 10
3 3 11 3 11
Cable Connectors (HAN-E) 4 4 12 4 12
5 5 13 5 13
6 6 14 6 14
Cables
T/C - Controller
7 7 15 7 15
PWR - Controller T/C-Mold
PWR-Mold
8 8 16 8 16

Cables
Harting Standard Power and Thermocouple Cables
Power: 16M – 2L/16F – 2L | T/C: 16F – 2L/16M – 2L (HAN-E)
Controller Connectors (HAN-E) Female Male
Zone
T/C (+) T/C (-)
Power Power
T/C White Red
1 1 9 1 9
PWR 2 2 10 2 10
3 3 11 3 11
Cable Connectors (HAN-E) 4 4 12 4 12
5 5 13 5 13
6 6 14 6 14
T/C - Controller 7 7 15 7 15
PWR-Mold PWR - Controller T/C-Mold
8 8 16 8 16

Industry Trending Towards Electrification
• Electrification refers to the application of servo motors for controlling hot runner
or mold functions
• Functions include but Ejector, Coining or
not limited to: Stripper Plates
-- Valve Stems
-- Core Pulls
-- Coining Plates
UltraSync-E™
-- Stripper Plates
Synchronous VG
-- Ejector Plates Control
Core Pulls
Why Electric over Hydraulic or Pneumatic?

• Electric servo systems are:
-- More Precise: Servo actuators provide a much finer level of control throughout
the entire motion process enabling force, speed and torque to vary at different
steps during motion
-- More Efficient: Due to the conversion of electrical power to fluid power,
hydraulic systems are inefficient when compared to servo electric systems
(Typically 50% efficient, compared with 80%) resulting in significant energy
savings
-- Cleaner: An electric solution is naturally cleaner and environmentally friendly
with no risk of contamination or need to dispose of hazardous hydraulic fluid
-- More Reliable: Electric actuators require very little maintenance because there
are no oil hoses or seals to leak and repair
Typical Hydraulic Control System Servo Control System

Servo Control
• Complex
• Difficult to control
• Filled with contaminates
• Less Efficient

Altanium® Servo Control Differentiation
• Ease and Speed of Integration
Servo Control
-- Initial installation and commissioning can be done in half the time of a
conventional system
-- Actuators and drives commissioned at the factory
-- On-site start-up support and training
-- Easily repeatable for like-applications
• Ease of Use and Performance
-- Modifications to motion profile and system settings are significantly easier to
execute
-- Scan rate from the time the command is received and executed is
considerably faster (2ms per axis vs. ~17ms)
• Ease of Doing Business (Customer Intimacy)
• Full service application engineering support during order process
• Turn-key motion control solution: controller + actuators
• Scalable Integrated Solution
-- Standard all-in-one operator interface
-- 6 axes of servo control plus temperature and UltraSync-E™ control
-- Motion profile settings transferable between systems
-- Customizable I/O interface w/ IMM
• Controller Re-Purposing
-- Standard solution allows for re-purposing for use on other molds/applications
-- Drive units cover a wide range of motor sizes
• Global Support Network
-- Spare parts and technical service

Altanium® Servo Control Configurations
• Altanium® servo control (ASC) pertains to any product that connects to and
controls a servo motor
• These include the following:
-- UltraSync-E™ (USE): Synchronous electrically actuated valve stem control
-- Mold Servo Control (MSC): Electrically actuated mold functions
• Both products are available in standalone or integrated configurations with hot
runner temperature control (HRC) when using the Matrix2 interface
Matrix2 Interface
Standalone Configurations
OR
HRC MSC HRC USE
Integrated Configurations
Servo Control
MSC + USE MSC + HRC

Altanium® Servo Control System Architecture
Servo Control
Matrix2
Altanium® Servo Con-
trol systems are only
available with the
Matrix2 interface
2 or 3 Stack Enclosure
Servo Drives
1 Stack Enclosure
Used to amplify the
command signal from
the control system and
transmit electric
current to the servo
motor to produce
motion
Linear Axes
Output shaft attached
to motor moves in a
linear motion OR OR OR OR OR OR
Rotary Axes
Output shaft attached
to motor moves in a
Mold Servo Control UltraSync-E™
rotary motion
Machine Interface
Connectors and
cabling used to route
the digital I/O and • Indexing and Safety
safety signals between Signals
the machine and • Connectors and pin-out
controller are Husky Standard or
Customer Defined
1 Stack: 1-2 Drive 2 Stack: 2-7 Drives
Enclosures
House the drives and
1-2 Axis 2-7 Axis
associated circuitry H=1668mm [46”] H=1244mm [49”]
(Size is determined by W=450mm [17”] W=512mm [20”]
D= 560mm [22”] D= 560mm [22”]
the number & electrical
rating of drives)

Altanium® Servo Control Screen Overview
• Key features supported by the Altanium® Servo Controller:

-- User configurable digital I/O for indexing and interlock signals from IMM
-- Two speed jogging mode
-- Ability to add a custom name to individual axis and I/O signals
-- Grouping for easy parameter changes and manual operations
-- Position and force warning and alarm settings
-- User definable permissions for initiating calibration, enabling override mode, indexing to
a position and at a position
-- Multi-step motion profile for each indexed move
-- Time and force curves displayed for each axis
Servo Home Screen

• Overview of all Axes
• Access to other Servo screens
• Status, Force and Positions per
Axis
• Display all/actual Axis positions
• Manual Operations
-- Home Position
-- Index Move
-- Stop
-- Calibrate
• Manual Jogging
Controller Setup Screen

• Enter Group name
• Group Definition for Activation
• Individual Axis enabling
• Status Overview of all Axes:
-- All Calibration OK
Servo Control
-- All Home
-- No Faults
-- Ready to Engage (Auto Mode)

Servo Control
Axis Setup Screen
• Axis Type Selection (Linear/
Rotary)
• Calculated Max Values per Axis
• Force / Speed / Accel / Decel
Limits
• Define Positive Motion
(Extend/Retract/CW/CCW)
• Manual Jogging Speed
Definition
• Idle and Relax Settings
• Index Speed Scaling (%) for
Manual and Automatic Mode
-- Controller Engaged, IMM in
Auto
-- Controller Engaged, IMM in
Manual
-- Controller Disengaged
-- Homing
Axis Position Setup Screen

• Max/Min Stroke
• Number of Positions
• Name of Positions
• Target Value per Position
• Calibration Settings
-- Calibration Reference
-- Calibration Force and Speed
-- Go-To Position after
Calibration
• Tolerance Window for At
Position
• Alarm Window for Position
Deviation
• Force Warning % (Trend info)

Axis Permissions Screen

• 8 Permission settings per Axis
• Position/Signal selection
• Status LED
• Signal Inversion (NO/NC)
• Permission as Start or
Continuous Condition
• Jogging using Index Position
(Otherwise jog in override mode
only)
• Sequencing of Axis/Steps
-- Start Trigger (Signal) per
Indexed Move
-- Apply Hold Force
-- Set Relax Limit
Motion Profile Screen

• Target Positions per Axis and
Step
• Define Number of Motion Steps
• Motion Profiles
-- Position (Forward/Back)
-- Speed
-- Accel / Decel
-- Force Limit per Step
• Motion Curves
-- Speed/Force per Indexed
Motion Step
-- Curve Values Displayed by
Touching Curve
• Measured Values every Cycle
Servo Control
-- Position
-- Move time
-- Peak force
• Stored for viewing in Process
History screen

Servo Control
Servo I/O Screen
• Access to all Safety and Digital I/O

channels
• Provides status of all connected signals
• Fields for adding user definable labels to
each I/O channel
• Each I/O channel can be inverted or set to
be forced high or low
• All I/O channels are labeled with the call
out in the electrical schematic for easy
identification
• Configurable signals are outputs that use
Boolean logic and can be assigned
inputs, outputs and other signals as
conditions for a specified adjustable
signal that when all are TRUE the
specified signal is ON

Altanium® Servo Control Axes
• Control for up to 6 axes of mold functions and 1 UltraSync-E™ axis
-- Axes refer to the number of servo motors to be controlled: 1 motor = 1 Axis
• Applications include any mechanical movement in the mold or other area of the
molding cell
Number of Supported Axes Supported Motion Types
6 Axes for Mold Functions Linear Rotary
1 Axis for UltraSync-E™

Servo Control

Standard Motors and Actuators
• The number of axes, type of motion, force, torque, speed and lifetime
Servo Control
requirements will determine the quantity, type and size of the motor or actuator
• The motor and actuator brands that will be offered are:
-- Rotary Axis Motor: Baumueller

• DSC Series:
- Used on UltraSync-E™
- Speeds up to 4000 rpm
- Compact design with high
power density
- Excellent smooth running characteristics Output
Shaft
- High overload capability
-- Linear Axis Actuator: Exlar

• GSX Series (High performance)
and GSM Series:
- All-in-one compact unit
- High capacity roller screw exceeds
ball screw load ratings and life
- EnDat® 2.1 absolute encoder
(other options available)
Roller screw translates
- Very popular in industry for linear rotational motion to linear
within the actuator –
applications Output Shaft no external mechanical
solution required
• Motors and actuators will be included on all quotes for new mold applications
• Retrofit applications will be evaluated for compatibility based on the supported
feedback type
• Motors and actuators must be tuned at the factory with the controller before
shipping to the customer or mold maker

Servo Motor and Actuator Feedback
• Closed loop feedback is what differentiates a servo system and is used to sense
the speed, direction and position of the motor shaft
• Altanium® Servo Controllers support two types of feedback from the motor
or actuator:
-- Absolute Encoder: EnDat® 2.1

• Digital feedback of absolute position
• If power is lost, its output will be correct
whenever power is restored
• It is not necessary to recalibrate
(move to a reference position – “Home” or “Start”)
-- Resolver
• Analog feedback of absolute position within one
revolution
• More robust solution for demanding
environments
• Requires recalibration after power loss
• Ensuring the feedback type is compatible with the Altanium® Servo

Controller is critical in determining if it can be used as a retrofit solution for an
existing application
• Most manufactures offer a wide range of supported feedback types, including the ability
to retrofit an existing motor or actuator so it is compatible with the Altanium® Servo
Controller
Servo Control

Altanium® Servo Control Application
Assessment
Servo Control
• Application scenarios and minimal required information to quote
-- New mold design with no existing servo actuators or controller
• Minimal Information Required: Refer to Servo Motor Sizing chart below
-- Existing mold with hydraulic actuators to be retrofitted with electrical
actuators and Husky controller
• Minimal Information Required: Refer to Servo Motor Sizing chart below
-- New mold design with their own servo actuators and a Husky controller
• Minimal Information Required: Manufacture and model numbers of actuators
-- Existing mold with electrical actuators and controller, but wants to replace only
the controller
• Minimal Information Required: Manufacture and model numbers of actuators
Servo Motor Sizing – Minimal Required Information
General Unit of Measure
Number of axes to be controlled 1-6 - -
Type of motion for each axis Rotary Linear
Standalone or integrated w/Temp w/UltraSync-E™ Both
Stroke and Speed Requirements Unit of Measure
Maximum Stroke mm inch rev
Index Stroke Length mm inch rev
Index time Seconds - -
Maximum Speed mm/sec in/sec rev/sec
Minimum Speed mm/sec in/sec rev/sec
Load and Life Requirements Unit of Measure
Gravitational Load N lbF -
External Applied Load N lbF -
Inertial Load N lbF -
(or) Mass kg lbm -
(and) Acceleration m/sec² ft/sec² -
Friction Load N lbF -
Rotary Inertial Load Kg-m² lbF-in-sec² -
(or) Rotary Mass kg lbm -
(and) Radius of Gyration mm inch -
Cycling Rate sec cycle/min cycle/hr
Life Requirement cycles hours -

Altanium® Servo Control Motion Breakdown
• There is a limit of up to 4 index positions for each axis
-- Motion can only be a sequence of up to 4 indexes that have to be executed sequentially
without skipping any of the programmed steps and cycle back to the 1st position after
the 4th
-- Each indexed move can be profiled up to 4 steps (Speed, Accel and Decel)
-- Length, time and speed details for each index segment is required to properly size the
motor or actuator
Rotary Motion Example

Home Pos.
Index Pos. 4
Note: Each indexed move can be greater than 360⁰

0°
Rotary Axes 360°
Index Move
Index 270° 90° Index Pos. 1
Pos. 3
180°
90° Index Pos. 1
11
In
0°
de
Prof. S
xe
tp. 1
d
M
16
Index Pos. 2
ov
180°
0°
Index Move
Pr
of
Profile
.S
tp
Index Pos. 2
.2
Prof. S
tp. 3
Linear Motion Example

Home Pos.
Index Pos. 4 Index Pos. 1 Index Pos. 2 Index Pos. 3
Linear Axes
Index Move
Servo Control
Home Pos.
Index Move Index Pos. 4 Indexed Move Index Pos. 1
Profile
Prof. Stp. 1 Prof. Stp. 2 Prof. Stp. 3

Altanium® Servo Control Interface to Machine
• The machine interface are connectors that contain all of the safety and indexing signals
Servo Control
that connect using cables that run between the controller and machine
Indexing and Safety Signals

(Start/End of Motion, Safety Gate, E-Stop, etc…)
• Digital I/O signals only (No analog signals supported)

-- 1 Axis = 8 User Definable Outputs, 6 User Definable Inputs
-- 2-6 Axes = 15 User Definable Outputs, 22 User Definable Inputs
Standard IMM Interface

• Husky standard X200 and X201
connectors at the controller:
-- Connector type is Harting Han A 32P
-- Cables supplied as standard – Flying lead
on field end
-- Connector can be added to field end – Fee
may apply
Custom IMM Interface

• Other standards are supported:
-- Customer or industry defined standard –
Fee may apply
-- Any customization will be handled
by application engineering as a special

Injection Molding Resin Grades
Processing Melt Temp Processing Mold Temp Temperature High Weepage
Acronym Corrosive
Range °C [°F] Range °C [°F] Sensitive Temperature Prone
ABS 160 - 290°C [320-554°F] 10-90°C [50-194 °F] NO NO NO NO
ASA 190-280°C [374-536°F] 30-80°C [86-176°F] YES NO NO NO
CAB 180-240°C [356-464°F] 40-80°C [104-176°F] YES NO NO NO
CAP 195-255°C [383-491°F] 65-95°C [149-203°F] NO NO NO NO
COC 200-300°C [392-572°F] 40-130°C [104-266°F] YES NO NO NO
COP 240-320°C [464-608°F] 25-110°C [77-230°F] NO NO NO NO
EVA 160-220°C [320-428°F] 10-40°C [50-104°F] NO NO NO NO
EVOH 200-260°C [392-500°F] 30-80°C [86-176°F] NO NO NO NO
HDPE 120-290°C [248-554°F] 10-95°C [50-203°F] NO NO NO YES
Ionomer 180-260°C [356-500°F] 10-50°C [50-122°F] YES YES NO NO
LCP 280-380°C [536-716°F] 30-100°C [86-212°F] YES NO NO NO
LDPE 148-280°C [298.4- 536°F] 10-70°C [50-158°F] NO NO NO NO
LLDPE 135-280°C [275-536°F] 10-70°C [50-158°F] NO NO NO NO
MABS 200-280°C [392-536°F] 25-80°C [75-176°F] YES NO NO NO
MBS 190-230°C [374-446°F] 20-70°C [68-158°F] NO NO NO NO
MDPE 150-230°C [302-446°F] 20-40°C [68-104°F] NO NO NO NO
Nylon 210-350°C [410-662°F] 10-190°C [50-374°F] YES NO NO NO
PARA 250-290°C [482-554°F] 120-140°C [248-284°F] YES NO NO NO
PBT 40-320°C [104-608°F] 15-270°C [59-518°F] YES NO NO NO
PBT+PC 220-300°C [428-572°F] 15-95°C [59-203°F] YES NO NO NO
PC 250-325°C [482-617°F] 45-150°C [113-302°F] YES NO NO NO
PC+ABS 180-300°C [356-572°F] 30-100°C [86-212°F] YES NO NO NO
PC+PET 240-300°C [464- 572°F] 20-120°C [68-248°F] YES NO NO NO
PCTA 235-290°C [455-554°F] 15-40°C [59-104°F] YES NO NO NO
PE 180-280°C [365-536°F] 10-50°C [50-122°F] NO NO NO YES
PEBA 160-280°C [320-536°F] 20-40°C [68-104°F] NO NO NO NO
PEEK 350-405°C [662-761°F] 150-220°C [302-428°F] YES NO YES NO
PEI 320-440°C [608-824°F] 65-180°C [149-356°F] YES NO YES NO
PEN 280-320°C [536-608°F] 20-60°C [68-140°F] YES NO NO NO
PES 245-400°C [473-752°F] 90-190°C [194-374°F] YES NO YES NO
PET 240-315°C [464-599°F] 10-145°C [50-293°F] YES NO NO NO
PET-G 220-305°C [428-581°F] 10-65°C [10-149°F] YES NO NO NO
PFA 350-420°C [662-788°F] 120-240°C [248-464°F] NO YES YES NO
PLA 160-230°C [320-446°F] 10-40°C [50-104°F] YES YES NO NO
PMMA 195-305°C [383-581°F] 25-95°C [77-203°F] YES NO NO NO
POM 170-235°C [338-455°F] 50-120°C [122-248°F] YES NO NO NO
PP 160-295°C [320-563°F] 10-100°C [50-121°F] NO NO NO YES
PPA 270-360°C [518-680°F] 60-180°C [140-356°F] NO NO YES NO
PPE 260-310°C [500-590°F] 60-100°C [140-212°F] YES NO NO NO
PPE+PS 240-340°C [464-644°F] 32-150°C [89.6-302°F] YES NO NO NO
PPS 280-345°C [536-653°F] 45-170°C [113-338°F] YES YES YES NO
PPSU 340-410°C [644-770°F] 110-180°C [230-356°F] YES NO YES NO
PS 175-320°C [347-608°F] 10-150°C [50-302°F] NO NO NO NO
PSU 270-395°C [518-743°F] 90-160°C [194-320°F] YES NO YES NO
PVC Flexible 155-210°C [311-410°F] 30-60°C [86-140°F] YES YES NO NO
Applications
PVC Rigid 160-210°C [320-410°F] 20-60°C [68-140°F] YES YES NO NO

PVDF 215-260°C [419-500°F] 50-125°C [122-257°F] NO YES NO NO
SAN 200-280°C [392-536°F] 15-90°C [59-194°F] NO NO NO NO
SBS 170-265°C [338-509°F] 15-60°C [59-140°F] NO NO NO YES
SEBS 175-230°C [347-446°F] 20-40°C [68-104°F] NO NO NO YES
SMA 205-290°C [401-554°F] 20-60°C [68-140°F] NO NO NO NO
TPE 130-280°C [226-536°F] 10-120°C [50-248°F] NO NO NO YES
TPO 120-280°C [248-536°F] 10-95°C [50-203°F] NO NO NO YES
TPU 165-260°C [329-500°F] 10-120°C [50-248°F] YES NO NO YES
TPV 170-280°C [338-536°F] 10-80°C [50-176°F] NO NO NO YES
UHMWPE 175-260°C [347-500°F] 80-110°C [176-230°F] NO NO NO NO

Gate Cooling
Benefits
Applications
• Consistent gate quality and vestige
• Improved control of material stringing,
resin drool and gate blushing
• Faster cycle time
Optimized Cooling
• Standard tips
-- Maximum distance between channel and
gate detail = 2-3x channel dia.
-- Minimum distance between channel and
critical surfaces = 1-1.5x channel dia.
-- Cooling should surround insert and
be uniform across the tool
-- Flow rate = 1.8-2.2 gpm [6.1I/min-8.3I/min] to achieve X
turbulent flow (Re>4000)
-- Cooling position based on heat sink location 2-3X
not proximity to gate detail min 1-1.5X
-- Insert material determined by

projected cycles/cycle time goals
• Extended tips (HT-X, VG-X, VG-XX) *

-- Should not have cooling in front of
seal ring Seal Ring
** P
• SideGate
-- Contact Hot Runner Sales Support
Application Engineer

Extended Tip- Gate Detail
* Minimum of 1-1.5x cooling diameter clearance to nozzle bore
** Position the cooling centerline at the mid-point of the seal-ring
locating diameter
Independent Cooling Circuits

• Cavity / manifold plate cooling circuits should

not be shared between plates
• Independent circuits prevent coolant leakage
when plates are separated
P
Gate Inserts
• Cools entire gate area circumference
• Insert cooling circuit provides improved
gate temperature control
• Replaceable wear item

Husky actively protects its technical and design innovations through a global intellectual property
strategy. Husky currently has more than 900 patents and patent applications worldwide. The equipment
shown in this publication may be covered by one or more of these patents.
®/© 2017 Husky Injection Molding Systems 2017

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Hot Runner

1 General Hot Runner Information

106 H-Series Card

General Hot Runner Information

Hot Runner Product Guide v 5.0 1

Valve Stem Piston

Tip Retainer Backup

2 Hot Runner Product Guide v 5.0

General Hot Runner Information

28- 300mm 29.3- 300mm 82 -320mm 82 -320mm

Ultra 750 & Ultra Helix™ 750 (VG

27.4- 290mm 27.4- 290mm 57 -305mm 64 -305mm

Ultra 500 & Ultra Helix™ 500 (VG

14–290mm 20 –290mm 70-305mm 85 -305mm

Ultra 350 & Ultra Helix™ 350 (VG

17 –170mm 17–170mm 53 -185mm 53 -185mm

13 –150mm 79- 165mm

Hot Runner Product Guide v 5.0 3

Bars represent typical Melt Flow Index ranges

4 Hot Runner Product Guide v 5.0

General Hot Runner Information

• Purge the Barrel

Optimize color change process

Run parts with new color

Hot Runner Product Guide v 5.0 5

Wide Operating Window

Wear Resistant Tip Inserts

6 Hot Runner Product Guide v 5.0

Hot Tip Nozzle Stacks

Tip / Gate iii. Tip land v ii

Vestige Height=1/2 Gate Diameter or

5% - 10% Occurrence: HDPE, POM

10% - 15% Occurrence: PA, LDPE

General Guideline: Stringing can occur on any hot tip system

Hot Runner Product Guide v 5.0 7

HT General purpose thermal gate.

HT-C Capped general purpose

Typically used for Hot-to-cold

8 Hot Runner Product Guide v 5.0

Hot Tip Nozzle Stacks

Standard Product Not Available

Hot Runner Product Guide v 5.0 9

Ultra HT-DX 12.5 7.0 20.1

Ultra 23.8 14.00 6.40 3.25 9.005 1.50

Ultra 23.8 6.67 4.905 3.00

* Flexible measurement to be confirmed with original gate detail drawing

10 Hot Runner Product Guide v 5.0

Hot Tip Nozzle Stacks

Size Tip Style A* B C D E F G Gate Detail

Ultra HT-U 31.0 21.0 13.5 5.34 14.01 9.1

Ultra 31.0 21.0 13.0 14.005 3.50

Ultra 31.0 8.5 9.005 4.2

* Effective interfacing diameter on manifold plates is 35 mm [1.377"]

Hot Runner Product Guide v 5.0 11

Gate Detail Dimensions

Ultra HT-D 42.0 18.010 13.0 6.30 BB

* Effective interfacing diameter on manifold plates is 35 mm [1.377”] (Ultra 750 only)

12 Hot Runner Product Guide v 5.0

Hot Tip Nozzle Stacks

The min drop-to-drop pitch is 18 mm [0.71”]

The sprue min radius is 32.0 mm [1.26”]

* Plunger style sprue bushing requires additional spacing. Review required

Hot Runner Product Guide v 5.0 13