Download - GÜNTHER Hot Runner Technology

Index 

iT 

Materials 

3 

Reference values for maximum throughput in cm /s 

Reference values for gate diameter 

Processing temperatures for common plastics 

Processing of POM, TPE, PP and shear-sensitive materials 

Gate point 

Gate geometry, gate inspection 

Reworking the gate 

Gate diameters < 1,2 mm, reducing gate ø 

Vacuoles under the gate, gate ø for reinforced materials 

Potential error sources in the gate area 

Gating 

Injection into an intermediate gate 

Gating into an angled surface 

Gating into a high gloss facing surface 

Part with a film hinge 

Hot runner nozzles 

Nozzle length at room temperature, modified forechamber geometry, use of a titanium sleeve 

References values for screw sizes 

Designation/assignment of the cables 

BlueFlow® 

product description 

OktaFlow® 

assembly notes 

PektaFlow® 

product description 

Extended nozzle tips, side gating 

Reference notes on a disassembly of a multi-tip nozzle 

Valve-gate technology 

Commissioning of valve-gate system, operating pressure levels for drive mechanisms 

NEST single valve-gate nozzle assembly 

Drive mechanisms 

Notes on valve-gate needle / maintenance of the sliding cam mechanism 

Hot runner systems / manifolds 

Manifolds 

Heater connections, straight / frame version 

Structural notices for air circulation and high-temperature applications 

Screw fastenings for _MT/_NT/_TT nozzles 

Manifold power calculation, correlation of cables 

Construction of the hot-runner system 

Complete mold halves “hot halves” 

Service program 

CADHOC System-Designer 

Delta tool calculation program, application database 

Online-catalog, MoldCae/Moldflow analyse 

Seminars for users and designers 

Page 

1.4. 2 + 3 

1.4. 4 + 5 

1.4. 6 

1.4. 7 

1.4. 10 

1.4. 10 

1.4. 11 

1.4. 11 

1.4. 12 

1.4. 20 

1.4. 20 

1.4. 21 

1.4. 21 

1.4. 30 

1.4. 31 

1.4. 32 

1.4. 33 + 34 

1.4. 35 

1.4. 35 

1.4. 36 

1.4. 37 

1.4. 40 

1.4. 41 

1.4. 42 

1.4. 43 

1.4. 50 

1.4. 51 

1.4. 52 

1.4. 53 

1.4. 54 

1.4. 55 

1.4. 56 

1.4. 60 

1.4. 61 

1.4. 62 

1.4. 63 

www.guenther-hotrunner.com 

4/11 Subject to technical changes 

1.4. 1

iT 

Hot runner nozzle 

Fig. Disassembly of a multi-tip nozzle 

Reference notes on disassembly 

of a multi-tip nozzle 

To avoid damaging nozzle tips, we 

suggest a mechanical construction 

which imposes a change in the way 

the nozzle is disassembled : 

1. Loosen the wedge and the counter-pressure 

insert. 

2. Push out the divided form inserts 

to the right and left over the nozzle 

tips to their limits. 

3. Now pull out the form inserts 

downwards in the direction of the 

cavity. 

4. Loosen the screw fastening for 

the suppressor and remove it 

5. Now the nozzle can be taken upwards. 

What should be observed in the 

construction phase: 

1 To prevent jetting, inject against a 

core, for example. 

2. The shear edge must amount to at 

least the injection gate diameter 

+ 0.2 mm (see drawing). 

3. There should not be any draft 

angle in the injection gate area 

(see drawing). 

1.4. 37 


Subject to technical changes 4/11

Materials 

iT 

Reference values for maximum nozzle throughput per second 

Nozzle length: 50/ 100 mm 

3 

Throughput in cm /s 

Low viscosity material: e. g. PA, PS, PP 

120 

100 

80 

60 

40 

20 

0 

ø 4 mm 

Nozzle length 50 mm 


ø 5 mm 

ø 6 mm 

The specified throughputs are reference 

values. Considerable deviations 

for specific materials cannot 

be excluded. We will be glad to 

assist you with the selection of 

channel Ø. 

Additional applications which have 

already been implemented can be 

found in the application database on 

our website 


menu item: “Application Database”. 

Medium viscosity material: e. g. ABS, PPO 

120 

3 


100 

80 

60 

40 

20 

0 

ø 4 mm 



ø 5 mm 

ø 6 mm 

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

30 

3 


25 

20 

15 

10 

5 

0 

ø 4 mm 



ø 5 mm 

ø 6 mm 



1.4. 2

iT 

Materials 

The specified throughputs are 

reference values. Considerable 

deviations for specific materials 

cannot be excluded. We will be glad 

to assist you with the selection of 

channel Ø. 

Additional applications which have 

already been implemented can be 

found in the application database on 

our website 


menu item: “Application Database”. 

Reference values for maximum nozzle throughput per second 

Nozzle lengths: 60/ 100 mm 

3 


Low viscosity material: e. g. PA, PS, PP 

2500 

2250 

2000 

1750 

1500 

1250 

1000 

750 

500 

250 

0 

ø 8 mm ø 10 mm ø 12 mm 



Medium viscosity: e. g. ABS, PPO 

2500 

2000 

3 


1500 

1000 

500 

0 

ø 8 mm ø 10 mm ø 12 mm 



3 


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

Polysulphone 

500 

450 

400 

350 

300 

250 

200 

150 

100 

50 

0 

ø 8 mm ø 10 mm ø 12 mm 



1.4. 3 



Materials 

iT 

Determining the gate diameter for standard materials depending on 

the part weight 

Gate diameter 

Please note: 

All specified reference values for the 

gate diameter apply only to hot 

runner nozzles with vertical gating. 

Gate diameter for fibre reinfor-ced 

materials 

The gate diameters for glass fibre 

reinforced materials or materials 

containing additives (flame retardants, 

heat stabilisers) 0.2 to 0.3 mm 

larger. 

The same applies to multi-tip nozzles. 

Please contact us for all other types 

of gating. 

Article weight 

Material: PC + ABS 

Material: PE 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 

Article weight g 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Material: PMMA 

Material: POM, PA 6, ABS 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 

Article weight 

g 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 




1.4. 4

iT 

Materials 

Material: PBT 

Material: PA 6.6 (glas filled + 0.3 mm) 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Material: PS 

Material: TPU, TPE 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Material: PPO 

Material: SB, SAN 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Material: PSU, PC 

Material: PP 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 1 3 5 8 10 100 1000 


Material: LCP 

Ø D mm 

2.8 

2.4 

2.0 

1.6 

1.2 

0.8 

0.4 

0.1 0,5 1 3 5 8 10 100 1000 


1.4. 5 



Materials 

iT 

Material 

Recommended 

processing temperature (°C) 

Recommended 

WZ-temperatur (°C) 

Processing window for common 

plastics 

PP 

PE 

PS 

ABS 

SAN 

PA 6 

PA 6.6 

POM 

PC 

PMMA 

PBT 

ABS / PC 

LCP* 

PPS 

PEEK 

220 - 280 

220 - 280 

220 - 280 

220 - 250 

220 - 250 

240 - 250 

270 - 290 

205 - 215 

280 - 310 

220 - 250 

245 - 270 

260 - 270 

300 - 345 

310 - 340 

360 - 400 

20 - 60 

20 - 60 

20 - 70 

40 - 80 

40 - 80 

40 - 60 

40 - 80 

60 - 120 

80 - 120 

40 - 90 

60 - 80 

70 - 100 

80 - 120 

140 - 145 

140 - 180 

* depending on polymer-type 

Price / performance 

The performance pyramid 

High temperature resistant 

plastics 

(HDT > 150°C) 

Technical plastics 

(HDT = 100 - 150°C) 

COC 

PAR 

PES 

PC 

PPO 

PI 

PEI 

PSU 

PEK 

FP 

LCP PAI 

PPS 

PA 46 PPA 

PET 

PBT PA6.6 

POM 

LFT 

High temperature resistant 

plastics 

High temperature resistant plastics 

with processing temperatures 

>300°C: 

• Liquid Crystal Polymer (LCP) 

• Polyphenylene sulphide (PPS) 

• Polyetherketone / 

Polyetheretherketone 

(PEK/ PEEK) 

• Polysulphone (PSU) 

• Polyether-Imide (PEI) etc. 

Standardplastics 

SAN ABS PMMA PP 

PS 

PVC 

SAN 

PE-LD 

amorphous 

PE-HD 

semy-crystalline 



1.4. 6

iT 

Materials 

ØD1 

ØD2 

Fig. Gate design A and hot-runner nozzle with 

nozzle piece version C 

Polyacetal (POM) and Thermo Plastic Elastomers (TPE) 

Gate design A 

When processing polyacetal (POM) and thermoplastic 

elastomers (TPE) with a hot runner nozzle with nozzle 

piece, version C and the gate design A, a good injection 

gate quality should be attained. Hot runner nozzles with 

nozzle piece, version C can be used for injection onto an 

intermediate gate and also for direct gating. In direct 

gating a higher residual sprue must be expected than 

when a nozzle with tip is used. The gate design A must 

be used for nozzles with tip and for open nozzles. It must 

be taken into account here that the injection gate 

diameter in gate bushing "D1" must be smaller than the 

diameter in the nozzle piece "D2” 

(D1 < D2). When a nozzle piece, version C is used, the 

shear in the melt in the area of the injection gate is lower 

than when a nozzle with tip is used. 

Shear-sensitive materials 

Gate design C 

Single nozzles are mostly used when processing shearsensitive 

materials through an intermediate gate. The 

gate design C is exclusively used for open nozzles with a 

nozzle piece, version A. 

ØD2 

It must be taken into account here that the injection gate 

diameter in the "D1" gate bushing must be larger than 

the diameter of the nozzle piece "D2" (D1 > D2). 

ØD1 

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

nozzle piece version A 

55° 

2,5...3,5 

Parts made of Polypropylene (PP) 

Hot runner nozzles with modified tip geometry should be 

used to process polypropylene. At a height of 2.5 to 3.5 

mm (depending on the nozzle type) the tip angle is 

reduced from 55° to 40°. 

This modified geometry must be ordered separately. 

40° 

Fig.Tip geometry for polypropylene 

1.4. 7 



Gating 

iT 

80° 

6,3 

Gating 

The hot runner nozzle’s function is 

essentially influenced by gate size 

diameter “D”. 

d 

H 

An enlargement of gate size must 

be done at an 80° angle. The edge 

must be sharp to achieve clean 

separation. 

Fig. Gate geometry 

ØD 

sharp-edged 

Note: 

The most frequented faults on 

commissioning a mould are due to 

the incorrect design of the gate 

geometry. 

H [mm] 

4,0 

Inspecting the gate 

The correct position of the 80° angle 

is inspected with a measuring ball. 

d = 4 mm 

3,5 

d = 3 mm 

3,0 

2,5 

2,0 

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

Ø D [mm] 

Fig. Inspecting the gate 


It is wrong to rework the gate by 

boring it out. The flow gap will not be 

substatially enlarged but the tear-off 

height on the part will become larger. 

Wrong 

Fig. Reworking the gate 



1.4. 10

iT 

Gating 

L + L + 0.02 


With gate diameters smaller than 

ØD = 1.2 mm, the nozzle must 

beinstalled further back. 

You will find a Delta Tool calculation 

program on our homepage at 


available for download free of charge. 

ØD 

Fig. Nozzle installed in a retracted position 

Within the framework of permissible processing 

parameters, the smallest possible gate diameter means: 

small gate diameter 

tool temperature 

processing temperature 

Reducing the gate diameter 

The gate diameter cannot be 

arbitrarily reduced. The smallest 

permissible diameter is dependent 

on the material used. 

Furthermore, the gate size is also influenced 

by the mold temperature 

and processing temperature. 

Fig. Reducing the gate diameter 

This is the point at 

which the material 

solidifies at last. 

Vacuoles under the gate 

Direct gating with a hot runner system 

can produce vacuoles under the 

gate. 

Remedy: 

Longer holding pressure time to 

compensate for shrinkage. 

Fig. Vacuoles under the gate 

Gate diameter for fibre reinforced 

materials 

The gate diameters for glass fibre 

reinforced materials or materials 

containing additives (flame retardants, 

heat stabilisers) 0.2 to 0.3 mm 

larger. The same applies to multi-tip 

nozzles. 

1.4. 11 



Gating 

iT 

0.5 

At 250°C the hot runner nozzle extends 0.5 mm into 

the part if the nozzle is installed to the nominal 

length. 

Fig. Hot runner nozzle installed correctly 

Potential error sources 

Problem: 

- Higher vestige 

- No flow gap despite a larger gate 

Fig. Cylindrical part at the gate 

Problem: 

- The expanded nozzle closes the gate. 

Fig. Gate

Injection 

iT 

ØD 

L 

Correct injection into an intermediate 

gate 

In order to obtain defined separation, 

the aperture in the face surface of the 

intermediate gate Ød should be 

larger than ØD. This is particularly 

true for reinforced thermoplastics 

(engineering plastics). 

If possible, employ a catch pit in the 

intermediate gate. 

Ød 

˜ 

1 mm > ØD 

catch pits 

Fig. Injection into an intermediate gate 

advantageous 

Gating into an angled surface 

Direct gating into an angled surface 

never results in an optimal gate point 

with a small vestige. We therefore 

recommend gating into a surface at 

right angle to the nozzle axis. 

advantageous 

disadvantageous 

Fig. Gating into an angled surface 



1.4. 20

iT 

Gating 

Tempering 

Reserve gating into a high gloss 

facing surface 

Sufficient cooling is recommended 

for the gate area, next to the nozzle 

and on the ejector side to dissipate 

the heat additionally induced by 

shear. 

Insert 

The cooling circuit control must be 

separated from the other tempering 

circuits. 

Tempering 

Fig. Reserve gating into a high gloss facing surface 

Film hinge 

Articles with a film hinge 

When gating a part with a film hinge, 

the gating point must be located 

away from the surface center 

opposite to the film hinge. The flow 

front may not come to a standstill 

during the filling process. The film 

hinge must be filled last. 

Fig. Parts with a film hinge 

1.4. 21 




iT 

Z ±0.02 

Fig. Nozzle length at room temperature 

Nozzle length at room temperature 

Our nozzle length is made to the size 

that already provides for ist length 

change when heated to 250° C. The 

nozzle tip will then extend by 0.5 mm 

into the cavity contour. Dimension Z 

(as measured at room temperature) 

is equal to: 

Z = L + 0.5 - l (250°) 

l consequently depending on L 

itself. 

l is the temperature dependent 

longitudinal expansion of the 

hot runner nozzle. 

Standard 

90° 

Increased angle 

120° 

Attention! 

Provide for adequate 

wall thickness. 

Insulation gap 


Modification of fore chamber 

geometry 

Fore chamber geometry can be 

modified for special applications or 

difficult-to-process materials (e. g. 

V0-adjusted materials). 

To avoid mistakes, we recommend 

that you consult with our 

application engineers. 

Enlarging the angle to 120° 

The standard angle of 90° in the forechamber 

can be widened to 120°. 

This will enlarge the insulation gap 

between the hot runner nozzle and 

the mold. The nozzle can be operated 

at a lower temperature so that 

thermally sensitive material will not 

be damaged. 

Fig. Modification of forechamber geometry 

Using a titanium sleeve over the 

nozzle shaft in combination with 

an angle of 120 °. 

The insulation gap between the hot 

runner nozzle and the mold also 

becomes larger and the heat transfer 

to the cavity plate is reduced. 

Titanium sleeve 


120° 

Fig. Employment from a titanium sleeve 



1.4. 30

iT 


Reference values for screw sizes 

The centering flange and screws of 

single nozzles must absorb the 

emerging lift forces. 

Screws and centering flange are to 

be appropriately dimensioned and 

the pitch circle of the screws is to be 

kept as small as possible. 

Guide values for screw selection can 

taken from the table below. Tightening 

torque M A for producing the screw 

connection must afford sufficient 

pretensioning force F v so that the 

required initial tension is still present 

when under the influence of operating 

force (i. e. operating force of the hot 

runner nozzle). 

Pretensioning force F v should be a 

factor 2 to 4 greater than the anticipated 

operating force. Screws 

should be selected which are as 

long as possible. 

F = force 

p = injection 

pressure 

A = area of the 

nozzles shaft Ø 

Example: 

Hot runner nozzle: 5SET50 ( ØS = 22 mm) 

Injection pressure: 2000 bar (200 N/ mm 2) 

Number of screws: 4 

Reliability: 2-cavity 

Lift force on the hot runner nozzle: 

p 

D 2 ( mm) • π 

A = 

4 

A = 

F = p (N/ mm 2) • A ( mm 2) 

F = 200 N/ mm 2 • 380 mm2 

F 

= F A 

= 76000 N 

F = 76000 

ges 

22 mm 2 • π 

4 

A = 380 mm 2 

N 

Tightening torque for hot runner nozzles 

Pretension F v and tightening tor-que M A, 

for screws with head beaning surfaces per 

DIN EN ISO 4762 and 4014. 

Shaft screws ( µ ges. = 0.125) 

Pretension 

F v = 

F v = 

F v 

per screw: 

F ges ( N) 

Number of screws 

76000 N 

4 

F v = 38000 N per screw 

• Sicherheit 

• 2 (-fach) 

Chosen screws in consideration of 2-cavity 

reliability. 

4 x M10 - 12.9 je 45 kN per scres 

Thread 

designation 

Regular type 

screw threads 

M8 

M10 

M12 

M16 

M20 

M24 

Maximum pretension 

Property class 

10.9 12.9 

24 

38 

56 

105 

165 

235 

28 

45 

65 

122 

190 

275 

F V 

in kN 

Fine pitch 

thread 

M8x 1 26 31 

40 

M10x1,25 41 43 

77 

M12x1,5 

M16x1,5 

M20x1,5 

M24x2 

59 

114 

188 

265 

69 

134 

220 

310 

Maximum tightening torque M in Nm A 

Property class 

10.9 12.9 

37 

73 

125 

315 

615 

1050 

132 

340 

680 

1150 

43 

84 

148 

370 

700 

1250 

46 

90 

155 

390 

800 

1350 

1.4. 31 




iT 

Power receptacle, 

alternating 230 V 

PE=earthed lead 

N = Neutral lead 

L = earthed lead 

Thermoplug CMLK 

Nozzle type: 

- 8-10SET/DET 

- 5-12NEST 

- 4-6SHT/DHT/NHT 

- 8-16SLT/DLT 

- 8-12NLT 

- 4-6SMT/DMT/NMT 

Red = plus 

Blue = minus 

Shield 

Fig. Designation / correlation of cables 



PE = earthed lead 




Nozzle type: 

- 4-6STT/DTT/NTT 

- 4-6SMHT/DMHT 

Red = Plus 

Blue = Minus 

Shield 




1.4. 32

iT 


Thickfilm heaters for hot-runner 

nozzles 

BlueFlowGünther's new BlueFlow ® 

technology incorporates several 

advantages as compared to 

conventional heating methods: the 

heating elements are not only 

considerably smaller in diameter, 

they also allow a substantially better 

temperature distribution and 

accordingly, a quicker thermal 

response. 

Further outstanding features are 

their high electric strength and 

resistance to moisture. All in all, 

these four features are important 

steps taken towards a more spacesaving, 

precise and energy-efficient 

hot runner design and, therefore, a 

more effective injection molding 

process. 

Hot runner nozzle heater 

Heater are pressed into a brass 

body. The heater is fixed in place by 

the mechanical structure of the 

carrier body. The homogeneous 

brass body ensures optimal heat 

transfer from the heater to the 

material tube, showing a highly 

reproducible temperature pattern. 


Shield 

Blue = minus 

Red = plus 



Nozzle type: 

- 5SEF/DEF 

- SMF/DMF/NMF 

PE=earthed lead 




22 mm 

18 mm 

Brass body with pressed-in heater 

BlueFlow® Hot runner nozzle 

Fig. Hot runner nozzle heater 

1.4. 33 




iT 

High Quality. Blue. BlueFlow® 

The BlueFlow® hot runner nozzle 

sets new standards for quality and 

design of parts made of thermally 

sensitive plastics. This re-sults in 

better or even completely new 

application possibilities, depending 

on the application area in different 

sectors of industry. 

The thick film heater makes it 

possible to adjust the heating capacity 

to the exact power requirement 

in each single section over the 

entire nozzle length in order to reach 

a homogenous temperature. 

The plastic material in the material 

tube is hardly exposed to thermal 

stress, which means that the 

physical properties of the end 

product are obtainable even with 

thermally sensitive plastics and very 

small parts. 

FIg. Microfilter 

Example: Microfilter (automotive 

sector) 

Microfilter (outlet valve for an 

automotive application), injectionmolded 

in one process step from 

unreinforced PA66. This method has 

replaced the earlier procedure of 

insert-molding of an available metal 

or plastic mesh to obtain a ready-toinstall 

component. The resulting 

savings are dramatic: costs have 

decreased by 60-80%, depending 

on the product. 

Details: thread size 0.13; 

1848 gaps with 0.07 x 0.07 mm. 2 

Passage surface approx. 9 mm . 

Max. allowed flash is 4.5 µm. 



1.4. 34

iT 


Hot-runner nozzle OktaFlow ® 

for side multi-tip gatin under 90° 

without cold slug, in connection with a 

manifold or can be used as a single 

nozzle with heated adaptor.) 

Assembly of the star manifold 

Insert the star manifold and use 4 

hexagon socket head cap screws 

M3x12 to fasten it to the sleeve-type 

heating. 

Assembly of support 

Insert the support and mount the lid 

from the parting line. Note: the lid 

must be solidly bonded to the insert. 

Assembly of the hot-runner nozzle 

Push the hot-runner nozzle (MT) in 

from the nozzle side! 

Hot-runner nozzle PektaFlow® 

Number of tips: up to 24 tips, for side 

multi-tip gating under 90° without 

cold slug. 

Be used as a single nozzle with 

heated adaptor. 

Hot-runner nozzle Pekta Flow ® type PLT 

are designed for challenging applications 

e.g. in medical technology 

and packaging. 

• Direct injection onto the product 

• Divided inserts 

• Tips individually replaceable 

• Leading-edge area heated for 

optimum temperature 

development 

• Supported on floating bearings and 

therefore independent of the ther 

mal expansions 

1.4. 35 




iT 

Without extended nozzle tip 

L +0.02 

With extended nozzle tip 

L1 +0.02 

L1 +0.02 

Extended nozzle tips in 

connection with the material 

It is often necessary to use several 

different nozzle lengths when gating 

a part. Extended nozzle tips allow 

sprueless molding of parts even in 

space constrained environments. 

Shimmed 

Inserted 

L1 +0.02 

L1 +0.02 

Fig. Use of nozzle with extended tip 

Side gating 

Under 90° without a ”cold slug” in 

combination with a manifold. Gating 

should always be against the core. 

Always specify the material to be 

processed and the part weight when 

making inqiries. Also specify whether 

a part is to be gated with several tips, 

or if several parts are to be molded. 

Note: 

Slide out the inserts only horizontally! 

Fig. Side gating under 90° without a “cold slug” 



1.4. 36

Valve gate technology 

iT 

When the hot-runner system is being turned off, all 

control circuits can be turned off at the same time. To 

prevent the hot-runner system being damaged by the 

build-up of heat, let the mould cooling run on at about 

30°C for another 30 minutes approximately. The valve 

gate needles should be in the “closed” position here. 

Fig. Valve gate system 

Commissioning the valve gate system 

Before heating the nozzles and the manifold, switch on 

the mould temperature control. 

Heating the hot-runner system: 

- Heat the manifold with the controller unit's soft start 

function. With the softstart function the manifold is 

heated to about 100°C and held at this temperature 

for approximately 10 minutes. 

- The nozzles and manifold must be heated evenly. 

Heating the manifold to the target temperature can 

take up to 20 minutes. 

The needle mechanism may be put into operation when 

the hot-runner system reaches production temperature. 

The idle system must be held at production temperature 

for at least 10 minutes to ensure thermal stability. 

When putting into operation for the first time, several 

injections may be necessary in order to fill the hot runner 

completely with plastic. Until the parts are filled 

completely, the cavities must be checked after every 

cycle for parts that have not been filled completely. 

If the process is interrupted, the hot-runner temperature 

must be lowered (depending on the material and 

downtime by 100…150°C). The needles must be in the 

"closed" position. To prevent damage being caused to 

the gate bores / valve needles by cold material, the valve 

needles may not be actuated when the injection 

moulding machine is being set up or during injection out 

through the unit. If the melt is to be injected out through 

the open mould / hot runner, the needles must be opened 

during the injecting-through process and closed during 

the dosing phase. 

Before doing any disassembly, make sure the hot runner 

is switched off. To prevent damage to the needle guide / 

needle, the needles must be in the opened position. 

Before putting the system into operation again, make 

sure the needles are in the “closed” position again. 

Connection values 

Electric 

Voltage 230 V~ 

System * 

max. permissible operating 

pressure in the hot-runner system 2000 bar 

* 

If special nozzles or other components with a pressure limit (less 

than 2000 bar) are fitted to systems or individual tools, this situation 

is documented in the height adjustment and on the type plate. 

Hydraulic 

Single valve- gate nozzle 

Lifting plate mechanism 

Sliding cam mechanism 

Pneumatic 

max. permissible operating 

pressure in the hot-runner system 

Single valve gate nozzle 

Single needle valve 

Lifting plate mechanism 


To attain the right needle speed (needle closing time 20- 

40 ms / 7-10 mm travel), the valve must be designed to be 

large enough for the actuation (hydraulic/pneumatic). 

The connection hoses too must be dimensioned to suit 

the flow volume. 

The distance between the pressure generation and the 

pressure consumption (mould) should be as small as 

possible. 

Note! 

The first filling of the hydraulic cylinders should be done 

at a low speed or the cylinders should be deaerated. 

40 

40-60 

40-60 

8 

mind. 8-10 

8 

8-10 

8-10 

bar 

bar 

bar 

bar 

bar 

bar 

bar 

bar 



1.4. 40

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Insulation ring 

Steel piston ring, large 

Marking XXX 

Steel piston ring, small 

Power connection 

Marking XXX 

Fixed thermocouple 

connection 

Power connection 

Fixed thermocouple 

Scew M10x1 

Needle closing 

Needle opening 

Fig. Single valve-gate nozzle 12NEST 

There are three 0.1-mm shims over / under the needle 

head. 

Caution 

When assembling / dismantling the needle holder (A/F 

10), care must be taken not to deform the steel piston 

rings. Use the flat of the piston! It is essential to put the 

metal O ring back in after replacing the disk package. The 

piston and/or the steel piston rings must be greased 

again before assembly (GÜNTHER recommends Klüber 

paste UH 196-402 [NSF registered]). 

Furthermore, it is essential to ensure that the steel piston 

rings have been inserted correctly. The rings have a 

marking (XXX) on the face surface, indicating the side 

that must point towards the pressurised side. 

Installation of the complete nozzle 

The cables for activating the needles are located at the 

bottom of the nozzle. Accordingly the centring ring can be 

produced as a “bell”. This measure makes it possible to 

reduce the height of the mould. 

Screw centring with at least 4x M12 (10.9) screws, with 

due consideration to lift forces. For an optimum thermal 

separation between the nozzle and the mould, use the 

(blue) insulation ring. 

Caution: Grind in the K dimension in compliance with the 

data in the chapter. 2.3 yellow page. 

Inlet/ outlet pipes for activating the needle 

It is preferable to use channels with diameters of 6 mm 

and a minimum length of 200 mm. The inlet and outlet 

lines must be placed in the cooled mould plate in order to 

prevent the medium overheating. If the mould 

temperatures exceed the thermal stress capability of the 

pneumatic valves, a separately cooled manifold must be 

installed. The mechanics of the needle drive and the 

valve gate nozzle are absolutely capable of withstanding 

high temperatures. 

Note on guarantee 

GÜNTHER guarantees nozzle type NEST only if they 

have been fitted or serviced on GÜNTHER premises or 

by a GÜNTHER specialist. GÜNTHER will not provide 

any guarantee for damage caused by the incorrect fitting 

of the steel piston ring operated nozzle type NEST by 

the pur-chaser, its representatives or contractors. 

The same applies to inappropriate or neglected 

maintenance. 

1.4. 41 




iT 

Electromagnet ME 10/UV75 

The ME 10 bistable heavy-duty lifting magnet serves 

to actuate the valve gate needles in valve gate 

systems. 

Excellent for fully electric injection moulding machines 

and for clean room use. 

Single needle valve ENV 

Needle actuation in single and multiple systems. 

Sequential opening and closing of the needles. 

Special holes in the mould clamping plate allow the 

down-stroke depth of the valve gate to be adjusted 

individually from the outside. 

Maximum working temperature is 100° C. 

Pay attention to the balancing of the oil feed and oil 

outlet ducts as well as of the air feed and air outlet ducts. 

Note on guarantee 

GÜNTHER guarantees single needle valves only if they have been fitted or serviced on GÜNTHER premises or by a 

GÜNTHER specialist. GÜNTHER will not provide any guarantee for damage caused by the incorrect fitting of the O-rings 

in hydraulically/pneumatically operated single needle valves by the purchaser, its representatives or contractors. 

The same applies to inappropriate or neglected maintenance. 

Note: See operating instructions for details. 

Lifting plate mechanism ANEH 

The lifting mechanism is recommendable for a precisely 

simultaneous opening and closing of all needles. 


down-stroke depth of the valve needles to be adjusted 


The maximum working temperature is 100° C. 

Sliding cam mechanism ANES 

For narrow cavity spacing a sliding cam mechanism is the 

preferred drive. 

Exact opening and closing of all needles. 


down-stroke depth of the valve gate to be adjusted 


Maximum working temperature is 100° C. 



1.4. 42

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Notes on valve needles 

The needle length is dependent on the nozzle length, 

type of actuation and manifold structure. The needles 

have a basic hardness of 64 HRC (HSS steel) and are 

coated. The needles are fitted with a cylindrical seal 

towards the cavity and are adjustable. 

The 2 mm Ø needle design for nozzles with material 

tube-Ø 4-6 mm, threads M6x 0,5 

gate-Ø: 0,8 mm, 1,0 m, 1,2 mm, 1,4 mm, (1,6 mm). 


tube- Ø 8 mm, threads M8 x 0,5 

gate Ø: 2,0 mm, 2,5 mm. 


tube- Ø 10-12 mm, threads M10 x 0,75 

gate- Ø: 3,0 mm, 4,0 mm. 

Tools to disassembling the needle guide (piece of PM), 

see chapter 7. 

Maintenance 

Sliding cam mechanismus -ANES- 

When fitting the sliding cam mechanism, use a hightemperature 

long-life grease to lubricate the movable 

parts. This allows the sliding cam mechanism to work 

without any problems even at higher temperatures over a 

long period of time. Make sure the mould temperature 

does not exceed 100° C in the area of the frame plate/ 

clamping plate. 

During maintenance the sliding cam mechanism must be 

checked for dirt and wear. Melts that have exuded from 

the manifold sealing because of the stroke movement of 

the needles must be removed. In older hot-runner 

systems the sliding cam mechanism can be relubricated 

through the ball impact holes (DIN 3410 Form F); in new 

systems the sliding cam mechanism can be relubricated 

without disassembly. 

Thread tightening torque for needle adjustment 

Needle Ø Thread Tightening torque 

M A [Nm] 

Ø 2 mm M6 x 0,50 15 

Ø 3 mm M8 x 0,50 30 

Ø 5 mm M10 x 0,75 45 

Type NEP 

Type NHP 

Fig. 


with externally accessible 

grease fittings 

Fig. 

Ball impact holes 

To ensure optimal greasing performance also at higher 

temperatures, avoid using different greases. We 

recommend the lubricating grease from Klueber 

Barrierta L55/2 high temperature long-life grease. The 

lubricating grease can be purchased either directly from 

the manufacturer or from us. Safety data sheets can be 

called up at www.klueber.com. 

Introduction: Lubrication after 150.000 shots or 

1x weekly. 

Maintainance work (cleaning) must be done on the 

needle-driving mechanisms every 400.000 shots! 

This frequency depends greatly on the material to be 

processed or the application. If a thermoplastic 

elastomer (TPE) is being processed, it may be necessary 

to do maintenance work on the sliding cam after just 

approximately 200.000 shots. This also concerns 

polymers, in which the viscosity is greatly reduced by the 

shearing. 

1.4. 43 




iT 

V2 

NEW: Sign up at www.guenther-hotrunner.com to start 

configuring your individual hot runner system with 

CADHOC V2 System Designer. 

You will save time and cut costs by having detailed 

information at an early phase of your project. 

NEW: Hot half on the basis of the 

• 8-cavity H manifold“ 

• 2-cavity straight manifold" and 

• 4-cavity cross manifold" 

For mould size up 196x296 mm to 796x996 mm 

(depending on the manifold size and manifold design). 

Hot half as 2-plate system, incl. guide elements, cable 

duct, cooling etc. 

NEW: Hot half as 2-plate system, incl. guide elements, 

cable duct, cooling etc. All system nozzles with a tip 

and an open nozzle piece can be used (Catalogue 

Chapter 2.1). 

NEW: Valve-gate systems with 

single needle valves for “individual” types of manifold. 

• Straight manifold 1-cavity, 2-cavity und 4-cavity 

• H manifold 4-cavity and 8-cavity, 

• T manifold 2-cavity and 

• Cross manifold 4-cavity 

with nozzles from our valve gate portfolio. 

Catalogue Chapter 2.3). 



1.4. 50

iT 


View straight/frame version 

Position of power connections 

Note: 

• Nozzles should always be surrounded by heater loops. 

• Heater lines should be routed mirror-inverted (cold 

ends of the tube heaters compensate for one another). 

• When possible, reserve an area for connectors where 

no material-carrying bore holes are located. 

• For high temperature applications > 320°C external 

connectors are appropriate. 

Fig. View: straight version 

Fig. Internal heater 

connections 

Fig. External heater 

connections 

Frame plate / rail 

Edges absolutely burr-free 

Supporting plate / 

cavity plate 

Fig. View: f rame version 

Fig. Cable channel 

Not recommended 

Recommended 



1.4. 51 




iT 

Air circulation 

Attachment 

: 

housing 

Insulating plate 

Clamping plate 

Fig. Optimal air circulation 

Distance bolts 

Manifold 

Frame structure 

Fig. Cross section of a mold - optimal air circulation 

High temperature application 

Special hot runner design is necessary 

for plastics with processing 

temperatures over 320°C. This includes 

full insulation, external heater 

connectors and high tempe-rature 

resistant thermo-couples. 

In the nozzle area it requires a fixed, 

high temperature resistant thermocouple 

connection, a hard metal tip 

(for reinforced polymers) as well as a 

high temperature pro-tective sleeve 

for cables. 

Fig. Manifold for high temperature application 



1.4. 52

iT 


Titanium washer 

Screw M6, 

M8, M10, (12.9) 

depending on 

manifold design 

Nozzle type 

_MT, _NT, _TT 

Fig. Manifold with _TT nozzle type, screwed to the 

parting line 

Fig. Screw fastenings for _MT/_NT/_TT nozzles 

Note: 

Hot runner nozzles of the _MT/_NT/_TT type are not 

screw-fastened to the manifold. The system is started 

with cold-state play. Please refer to the respective heat 

expansion table. In its cold state, the hot runner system 

has no positive seal between nozzles and manifold. 

Operating temperature must first be reached in order to 

seal the system. Please provide for adequate screw 

fixation of the clamping plate towards the cavity plate 

close enough to the manifold with at least 2x M10 per 

nozzle or, based on the length, 2x M10 per every 80 mm. 

We recommend connecting with screws of the 12.9 

property class. 

Advantages: 

• For high number of cavities and tight pitch spacing 

• Easy front mounting of the nozzles - 

the mold can remain on the machine for maintenance 

• Two fits provide a precise positioning to the pitch 

distance 

• Safety due to spatial and thermal separation of the 

connecting cable from the manifold 

• Protection against leakage by sealing the manifold 

from the cable channels om the cable channels 

Please use a pry bar or a nozzle extractor tool to 

professionally disassemble the nozzle from the gate 

bushing and/or cavity plate. See chapter 8. 

1.4. 53 




iT 

Manifold power calculation (230 V) 

Power Voltage Current Approximate resistance 

Watt Volt A 

values to be measured in 

Ohm [S] 

2300 

3680 

1500 

1400 

1100 

1000 

750 

500 

630 

500 

400 

250 

600 (max.) 

600 (max.) 

230 

230 

230 

230 

230 

230 

230 

230 

230 

230 

230 

230 

5 

24 

10 

16 

6.5 

6.1 

4.8 

4.4 

3.3 

2.8 

2.2 

1.8 

1.4 

1.1 

125 (max.) 

25 (max.) 

23.0 

14.375 

35.4 

37.7 

47.9 

52.3 

69.1 

82.1 

104.5 

127.8 

164.3 

209.1 

0.1 - 0.2 

0.2 - 0.4 

P = U • I 

R = U/I 

P = U 2 / R 

Example: 

P = (230 V) 2 / 23 Ohm 

P = 2300 W 

PE earthed lead 

Thermocouple 

cable 

Alternating current 230 V 

Red = plus 

Blue = minus 

Fig. Manifold - correlation of cables 



1.4. 54

iT 


Assembly of the manifold 

1 2 3 4 5 6 7 

24 

8 

23 

22 

9 

10 

21 

11 

20 

19 

SNT SMT SHT STT 

12 

11 12 10 18 

17 16 15 

14 13 

Signs and symbols 

1 

PE-ground cabel connection, chap. 7 

9 

Manifold, chap. 4 

18 

Cylindrical pin to prevent twisting, chap. 4.1 

2 

Connection elements, chap. 6 

10 

Nozzle holding plate 

19 

Nozzle protrusion 

3 

4 

Bores in the clamping plate 

to fix the nozzle 

Surface mounted thermocouple, 

chap. 7 

11 

12 

13 

Cable channel 

Cavity plate 

Hot runner nozzles, chap. 2 

20 

21 

22 

Nozzle lengt, chap. 2 

Height of the nozzle head, chap. 2 

Manifold height 

5 

6 

7 

8 

Pressure pads, chap. 8 

Heat expansion gap dimension K, 

chap. 4.1 

Clamping plate 

Air gap at the top and bottom 

depending on tool position 

14 

15 

16 

17 

High temperature insulating plate, optional 

Gate bushing, chap. 2.2 

Support piece, chap. 8 

Tempering 

23 

24 

Installation height of the hotrunner 

Height of the pressure pad + 

Heat expansion gap dimension K 

1.4. 55 




iT 

Complete “Hot Halves” 

The hot half is delivered as a nozzleside 

mold half without cavity plates. 

The nozzle overhang over the supporting 

plate can be set individually. 

The height-matched hot runner is 

completely wired and functionally 

tested. This ready-to-install solution 

eliminates extensive design matching 

work and possible installation errors. 

Prior to delivery, hot halves are 

subjected to a functional test which is 

documented according to DIN EN 

ISO 9001:2000. 

Complete “Hot Halves” normally 

guarantee a smooth production 

start-up. 

Fig. Cross section of a mold 

Fig. Complete mold half “Hot Half”, valve gate system 



1.4. 56


iT 

Our comprehensive program of services 

is meant to provide you with the 

service you need, from consul-tation 

and layout for hot runner systems to 

practice-oriented seminars for users 

and designers. 

On the GÜNTHER website you will 

find many tools and programs to 

make your work easier. 

You can now configure your hot 

runner system individually via the 

GÜNTHER Internet platform. 3-D CAD 

data including negative volume and 

drawings are available for downloading 

for each hot runner system. 

To round this service off, price 

information (as a PDF file) is also 

provided. 

Once you have configured your 

individual hot runner system, you 

can select various data formats. The 

„CADHOC V2“ System Designer and 

the systems running in the background 

generate the required data. 

All files are then compressed and 

made available for downloading. 

You will be notified by e-mail a few 

minutes later. 

This e-mail will contain a link to the 

product data for the configured hot 

runner system. 

With its high functionality, the system 

is designed to suit the requirements 

of our customers, first of all 

designers of injection molds and 

sales personnel, to meet the desire 

for quicker availability of complete 

hot runner systems including negative 

volumes. 

Register once on our Internet platform „www.guenther-hotrunner.com“ and 

you can then start the CADHOC V2 system designer to configure your own 

individual hot-runner system. 

Advantages of the new CADHOC system-designers version 2: 

• optimised calculation of the nozzle size 

• extensive choice of types of plastic 

• two different methods of configuration 

- application-specific by entering processing parameters 

- direct configuration without entering processing parameters 

• shorter waiting periods during the configuration process 



1.4. 60

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Reworking the 1.2 mm gate 

For gate diameters smaller than ØD 

= 1.2 mm, the nozzle must be 

installed further back from the gate. 

You will find a Delta Tool calculation 

program on our homepage at 

www.guenther-hotrunner.com under 

the menu item “Service” available 

for download free of charge. 

Fig. Delta Tool calculation program 

Application database 

The application database is a program 

for selecting from design proposals 

and machine parameter data. 

Following the entry of simple search 

criteria for hot runner requirements 

and material compa-tibility, the 

program makes available a selection 

of systems which have already been 

implemented along with their results. 

You can also enter your own applications 

directly into the data-base. 

The application will be reviewed and 

subsequently released under the 

menu item “Service”. 

The registration is free of charge. 

Fig. Application database with many applications already implemented 

1.4. 61 




iT 

Download / catalog 

Under the menu item Catalog you 

will find all hot runner components 

with their relevant data available as a 

PDF file. 

The online catalog provides you with 

the newest version of the technical 

information. 

Here you can find GÜNTHER hot runner 

components with all the relevant information 

as a PDF file. Make use of extensive 

TM 

Acrobat Reader features, such as shortcuts, 

bookmarks and icons, for a comfortable and 

quick search for information! 

Fig. Online catalog 

Pressure drop / 

Filling analysis 

The melt channels are dimensioned 

by GÜNTHER on the basis of application-specific 

rheologic calculations, 

with pressure drop, shear 

and dwell time standing in the foreground. 

Our calculations can be expanded to 

include the filling analysis of plastic 

parts per Moldflow. This is particularly 

advisable when laying out family 

molds with different cavities. By 

performing this calcu-lation, we offer 

you support in determining an optimal 

gate position and demon-strate the 

flow front course for the ideal part 

filling along with anticipated air 

pockets and the course of the weld 

line. 

Fig. Filling analysis 



1.4. 62

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Seminars for users and designers 

Topics, such as layout, smooth 

running operation and professional 

maintenance of GÜNTHER hot runner 

systems, are handled in a comprehensive 

manner. 

Additional services in our program 

include performing injection molding 

experiments in our in-house labora- 

tory as well as conducting external 

seminars. Please look for dates and 

locations on our website 

www.guenther-hotrunner.com under 

the menu item ”Seminars” or ask by 

phone at 

+49 (0) 64 51 - 5008-0. 

Fig. Seminars for designers and users 

Webinar, what's that? 

Webinar is an acronym formed from 

the words web (world wide web) and 

seminar. 

In short, it is a seminar held over the 

Internet. 

Advantages for you: 

• 

• 

concise and specific information 

no travelling and overnight accommodation 

expenses, 

no loss of working days! 

• 

See website 


1.4. 63

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