Hot Runner PDF

DME
HOT RUNNER
&
CONTROL SYSTEMS
Hot Runner Systems
Table of Contents
Hot Runner Systems Temperature Control Systems
Customer Commitment........................................................4 SS TSP & TSP Plus
Terms and Conditions of Sale ............................................5 TSP (Touch Screen Panel)......................................110-112
Sales and Ordering Information ........................................6 TSP Plus (Touch Screen Panel..............................113-114
Hot Runner Warranty ..........................................................7
Hot Runner Systems Overview ...................................... 8-9
Custom Applications Engineered Hot Runner Systems Smart Series®
Standard Global Manifold and Components .................10 Typical System Configurations......................................119
Hot Runner Quote Request Form .....................................11 Single Zone Controllers...........................................120-121
Hot Runner Selection Guide .............................................12 2-zone Controllers............................................................122
Plastic Materials,Specifications/ Bushing Selection ..13 Single & 2-zone Accessories.................................123-124
Single Zone High Power Controller & Accessories...125
Thermal Gate Hot Runner Systems Smart Series 15 AMP Mainframe
DME Hot Runner Technology......................................16-17 Configurations...........................................................126-127
Stellar Micromolding....................................................18-23 Smart Series 30 AMP Mainframe
Configurations..................................................................128
Digital Current/Voltage Monitor.....................................129
Standard Pre-Engineered
Floor Stand........................................................................130
Hot Runner Systems Step-Down Transformer Kits..........................................130
The Hot One Technology.............................................24-42 Blank Panels, Fuses & Crimp Connectors...................130
Meteor Hot Runner......................................................43-50 Mainframe Connector Wiring.................................131-133
Table of Contents
Mold Power & Thermocouple Cables..........................134

Mold Power Input Connectors.......................................135
Hot Sprue Bushings
Mold Thermocouple Connectors...................................136
D-MAX............................................................................53-59 Mold Connector Pocket Layouts............................137-138
Gate-Mate .....................................................................60-67 Pre-wired Combination Terminal Mounting Boxes....139
Straight-Shot ................................................................68-78 Terminal Mounting Boxes...............................................140
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> High-Performance ....................................................69-70 SSM Modules............................................................141-142

Hot Runner Systems
> S-Series ...........................71 DSS Modules.............................................................143-144

> E-Series ....................72-73 TSM Modules............................................................145-146
> ER-Series .................74-75 TAS Temperature Alarm/System Modules...........148-148
> T-Series ...........................76 Replacement Parts...................................................149-151
> TR-Series .........................77 Input Wiring Diagram..............................................152-154
> Replacement Parts ........78 Alternate Cable Configurations..............................155-158
Integrally Heated Sprue Bushings ...........................79-84 Stand Accessories..........................................................159
Hot Runner Services

Valve Gate Controller Products &
Moldflow........................................................................86-87
Moldflow Quote Request Form........................................88 Solutions
Hot Runner Service Center.........................................89-90 SVG Pneumatic Control Systems...........................161-161
SVG Hydraulic Control Systems.............................163-164
Obsolete System Replacement Parts VCAP Air Valve Assemblies...........................................165
Compact 4-zone Pneumatic/Hydraulic controller......165
Gate-Mate......................................................................92-93 Single Zone Timer............................................................166
Cool One.......................................................................94-101
Technical Support....................................................167-172
Modular Components Deliver High Performance......102
U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.com www.milacron.com

text Systems
Hot Runner 3
Index
Index
Alternate Cable Configuration........................................151-152 Pre-Wired Combination Terminal Mounting Boxes .............. 135
Alternate Cable Wiring Diagram .......................................... 153 Plastic Materials and Specifications......................................12
Blank Panels, Fuses & Crimp Connectors............................. 128 Obsolete Hot Runner Replacement Parts........................92-101
Bushing Selection....................................................................12 Cool One & Micro Cool One.......................................94-101
Gate-Mate Nozzles............................................................92
Cable Storage Baskets...........................................................157 Gate Shell Insulators.........................................................93
Cartridge Heaters............................................................... 36-38
Control Systems..............................................................103-164 Replacement Parts (Temp Control) ................................ 145-147
D-MAX High Performance Hot Sprue Bushings ................ 53-59 Sales and Ordering Information ............................................... 6
Digital Current/Voltage Monitor ........................................... 125 Selection Guide, Hot Runner Technology ............................... 11
DSS Modules ................................................................. 139-140 Single & 2-Zone Controller Accessories ....................... 118-121
Single Zone Controllers ................................................. 116-117
Flexible Tubular Heaters .................................................... 31-32 Single Zone High Power Controller & Accessories.............. 121
Floor Stand (Temp Control) ................................................... 126 Single Zone Timer ................................................................. 161
Smart Series 15 AMP Mainframe
Gate-Mate Hot Sprue Bushings.........................................60-67 Configurations ................................................................ 122-123
Global Manifolds .................................................................... 10 Smart Series 30 AMP Mainframe
Configurations ....................................................................... 124
Hot One Components & Accessories ................................ 24-42 SSM Modules ................................................................ 137-138
Hot Runner Systems

Hot One Hot Runner Technology – Overview .................... 15-17 Stellar Micromolding Hot Runner Systems ....................... 18-23
Hot Runner Modular Components ........................................ 102 Step-Down Transformer Kit .................................................. 126
Hot Runner Quote Request Form ........................................ 13 Straight Shot™ Hot Sprue Bushings ................................. 69-77
Hot Runner Services .......................................................... 85-90
Hot Runner Selection Guide ................................................... 11 TAS Temperature Alarm/System Modules .................... 143-144
Hot Runner Warranty ................................................................ 7 Technical Support Data (Temp Control) ......................... 163-164
Hot Sprue Bushings, D-MAX High Performance ............... 53-59 Terminal Mounting Boxes ...................................... 135-136, 154
Hot Sprue Bushings, E-Series Straight Shot ..................... 72-73 Terms and Conditions of Sale ................................................... 5
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Hot Sprue Bushings, ER-Series Straight Shot ................... 74-75 Thermocouple Cables ........................................................... 130
Index
Hot Sprue Bushings, High-Performance ............................ 69-70 Thermocouple Input Connectors ........................................... 132
Hot Sprue Bushings, Integrally Heated ............................. 79-84 TSM Modules ................................................................ 141-142
Hot Sprue Bushings, Straight Shot Replacement ................ 181 TSP Temperature Controllers ......................................... 106-108
Hot Sprue Bushings, S-Series Straight Shot .......................... 71 TSP Plus Temperature Controllers ................................. 109-110
Hot Sprue Bushings, Straight Shot™ ................................ 72-78 Tubular Heaters, Flexible ................................................... 31-32
Hot Sprue Bushings, T-Series Straight Shot ..................... 76-77 Two Zone (2-Zone) Temperature Controllers ........................ 118
Typical System Configuration (Temp Control) ...................... 115
Input Power Wiring Diagrams........................................148-149
ntegrally Heated Hot Sprue Bushings ............................... 79-84 VCAP Air Valve Accessories ................................................. 161
Valve Gate Controls ....................................................... 157-161
Mainframe Connector Wiring ........................................ 127-128 Valve Gate Single Zone Tiimer...............................................162
Meteor Hot Runner Systems ............................................. 43-50
Moldflow™ Services.......................................................... 86-88 Warranty Information................................................................ 7
Mold Connector Pocket Layouts .................................... 133-134
Mold Filling/Mold Cooling Analysis Form ........................... 88
Mold Power Cables............................................................... 130
Mold Power Input Connectors .............................................. 131
Mold Thermocouple Connectors........................................... 132
U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

4 Hot Runner Systems
Customer Commitment
Applications Engineering
Is there a hot runner application on your wish list that To take advantage of any or all of these services, or if
you don’t see here? DME can help. Our design and you have any questions, problems, or ideas please call
applications engineering group consists of professional DME at:
engineers and experienced designers. Once you provide
800-626-6653 (U.S.)
the information necessary for proper application design
and analysis, the DME applications engineering team 800-387-6600 (Canada)
will go to work diligently analyzing, designing and Part prints or system design prints may be sent in the
manufacturing a hot runner system that will best suit following ways:
your needs and requirements.
dme_appl_eng@milacron.com
248-544-5707 (U.S.) fax
Technical Service
905-677-5280 (Canada) fax
DME is proud to say that it is an industry model for
Customer Commitment
technical service coverage and response. The DME

technical service department covers the entire United DME offers you a wide range of services from
States and Canada, with additional service representatives component selection to on-site system installation.
in Europe, Asia and throughout the world. Because Our ever-growing list of services include the ability to:
DME knows you need assistance starting, operating,
and maintaining hot runner systems it has made a Analyze the best system to fit your needs
great effort to strategically staff a Technical Service Assist in system design
Department that is responsible for the success of
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DME’s molding systems.

Perform computerized system analysis and resin
Hot Runner Systems
qualification before any metal is cut

Marry your system to the mold base, plates and
Field Sales and Customer Service components required
When you need a knowledgeable person to help you order Provide quotations for and perform all of the special
parts and components, DME has you covered. Our direct machining required
field sales force puts a local sales representative in your Assemble and wire the system
area. One who understands your business and can offer
valuable assistance in helping you select the molding Check mechanical fit of all components and perform
system best suited to your application and your budget. electrical load testing
In addition, DME provides a customer service department Assist with system start-up and maintenance
that has been extensively trained on all of DME’s
All of which gives you ... more time to concentrate on
products and systems, making it easier for you to order
cavities and cores!
and have your questions answered. We can provide you
price and delivery information on all DME items quickly and
accurately.
U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

Hot Runner Systems 5
Terms and Conditions of Sale
1. FOB POINT / PRICES: Products are sold FCA Madison Heights. “Returned Goods”: No goods are returnable without prior approval,
Any taxes are in addition to the prices and may be invoiced later. prepaid transportation and an issued RMA number. All items are
2. SHIPPING SCHEDULE: The shipping schedule is our current estimate subject to our inspection before credit will be allowed.
of delivery dates and we agree to use reasonable efforts to comply NO GOODS ARE RETURNABLE LATER THAN THIRTY DAYS AFTER
with the schedule. RECEIPT OF MERCHANDISE.
3. WARRANTY: 9. PATENT INDEMNITY: We shall defend any suit or proceeding
(a) Any DME trademarked or tradenamed product or part thereof brought against Buyer and pay all costs and damages awarded
manufactured by or for us which, under normal operating conditions against Buyer provided that:
in the plant of the Buyer thereof, proves defective in material or (a) The suit or proceeding is based upon a claim that the product or
workmanship, as determined by our inspection, within 12 months part thereof is an infringement of any claim of a presently existing
from the date of shipment will be replaced or repaired free of charge U.S. patent;
to Buyer. (b) The claim of infringement is not based, directly or indirectly,
This warranty is contingent upon the following conditions: that we upon (i) the manufacture, use, or sale of any product furnished by us
promptly receive notice of the defect; that Buyer establish that the which has been modified without our consent; or, (ii) the manufac-
product has been properly installed, maintained, and operated within ture, use, or sale of any combination of a product furnished by us
the limits of related and normal usage as specified by us; and that, with products not furnished by us; or (iii) performance of a patented
upon our request, Buyer will return to us at our expense the process using a product furnished by us or production thereby of a
defective product or part thereof. patented product; and,
(b) The terms of this warranty do not in any way extend to any (c) We are notified promptly and given information and assistance
product or part thereof which have a life, under normal usage, (at our expense) and the authority to defend the suit or proceeding.
inherently shorter than 12 months. We shall not be responsible hereunder for any settlement made
(c) The conditions of actual production in each end user’s plant without our written consent nor shall we be responsible for costs
vary considerably. Therefore, descriptions of the production or or expenses incurred without our written consent. If our product is
performance capabilities of any product or software materials adjudicated to be an infringement and its use in the U.S. by Buyer
Hot
are estimates only and are not warranted. is enjoined, we shall, at our own expense, either:
Custom
4. EXCLUSIONS OF WARRANTIES: (i) procure for Buyer the right to continue using our product;
RunnerHot
THE WARRANTIES TO REPAIR OR REPLACE DEFECTIVE PRODUCTS (ii) replace it with a noninfringing product;
OR PARTS AS SET FORTH IN PARAGRAPH 3, AND ANY ADDITIONAL (iii) modify it so it becomes noninfringing;
WARRANTY EXPRESSLY STATED TO BE A WARRANTY AND SET (iv) remove the product or part thereof and refund Buyer’s net
FORTH IN WRITING AS PART OF THESE TERMS HEREIN ARE IN LIEU book value and transportation costs attributable to it.
Systems
OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING The foregoing states our entire liability with respect to any patent
Runner |Systems
BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANT- infringement by our products or any parts thereof. To the extent that
ABILITY OR FITNESS FOR A PARTICULAR PURPOSE. our product or any part thereof is supplied according to specifica-
5. LIMITATION OF REMEDIES AND LIABILITIES: tions and designs furnished by Buyer, Buyer agrees to indemnify us
in the manner and to the extent set forth above insofar as the terms
UNDER NO CIRCUMSTANCES SHALL WE OR ANY AFFILIATE OF thereof are appropriate.
OURS HAVE ANY LIABILITY WHATSOEVER FOR INCIDENTAL OR
10. FORCE MAJEURE: We shall not be liable for any delay in perfor-
Terms and
CONSEQUENTIAL DAMAGES HOWSOEVER CAUSED OR ARISING
(INCLUDING CONTRACT, NEGLIGENCE, STRICT LIABILITY OR mance or nonperformance which is due to war, fire, flood, acts of
OTHERWISE), such as, but not limited to, loss of profit or revenue; God, acts of third parties, acts of governmental authority or any
loss of use of the product, part thereof; cost of capital; cost of agency or commission thereof, accident, breakdown of equipment,
replacement equipment; claims that the warranty failed of its differences with employees or similar or dissimilar causes beyond
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essential purpose or claims resulting from contracts between Buyer, our reasonable control, including but not limited to, those interfering
Conditions
its customers and/or suppliers. Unless expressly provided for herein, with production, supply or transportation of products, raw materials
in no event shall we or any affiliate of ours assume responsibility or or components or our ability to obtain, on terms we deem reason-
able, material, labor, equipment or transportation.
Products
liability for (a) penalties, penalty clauses or liquidated damages
clauses of any description, (b) certifications or (c) indemnification of 11. ACCEPTANCE OF ORDERS: Buyer agrees that all orders, including
Buyer or others for costs, damages or expenses arising out of or any arising from our Proposal, shall include these terms and
related to the product or part thereof. conditions only, notwithstanding any different or additional terms
of Sale
6. CANCELLATION: Unless otherwise agreed, Buyer may cancel all or that may be embodied in Buyer’s order. All orders are subject to our
any part of the order by written notice received by us before our acceptance and we reserve the right to reject orders as, in our sole
completion of the order or applicable portion of the order. On receipt judgement, mandated by business conditions. We reserve the right
of such notice, all work on the order or part thereof canceled will be to not proceed with any order until all necessary information is
stopped as promptly as is reasonably possible. Buyer will then be received from Buyer.
invoiced for and will pay to us a cancellation charge. For completed 12. MERGER CLAUSE: This Agreement entirely supersedes any prior
items, the charge will be equal to their established prices. For items oral representations, correspondence, proposal, quotation, or
not completed, the charge will be equal to our full cost plus a agreement. This writing constitutes the final and total expression
premium in addition to a charge for any packing and storage and of such agreement between the parties, and it is a complete and
less a credit for the balance of the material as scrap. exclusive statement of the terms of that agreement.
7. PAYMENT TERMS: Payment is due in accordance with any 13. ASSIGNMENT: Neither party may assign this Agreement without
applicable progress, advance or other agreed upon payment the written consent of the other party, except that we may assign
schedule, or, if no such schedule has been agreed to, upon this Agreement to a third party that acquires substantially all of
Acceptance as specified in Paragraph 8, but in no event later than our assets or we may assign the flow of funds arising out of this
30 days from the date of invoice. No cash discount is provided. If, Agreement.
in our judgment, Buyer’s financial condition changes, we may stop 14. GOVERNING LAW: This Agreement shall be governed by and
work until financial arrangements satisfactory to us are made. construed in accordance with the laws of the State of Michigan.
8. ACCEPTANCE OF PRODUCT: Each such product shall be deemed to
be accepted within seven days after delivery of the product to the
Buyer, unless we receive written notification of rejection for cause
from Buyer within the seven day period.

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

Custom
70 East Hillis Street, Youngwood, Pa 15697, FAX: 724-925-2424

Hot Runner
1117 Fairplains Street, Greenville, MI 48838, Tel. 616-754-4601, FAX: 616-225-3924

3275 Deziel Drive, Windsor, Ont N8W 5A5, Tel. 519-948-5001, FAX: 519-948-4652
Please add “DME Company” and “Attn: Estimating Dept.” to above addresses when mailing prints. To obtain prices and
delivery on special mold base orders or to check status of special work in progress please contact Customer Service.
CANADA
TERMS AND CONDITIONS OF SALE: See previous page.
PHONE ORDERS: Contact our Mississauga, Ontario office at 800-387-6600, FAX: 800-461-9965.
MAIL ORDERS: Send to: DME Company, 6210 Northwest Drive, Mississauga, Ontario L4V 1J6.
CHECK OR MONEY ORDERS: Make payable to DME Company. Include remittance copy of invoice and mail to
Mississauga address above.
WALK-IN ORDERS, PICK-UPS, RETURNS, AND SPECIAL MACHINING: Contact our Mississauga office.
Hot Runner Warranty
DME Company
29111 Stephenson Highway, Madison Heights, MI 48071
Tel. 248/398-6000 FAX 248/544-5113
DME Hot Runner Systems and Temperature Controllers are warranted pursuant to DME Company’s standard terms and conditions (see page 5) for
the time periods set forth below. The warranty (i) covers items sold and shipped [supplied in accordance with orders placed by the customer with DME on or after
JULY 1, 2003], (ii) applies only to the original DME customer and, (iii) is not transferable to subsequent owners of the product except as specifically set forth herein
(see Transferability below for conditions).
WARRANTY PERIODS APPLICABLE TO SPECIFIED DME PRODUCTS; COVERAGE STARTS UPON DATE OF SHIPMENT:
Item Coverage
DME Hot One Hot Halves Plastic leakage, due to manufacturing defect, within hot
(plates designed, machined & assembled by DME, excluding Electrical Parts) runner plates covered for Two (2) years; excluding Gate
Detail.
Stellar Hot Runner Hot Halves Plastic leakage, due to manufacturing defect, within hot
(plates designed, machined & assembled by DME, excluding Electrical Parts) runner plates covered for Two (2) years; excluding Gate
Detail.
DME Hot One and Stellar Manifold and Components One (1) year
(neither plates nor assembly supplied by DME, excluding Electrical Parts)
DME Electrical Parts One (1) year
(all heaters and thermocouples)
Custom
Hot Runner
DME Mold Controls Two (2) years
(Temperature, Valve Gate & Cavity Pressure Controls, excluding Fuses & Triacs)
Replacement or repair will be made at the election of DME; implemented at a DME facility and/or by shipment of replacement parts to the customer for
Hot Runner
installation and/or return of defective parts to DME for repair.
Transferability:
Systems
This warranty may be transferred by the original DME Customer to a subsequent owner of the product if all of the following conditions exist: (i) the original
DME Customer purchased the product for purposes of re-sale or other immediate transfer and DME was made aware of these purposes at the time of
purchase in writing, (ii) within thirty (30) days from the date of invoice, DME is notified in writing of the transfer and provided with the name of the new
Systems
owner (hereafter “Transferee”), the contact person of the Transferee and the Transferee’s address.
| Hot Runner
Exclusions:
t Normal wear of the system and components including, but not limited to: Nozzle Tips, Nozzle Seal Rings, and Electrical connectors
t Damage to the critical seal-off areas on the manifold, nozzle bodies, or in the mating cavities or cavity inserts
| NewWarranty
caused by improper assembly, operation, disassembly and maintenance
t Wear or damage resulting from corrosion or processing of abrasive/aggressive resins
Products
t Damage due to failure to follow recommended operation and maintenance procedures specified in the DME Hot Runner Manual,
Hot Runner Nameplate, Service Bulletins, User Manuals or failure to follow standard industry operation and maintenance procedure
t Damage caused by abuse, neglect, and failure to adhere to DME instructions and operational recommendations
t Damage caused by improper installation, operation and maintenance
t Damage resulting from modifications to the product or component parts, abuse or neglect
t Failure caused by modifications made to the product without the prior written approval of DME
t Damage resulting from operation of products at injection pressures greater than 20,000 psi (1360 bar) on 250, 375, and
625 Series, and Stellar Systems; unless specifically designed and manufactured for higher
pressure applications in agreement with manufacturer
t Damage or failure caused by the product’s inability to perform as a component of a system design not supplied by DME
t Operator absence or operator error
t Operator maintenance and training capability
t Electrical interruptions
t Events beyond the control of DME
t Errors or actions by a third party
t Non-compliance with local laws, codes, ordinances or regulations codes or bylaws unless DME is informed of them
by our customer at the time of order placement

DME Hot Runner…
Your essentiaal resource for

hot runner sollutions
| Index
| HRS Overview
Whether your application requires best-in-class components or a turnkey

hot-half system, DME has a hot runner solution that meets your needs.
Runner Systems
DME: An Essential Resource for System Solutions

Hot Systems
Hot Runner Productivity DME offers a comprehensive family of hot runner

Moldmakers, molders and mold designers worldwide systems built on our modular architecture making cus-
look to DME for essential hot runner solutions — tom configuration easy and quick.
whether that is a single, best-in-class component or Systems include:
Runner
a complete, fully functioning hot half system. Offering Stellar® Micromolding Systems
Custom
the industry’s broadest range of hot runner products

engineered for tight pitch molding
and services as well as an unsurpassed knowledge
Hot
and expertise, DME is committed to helping customers The Hot One 250, 375 and 625 series
achieve maximum productivity, reliable operation, and
better performance.
A wide range of DME nozzles allows Stellar Micromolding Nozzles

versatility in system selection provide application flexibility

text Systems 9
Hot Runner 9
…from components and manifolds to turnkey hot halves

page content
Custom
Hot Runner
Our goal is simple: to be an essential resource for your molding challenges.
Hot Runner
Every step of the way.
Systems
Specialized Systems Knowledge That Gives Service and Support to
Systems
As one of the world’s leading hot runner You an Advantage Keep You Productive
manufacturers, we recognize that Our team of trained, experienced experts DME provides essential support to
| HRS
some application challenges demand can help you with needs analysis, design, keep your hot runner systems in-service.
| New
specialized solutions. Offerings include: configuration, operation, and all the other Our dedicated hot runner service center
Overview
services that enable you to focus on your is staffed by trained, experienced
Stellar Manifold and Components
core business. technicians who support DME systems,
Products
Stellar Hot Halves as well as other brands, to provide help
Hot One Manifold and Components
Applications engineering
when and where you need it, every step
Hot One Hot Halves
Moldflow analysis of the way.
Stellar & Hot One Systems are custom Moldflow predictive analysis optimizes DME Hot Runner Service Center provides
configured for your application part design and lowers costs total support for your hot runner system

Standard Global Manifold
DME Global Manifolds and Components are standardized worldwide to ensure that even the smallest detail provides
operational excellence regardless of where DME hot runner products are used. Whether you’re relying on a quick-delivery
manifold or an applications-engineered, custom manifold, the DME Global Manifold Standard ensures optimal hot runner
performance no matter where in the world it was built.
Key Features of the DME Global Manifold Include:

Flexible tubular heaters
Locating rings that fit virtually any injection press platen hole diameters
Heated Manifold Extension Nozzles available
High-tolerance, press-fit heaters
Upper and center Manifold supports constructed of high-strength, low-heat conductive titanium that minimizes
heat loss and maintains an even heat profile
Standard Global Manifold and Components
J-type thermocouples are black-and-white, coinciding with the IEC 584-3 International Standard
Flow channel sizes range from 6mm to 16mm
DME customers are assured that DME Manifold Systems are designed and built with a global standard that ensures efficient
molding anywhere in the world. And, since replacement parts are identical worldwide, they are readily available wherever
your mold is operating, not just where it was built. All DME nozzles, including, Stellar and the Hot One, perform flawlessly
with the DME Global Manifold Standard.
Heated “MEN“
|
From Machine Nozzle to

Hot Runner Systems
Manifold
Available in all balanced design layout patterns up to 24 nozzle drops*, including inline, X, Y, H, Double H
& Multiple Level Systems.
*Contact DME for Higher Cavitation
MANIFOLD DESIGN, SPECIFICATION & TOLERANCE STANDARDS
HARMONIZED FOR GLOBAL PRODUCT OFFERING
AMERICAS – EUROPE – ASIA – AUSTRALIA / NEW ZEALAND – INDIA – AFRICA
DME Hot Runner Technology Selection Guide 3/21/16 www.dme.net
The values expressed in grams are for reference NOZZLE FLOW CAPACITY RECOMMENDATIONS GENERIC POLYMER NAME (TRADE NAME) [A = AMORPHOUS or C = CRYSTALLINE]
Resin Application Key only and are determined by using a nominal
NOTE: THE CHART BELOW SHOWS COMMODITY RESINS IN BLUE TYPE; ALL OTHERS ARE ENGINEERING RESINS.
wall thickness of 1.8mm (.070") and unfilled poly-
Good propylene.
]
]
]
) [A
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Gate Diameter Range (Grams)
Poly
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[A]
[A]
/PC
[A]
Polymer Viscosity Key
[C]
[A]
GF
[C]
GF
(Ult
GF
[C]
[C]
MA
(Ny
(Po
(Po
(Po
MF
(Po
GF
GF
GF
GF
GF
GF
tion guidance.
ABS
PPO
PPO
PSU
PSU
PUR
TPO
PBT
PVC
PPS
PPE
TPE
LCP
PEE
PM
L = Low M = Medium H = High
PEI
PEI
Viscosity
PA
PA
PA
PS
PS
PP
PP
PP
PC
PC
PE
PE
Min Max Min Max Low Medium MFI High
NOZZLE TIP L L H M H M L M H M M H H M L H H H H H H H L H H M H H L H H H L M
(mm) (mm) (inch) (inch) MFI >16 7-16 MFI .02-7
Sprue Tip 2.0 2.0 0.080 0.080 20 15 10
Stellar
High Performance Standard Point Gate Tip 0.7 1.9 0.028 0.075 10 10 10
Heater
Wear Resistane Point Gate Tip 1.3 1.9 0.050 0.075 10 10 10
Hot One 250 Series Sprue Tip 2.0 3.1 0.080 0.125 625 475 315
Coil Heater Standard Point Gate Tip 0.7 2.5 0.028 0.100 200 150 100
Cast-In Heater Wear Resistant Point Tip 0.7 2.5 0.060 0.100 200 150 100
Cast-In Heater Wear Resistant Point Tip 0.7 3.1 0.060 0.125 310 200 150
Cast-In Heater Wear Resistant Point Gate Tip 3.2 4.4 0.125 0.175 800 550 400
S-Series & T-Series 4.1 4.1 0.160 0.160 700 500 300
E-Series 1.5 1.5 0.060 0.060 300 150 50
Radius ER-Series & TR-Series 500 300 200
3.2 3.2 0.125 0.125
Hot Sprue Bushings
1.6 1.6 0.062 0.062 300 150 50
High Performance Series
3.2 3.2 0.125 0.125 500 300 200
D-MAX Sprue Tip 2.0 3.1 0.080 0.125 700 500 350
250 Series Standard Point Gate Tip 1.25 2.5 0.050 0.100 250 175 125
High Performance Wear Resistane Point Gate Tip 1.5 2.5 0.060 0.100 250 175 125
D-MAX Sprue Tip 3.2 4.7 0.125 0.187 1100 800 500
High Performance Wear Resistant Point Gate Tip 1.5 3.1 0.060 0.125 350 250 200
D-MAX Sprue Tip 4.7 7.9 0.187 0.312 1600 1200 850
High Performance Wear Resistant Point Gate Tip 3.0 4.4 0.125 0.175 900 650 500
Plastic Materials and Specifications Bushing Selection
HOT SPRUE BUSHING TIP STYLE
PLASTIC MATERIAL PROCESS CONDITIONS
PROCESS MOLD HOT RUNNER DENSITY SOLID For use where gate vestige is allowed. Provides low resistance to flow with excellent flow rates.
MATERIAL
STANDARD RESIN TEMPERATURE TEMPERATURE TEMPERATURE MELTING DENSITY Extended style provides additional stock for machining profiles or part contours.
SYMBOL
SPRUE GATE TIP
[°C] [°F] [°C] [°F] [°C] [°F] [g/cm3] [Ibs/inch3] [g/cm3] [Ibs/inch3] STANDARD / EXTENDED
Styrene Butadiene SB 210 410 70 158 230 446 0.93 0.0366 1.02 0.0369
Polyurethane PUR 220 428 45 113 240 464 0.93 0.0366 1.11 0.0401
Styrene-acrylonitrile SAN 230 446 80 176 255 491 0.99 0.0358 1.08 0.0390
Ideal for low vestige commodity and engineering grade resin applications. The Ring Gate features
a sealed tip for efficient shut-off at the part surface. Available with standard or wear resistant
Polystyrene PS 210 410 45 113 230 446 0.95 0.0343 1.05 0.0379
needles. Extended style provides additional stock for machining profiles or part contours.
Polycarbonate PC 300 572 80 176 330 626 1.08 0.0390 1.20 0.0434 RING GATE TIP
STANDARD / EXTENDED
Polyphenylene Oxide-Styrene PPO 260 500 80 176 300 572 0.99 0.0358 1.13 0.0408
Polyethylene PE 200 392 25 77 225 437 0.74 0.0267 0.96 0.0347

Suitable for high viscosity resins, engineering plastics and applications requiring optimum gate
Polypropylene PP 225 437 40 104 245 473 0.73 0.0264 0.91 0.0329
cosmetics with minimal gate vestige. Available with standard or wear resistant needles.
Polyether-etherketone PEEK 330 626 165 329 370 698 1.13 0.0408 1.37 0.0495
Polyphenylene Sulfide PPS 300 572 110 230 330 626 1.53 0.0553 1.70 0.0614 POINT GATE TIP
Polyebutylene Terephthalate PBT 265 509 60 140 290 554 1.44 0.0520 1.57 0.0567
Polyamide 6 PA 6 220 428 90 194 250 482 0.98 0.0354 1.14 0.0412 BUSHING TIP AND PLASTIC MATERIAL COMPATIBILITY
Polyamide 66 PA 66 255 491 90 194 280 536 1.09 0.0394 1.26 0.0455 THERMOPLASTIC RESIN TYPE
Thermal Plastic Elastomers TPE 240 464 35 95 265 509 0.78 0.0282 0.90 0.0325
AMORPHOUS SEMI-CRYSTALINE
Polyoxymethylene (Polyacetal) POM 180 356 100 212 200 392 1.16 0.0419 1.42 0.0513
NOZZLE
ABS/PC *
PPE/PS *
PMMA *
POM *
SAN *
Polymethyl Methacrylate PMMA 235 455 70 158 250 482 1.09 0.0394 1.18 0.0426
PUR *
PPO *
PPS *
PBT *
TPO *
PET *
TPE *
PEEK
PEI *
PA *
PC *
ABS
PSU
LCP
SB
PS
PP
PE
Acrylonitrile Butadiene Styrene ABS 225 437 70 158 250 482 0.95 0.0343 1.08 0.0390
SPRUE GATE TIP

STANDARD / EXTENDED
RING GATE TIP

STANDARD / EXTENDED
NOTE: Temperature and density values shown above are general, and may not apply to your
application. Please refer to proper processing data for the resin grade intended for your specific
application. Failure to use temperature settings appropriate to the specific resin and resin grade
intended for your application may result in poor part quality, or inability to produce acceptable POINT GATE TIP
molded parts. Green – Works well with this resin
Yellow – Contact DME Engineering for guidance
Red – Not recommended
Hot One Hot Runner Technology 13
Hot Runner Quote Request Form
EMAIL TO DMEUS_AE_QUOTE@MILACRON.COM OR FAX

United States: 888-808-4363 t Canada: 800-461-9965 t International: 248-398-7394
DME / Milacron Applications Engineering

29111 Stephenson Highway QUOTE REQUEST FORM
Madison Heights, MI. 48071-2383 Email to: DME_AE_Quote@milacron.com
Tech Service Approval, Final Drawings and In-House Due Date Required for Firm Quote - QUOTE TYPE Preliminary Firm
Customer’s In-House Date Requirement
Date Sales Rep
Company Contact
Address Phone
Address Fax
City E-Mail
State Zip Acct# End User
Molding Material Melt Temp deg.
Manufacturer Range (min) (max)
Hot One Hot Runner Technology

Filler None Glass Other Percent %
Flame Retardant Yes No Mold Flow Index
Color Changes Yes No Mold Temp deg.
New Mold Retrofit DME Mold Base to be Quoted
Mold Base Size Mold Base Drawings Supplied
Gating Into Part Dimple Runner Retainer: Standard
Gate Style Sprue Ext Sprue Bodiless Point WR Bodiless Point H-13 w/ring Solid Ti
Number of Drops Number of Cavities Other
Part Name Part Number Job #
Part Drawing Supplied Yes No Sample Supplied Yes No
Wall Thickness of Part CAD Data Supplied Yes No
Part Weight Grams Ounces Total Shot Weight Grams Ounces
Runner Weight Grams Ounces
DROP LAYOUT Flow Diameters Balanced Yes No

|
Hot Runner Quote Request Form
Options Required
Leader Pins in Nozzle Plate Recessed Connectors Special Terminal Box
Mounting Bolts from Parting Line Flush Mounted Connectors Describe:
Mounting Bolts from Back Side Manifold Extension Nozzle - None Special Connectors
Cavity Mounting Screws Mold Flow Analysis (Piece Part) Describe:
SYSTEM TYPE (REQUIRED) QUOTE STYLE (REQUIRED)
STELLAR Hot Half - Plate Material #2 #7 (Stainless Steel) Other
(Z-Dim) Max 135mm [5.314 in.] / Min 27mm [1.063 in.] Manifold & Components Manifold Material
HOT ONE Nozzle Series (Standard) 250 375 625 Hot Half Plate Material #2 #7 (Stainless Steel) Other
Nozzle Series (High Performance) 250 375 625 Manifold & Components Mainfold Only Manifold Material
Nozzle Heaters Front-load (default) Rear-load
NOTES:
Selected components verified to fit application by: Sales Tech Rep Applications Engineer
Completed By: Date
Tech Service Approval Date
AE001 Rev 2.5.2016 Page 1 of 1

14
14 text
Table
pageofcontent
Contents
Hot Runner Technology............................................15-17

The best solution for precision thermoplastic
micromolding
Stellar Micromolding Hot Runner Systems..........19-23

The best solution for precision thermoplastic
micromolding
Hot One Hot Runner Technology............................25-42

A long-standing industry standard in
| Index
user-friendliness and affordability

| Index
Systems
Systems
Cartridge Heaters & Thermocouples....................36-42

Hot Runner
Custom-configured manifolds, manifold and

Hot Runner
component systems, and complete hot half

assemblies for quick delivery
Custom
Meteor® Hot Runner Systems.................................44-50

Custom-configured manifolds, manifold and
component systems, and complete hot half
assemblies for quick delivery
Online Price Guide Go to www.dme.net/prices for the latest pricing guide.

Hot Runner Technolog y
A LONG-STANDING
INDUSTRY STANDARD
IN USER-FRIENDLINESS
AND AFFORDABILITY
16 Hot Runner Technology
Features and Benefits
Our ongoing customer-driven philosophy has

fostered many new and innovative systems and
components, allowing you to take advantage
of more than seven decades of leadership
in injection molding technology. DME’s Hot
Runner Technology has become an industry
standard in technology, user-friendliness, and
affordability. Available in two styles – Manifold
& Components and as a complete Hot Half
System.
Tubular Heated Systems

Benefits
Using exclusive, distributed wattage Tubular

| Index
Heaters, the DME Hot Runner Systems can

Features and
process many engineering grade resins.

Tubular Heaters reduce the number of zones of
Hot Runner| Systems
heat required, providing the added benefit of

lowering your temperature control costs.
Technology
Custom
Hot Runner
DME’s Hot Runner Technology has become

an industry standard in technology, user-
friendliness, and affordability. Available in
two styles – Manifold & Components and as a
complete Hot Half System.

textTechnology
Hot Runner 17
Nozzles
Each DME nozzle series has its own advantages and characteristics
to meet your needs.
Stellar Nozzles
Point Gate
Sprue Gate
Nozzles
The DME Hot One is accompanied by a nozzle offering
that allows versatility in system selection to best suit
the material and molded part configuration. DME offers
different styles of nozzles: The “EHA” series, using square
Custom
“CIA”/”EHA” Nozzles
HotHot
coil heaters and The “CIA” series, using High Performance
heaters. Each nozzle series has its own characteristics
OneRunner
and advantages.
Hot
HotRunner
For example, the “EHA” series of nozzles can be used
Runner
for many applications using commodity resins with low
Systems
crystallinity. The “CIA” series, with High Performance
Systems
heaters developed exclusively for DME, can be used for all
Technology
applications, especially engineering grade resins with a high
degree of crystallinity.
| New
| New
“EHA”/”CIA” Nozzle Tips
Products
| Nozzles
Products
Sprue Gate/Extended
Sprue Gate – Used primarily Point Gate – Used for
in applications where gate applications needing optimum
vestige is not a concern. Offers gate cosmetics, this tip can run
minimal flow resistance and a wide range of resins. It has
Full Body Point Gate – Used
handles most resins very two interchangeable needles, for low vestige, commodity
effectively. Extended style standard and wear resistant. grade resin applications. The
provides additional stock for The wear resistant needle is Ring Gate features a sealed
machining of runner profiles or especially useful for abrasive tip for efficient shut-off at the
part contours. or filled material applications. parting line.
Ordering Options: Use this information and our design and machining guidelines to build your system, or take advantage
of DME Applications Engineering services to help you select the system best suited to your requirements. Then, either order the
steel and components to construct your system or let DME do all of the machining, assembly and wiring for you.
18 text
page content
Stellar Micromolding
Hot Runner Systems
PROVEN SOLUTIONS
FOR PRECISION
THERMOPLASTIC
MICROMOLDING
Stellar Micromolding Hot Runner Systems 19
Stellar Hot Runner Systems – Benefits
Engineered for the Challenges

of Tight Pitch Molding
The DME Stellar™ Hot Runner System brings high performance, exacting
precision and flexible, cost-effective modular construction to very small part
molding. With as little as 17mm between centers, Stellar is also ideal for
high-cavitation molding.
Demand the Best – Demand DME
Stellar Micromolding Hot Runner Systems

DME has been a leader in mold technologies for seven decades. Nobody
beats DME for quality products, quality service and quick delivery. Like all
DME products, Stellar Hot Runner Systems come with your satisfaction
100% guaranteed.
Get the Modular Advantage

Stellar is based on new DME hot runner system architecture to deliver
tremendous flexibility. Seven different “A” dimensions, two interchangeable
tip options, and a choice of manifold styles enable DME to easily configure
a Stellar solution that matches your application.
|
For a Wide Range
of Applications
Stellar is perfect for today’s rapidly
expanding array of micromolding
projects. Stellar was designed to
perform in a broad spectrum of
applications – including electrical,
electronic, medical, and cosmetic
packaging. And, Stellar was
designed to process demanding
engineering resins without
property degradation.
U.S. 800-626-6653 Canada 800-387-6600

dme@milacron.comwww.milacron.com
20 Stellar Micromolding Hot Runner Systems
Excellent
Results with
Engineering Thermoplastics
The complexity of today’s very small part
CUSTOMER DESIGN molding applications demands the added properties of high
CRITERIA FORMS
performance engineered materials.
CDC Stellar was designed for outstanding processing of these
materials. Challenging amorphous materials such as PET or

To provide your Stellar®
application speciﬁcations, crystalline materials including PBT and PA are easily processed
visit www.dme.net/cdc with the Stellar Hot Runner System. Highly conductive tip
designs and precise heat profiling in all nozzle lengths
ensure consistent processing temperatures.
Modularity Increases Application Flexibility

The Stellar Hot Runner System from DME is built on
a standardized architecture of modular components.
Key features include:
Seven different “A” dimensions from
|
65-145mm are available for compression style nozzles

Two interchangeable tip styles – Point Gate and Sprue Gate

High Performance Nozzle Heater with embedded thermocouple
Two tip material choices, standard and high performance

Stellar Micromolding Hot Runner Systems 21
Stellar Hot Runner Systems Benefits
High Process Temperature Capability

with Precision Heat Profiling
Today’s engineered materials challenge hot runner systems with high processing temperatures – often with very narrow
operating windows. Stellar hot runner nozzles utilize reliable profiled mini-tubular heaters to ensure optimal heat distribution. In
addition, Stellar nozzles are engineered with low conductivity heads and high conductivity tips for consistent
thermal performance.
Easy Serviceability – Right in the Machine

Productivity is especially critical when micromolding thousands of parts per hour. Every Stellar Hot Runner System can be
rapidly serviced for maximum uptime. Nozzle tips, retainers, mini-tubular heaters and thermocouples are all front-loaded and
easily replaced with the mold in the press.
|
Stellar Hot Runner Systems Benefits
Increase Productivity and Reduce Molding Costs With Stellar-Infused Quick-Change Systems
Now the production efficiencies of hot runner molding can be further enhanced when combined with a Master
Unit Die (MUD) Quick-Change Frame. An unlimited number of different parts can be produced with this industry-
leading combination of hot runners within a quick-change system because only the MUD Companion Insert Mold
is swapped out. The MUD Frame/Hot Runner System remains in the mold.
Combining DME Hot Runners with MUD Quick-Change Systems provides many advantages to virtually any injec-
tion molding operation, including:
t Enables molders to use the same DME Hot Runner System with many different cavity and core configurations with MUD
Companion Insert Molds
t Quickens production changeovers, often in as little as five minutes
t Provides cost justification for the Hot Runner System and/or the MUD Quick-Change System for multiple tooling projects
t Simplifies design with the use of the MUD Quick-Change Straps
Contact your DME representative or call us today to find out more about how the combination of a DME Hot
Runner System and the MUD Quick-Change System will not only substantially increase your production efficiency
but significantly reduce your molding costs. Many companies incorporate the DME hot runner/quick-change
combo into their Lean initiatives.

text
22
22 Stellar Systems
Gating Style Selection
Fig. 1 Standard Point Gate Tip

Sub-Assembly, SXG5110
t'PSVTFXJUIVOGJMMFESFTJOTVQUP¡$ ¡'
Fig. 2 High Performance Point Gate Tip

Sub-Assembly, SXG5020
t'PSVTFXJUIVOGJMMFEBOEGJMMFESFTJOTVQUP¡$ ¡'
Fig. 3 Sprue Gate Tip, SXT7040 - T=10mm

|
Fig. 4 Sprue Gate Tip, SXT7140 - T=.750

Table 1: Gating Style Item Numbers

TIP TIP TIP RETAINER APPLICABLE
SUB-ASSEMBLY ITEM CTE ITEM GATING STELLAR
ITEM NUMBER DESCRIPTION NUMBER (10-6/degC) NUMBER STYLE SYSTEM
Standard
SXG5110 Point Gate Tip SXT4010 17.5 SXF5100 Point Gate Standard
Sub-Assembly
High Performance
High
SXG5020 Point Gate Tip Sub- SXT5010 4.5 SXF5000 Point Gate
Performance
Assembly
Sprue Gate Tip

N/A SXT7040 12.8 N/A Sprue Gate All
N/A Sprue Gate Tip SXT7140 12.8 N/A Sprue Gate All
NOTE: All units are in mm.

text 23
Stellar Systems 23
Gate Details for use with Hardened Steel (50HRC min.)
Fig. 6 Gate Details for Standard Point Gate, High Performance Point Gate Tips
(SXG5110 & SXG5020) For gating onto a flat surface or into a recess* (“dimple”)
Ø2mm/0.08in x 45°
CLEARANCE
5mm/.20in MIN DIAMETER
DISTANCE R 0.25mm/ Ø19.0mm/
BETWEEN 0.010in MIN 0.75in +0.005 +.0002
Z DIMENSION WATERLINE Ø9.800mm –0.000 /.3858in –.0000
R 3.00mm/
AND DROP 0.118in MAX
+0.13 +.005
30° 2.03mm –0.00 /.080in –.000
90°
5mm/ R0.25mm/.010in MIN

R0.38mm/.015in MAX +0.00 +.000
.20in MIN 2.54mm –0.13 /.100in –.005
Stellar Systems
0.13mm/.005in 0.89mm/.035in
R4.76mm/.187in MAX LAND MAX*
0.62mm/.024in R3.18mm/.125in*
To Bottom of Radius
R12.70mm/.500in MIN*
MIN GATE DIAMETER

Ø0.71mm/.028in for unfilled resins
Ø1.27mm/.050in for filled resins
|
NOTES for Figure 6 & 7:
Gate Details for use with Hardened Steel (50HRC min.)

1. If gate detail does not properly
fit the application, contact
DME for assistance about
gate detail options.
Fig. 7 Gate Details for Sprue Gate Tips, SXT7040 & SXT7140 2. Position gate detail within
±0.013mm/.0005in from nominal.
19.5 0.77 3. The gate diameter can be
x 45
SXT7140 opened by the customer

to suit the application.
2 0.08
19.0 0.75
IO N(The land must be re-machined
SXT7040 E ST to the maximum dimension
QU after increasing the
IN gate diameter.)
4. Water lines are required in “A”
plate for proper gate cooling.
5. Position water lines as close
as possible but not closer than
the minimum distance shown to
provide a safe steel condition.
Z-DIMENSION
6. For faster color changes,

remove (“decone”) the
5.30 0.209
5 0.20 resin from the front of

MIN 45° each point gate tip prior
30° to changing colors.
7. The minimum “Z” dimension
is 13.00 and the maximum
“Z” dimension is 115 for point
gate and sprue gate tips.
5 0.20
+ 0.005 + 0.0002
MIN 10.000 0.3937
0.000 0.0000
SXT7040
3.30 0.130
MAX RUNNER + 0.012 + 0.0005
HEIGHT 19.050 0.7500
0.000 0.0000
SXT7140

24
Hot One Noz zles
ENABLING VERSATILITY
IN SYSTEM SELECTION
Hot Runner
Custom Systems
Hot Runner | Index
| Index
Systems
Hot One Nozzles 25
250 Series Nozzles

(.250 Diameter Flow Channel)
SQUARE COIL HEATER
REAR LOAD
(SCHXXXX)
250 Series Nozzle Sub-Assembly
Ø1.500 3 1 (Add .750 to A dimension for extended sprue gate and extended full body point gate tips.)
SUB-ASSEMBLY 1 2 3
A B
1.000
ITEM NUMBER NOZZLE BODY HEATER SEAL RING
— EHA0001 SCH0081
1.250 EHA1001 SCH1081
2.000 CIB1359
2 — CIA0001S CIH0081S
A
1.250 CIA1001S CIH1081S
— EHA0002 SCH0082
1/2-24 UN
1.250 EHA1002 SCH1082
2.500 CIB1360
Ø0.250 — CIA0002S CIH0082S
1.250 CIA1002S CIH1082S
SQUARE COIL HEATER
FRONT LOAD — EHA0003 SCH0083
(SCH1XXX or SCH2XXX)
1.250 EHA1003 SCH1083
Hot One Nozzles

3.000 CIB1361
3 1 — CIA0003S CIH0083S
1.250 CIA1003S CIH1083S
— EHA0004 SCH0084
1.250 EHA1004 SCH1084
Custom| Hot
B
3.500 CIB1362 EHR7154
— CIA0004S CIH0084S
1.250 CIA1004S CIH1084S
2 — EHA0005 SCH0085
250Runner
1.250 EHA1005 SCH1085
4.000 CIB1363
Series Systems
HIGH PERFORMANCE HEATER 1.250 CIA1005S CIH1085S
REAR LOAD
(CIHXXXX-S) — EHA0006 SCH0086
1.250 EHA1006 SCH1086
Nozzles (.250
3 1 5.000 CIB1364
1.250 CIA1006S CIH1086S
— EHA0007 SCH0087
| New
1.250 EHA1007 SCH1087
6.000 CIB1365
Diameter
2 1.250 CIA1007S CIH1087S
Products
Flow Channel)
HIGH PERFORMANCE HEATER WIRING INFORMATION:
FRONT LOAD Power leads are tan
(CIH1XXX-S) Ground leads are green
3 1
Thermocouple leads are black and white
White is negative (-) and constantan (non-magnetic)
Black is positive (+) and iron (magnetic)
B
.062
Replacement Seal Rings ITEM NUMBER
Used between manifold and nozzle to prevent leakage. New EHR7154
seal rings must be installed each time manifold is assembled. .561 DIA.
U.S. 800-626-6653 Canada 800-387-6600

26 Hot One Nozzles
375 Series High Performance Nozzles
SQUARE COIL HEATER

REAR LOAD
(SCHXXXX)
(Add .750 to A dimension for extended sprue gate and extended full body point gate tips.)
Ø2.000 3 1
SUB-ASSEMBLY 1 2 3
A B
ITEM NUMBER NOZZLE BODY HEATER SEAL RING
1.000
— EHA0008 SCH0088
1.250 EHA1008 SCH1088
2.000 CIB1366
2
A 1.250 CIA1008S CIH1088S
— EHA0009 SCH0089
5/8-20 UN 1.250 EHA1009 SCH1089
2.500 CIB1367
Ø0.375 — CIA0009S CIH0089S

1.250 CIA1009S CIH1089S
SQUARE COIL HEATER
FRONT LOAD
— EHA0010 SCH0090
(SCH1XXX or SCH2XXX) 1.250 EHA1010 SCH1090
3.000 CIB1368
3 1 — CIA0010S CIH0090S
1.250 CIA1010S CIH1090S
— EHA0011 SCH0091
B 1.250 EHA1011 SCH1091
3.500 CIB1369
| Index
1.250 CIA1011S CIH1091S

2 EHR7155
— EHA0012 SCH0092
Nozzles
1.250 EHA1012 SCH1092

4.000 CIB1370
Systems
HIGH PERFORMANCE HEATER

REAR LOAD 1.250 CIA1012S CIH1092S
Performance
(CIHXXXX-S)
— EHA0013 SCH0093
3 1
1.250 EHA1013 SCH1093
5.000 CIB1371
Hot Runner
1.250 CIA1013S CIH1093S
— EHA0014 SCH0094
Series High
1.250 EHA1014 SCH1094

6.000 CIB1372
2 — CIA0014S CIH0094S
375Custom
1.250 CIA1014S CIH1094S

— EHA0015 SCH0095
1.250 EHA1015 SCH1095
HIGH PERFORMANCE HEATER 7.000 CIB1373
FRONT LOAD — CIA0015S CIH0095S
(CIH1XXX-S)
1.250 CIA1015S CIH1095S
|
3 1
Hot One Nozzles
B WIRING INFORMATION:
Power leads are tan
Ground leads are green
Thermocouple leads are black and white
2
White is negative (-) and constantan (non-magnetic)
Black is positive (+) and iron (magnetic)
.062
Replacement Seal Rings ITEM NUMBER
Used between manifold and nozzle to prevent leakage. New seal EHR7155
rings must be installed each time manifold is assembled. .686 DIA.

Hot One Nozzles 27
625 Series Nozzles

SQUARE COIL HEATER
(Add .750 REAR
to A LOAD
dimension for extended sprue gate and extended full body point gate tips.)
(SCHXXXX)
Square Coil Heater
COIL HEATER
Ø2.000
RearLOAD
Load 3 1
REAR
(SCHXXXX)
(SCHXXXX)
SUB-ASSEMBLY 1 2 3
A B
Ø3.000 ITEM NUMBER NOZZLE BODY HEATER SEAL RING
1.000 3 1
3.000 CIB1381
1.500 1.750 CIA1023S CIH1104S
2 — EHA0016 EHB0074 SCH0096
2
A 1.750 EHA1012 SCH1092
A 4.000
5/8-20 UN
CIB1374
1.750 CIA1016S CIH1096S
Hot One Nozzles

1"-16 UN
Ø0.625
Ø0.375 — EHA0017 SCH0097
EHB0075
1.750 EHA1017 SCH1093
SQUARE COIL HEATER 5.000
Square Coil Heater
FRONT LOAD — CIA0017S CIH0097S
Front Loador SCH2XXX)
(SCH1XXX CIB1375
(SCHXXXX) 1.750 CIA1017S CIH1097S
3 1
6.000 — EHA0018 SCH0098
EHB0076
1.750 EHA1018 SCH1094
| Custom
B CIB1376
1.750 CIA1018S CIH1098S
625 Series
— EHA0019 SCH0099
EHB0077 EHR7156
1.750 EHA1019 SCH1095
2 7.000
Hot High
CIB1377
1.750 CIA1019S CIH1099S
Runner
High
HIGHPerformance
PERFORMANCE Heater
HEATER
— EHA0020 SCH0100
Rear LoadLOAD
REAR
EHB0078
1.750 EHA1020 SCH1095
Performance
(CIHXXXX-S)
(CIHXXXX-S) 8.000
3 1 CIB1378
Systems Nozzles
1.750 CIA1020S CIH1101S
2 2
B
— EHA0021 SCH0101
EHB0079
1.750 EHA1015 SCH1095
9.0003
3
CIB1379
| New(.625
1 1
1.750 CIA1021S CIH1102S
2
— EHA0022 SCH0102
EHB0080
1.750 EHA1015 SCH1095
Products
10.000
CIB1380
HIGH
High PERFORMANCE
Performance HEATER
Heater 1.750 CIA1022S CIH1103S
Diameter Flow Channel)

FRONT
Front LoadLOAD
(CIH1XXX-S)
(CIHXXXX-S)
3 1
2 2
B WIRING INFORMATION:
Power leads are tan
B Ground leads are green
3 3 Thermocouple leads are black and white
1 1  White is negative (-) and constantan (non-magnetic)
2  Black is positive (+) and iron (magnetic)
Replacement Seal Rings .062

Item Number
Used between manifold and nozzle to prevent leakage. New EHR7156
seal rings must be installed each time manifold is assembled. 1.063 DIA.
U.S. 800-626-6653 n Canada 800-387-6600 n dme@milacron.com n www.milacron.com

28 Hot One Nozzles
Gate Tip Detail

Sprue Gate/Extended Sprue Gate
SERIES GATE TIP ITEM NUMBER B DIA. T DIA. L C
Ø2.03 EHT0010 .500
.250 .375
SPRUE GATE EHT0011 .750
EHT0012 1.000 .100
A 250 .080
EHT0013 .500
1.000 1.125
EXTENDED SPRUE GATE EHT0014 .750
EHT0015 1.000 .850
EHT0016 .500
C SPRUE GATE EHT0017 .750 .250 .375
L 375
EHT0018
.125
1.000
EHT0019 .500
ØT EXTENDED SPRUE GATE EHT0020 .750 1.000 1.125
EHT0021 1.000
5° PER SIDE SPRUE GATE EHT0022 .250 .500
625 .187 1.000
EXTENDED SPRUE GATE EHT0023 1.000 1.250
(Add .750 to A dimension for extended sprue gate tips.)
Point Gate (Bodiless)

INCLUDES
SERIES GATE TIP ITEM NUMBER T DIA.
NEEDLE RETAINER TIP
EHT0005 EHT0024
STANDARD EHN0015
EHT1314 EHT0324
NEEDLE 250
EHT1308
.375
EHT0324
WEAR RESISTANT EHN0401
EHT1313 EHT1324
EHT0039 EHT0025
A STANDARD EHN0016
RETAINER TIP EHT1312 EHT0325
375 .500
EHT1303 EHT0325
EHT1309 EHT1325
EHT1306 EHT1354
STANDARD EHN0019
EHT1311 EHT0326
625 .625
EHT1307 EHT0326
EHT1310 EHT1354
ØT
| Index
Point Gate (Full Body)

Gate Tip Detail
INCLUDES
SERIES TYPE ITEM NUMBER T DIA. O DIA. E
NEEDLE RETAINER TIP
EHT2001 .060 EHT0026
.375
EHT2002 .080 EHT0027
STANDARD EHN0015
Runner |Systems
EHT2003 .060 EHT0028

.500
EHT2004 .080 EHT0029
250 .187
NEEDLE EHT2005 .060 EHT1326
.375
EHT2006 .080 EHT1327
EHT2007 .060 EHT1328
.500
EHT2008 .080 EHT1329
RETAINER TIP EHT2009
.500
.080 EHT0030
A EHT2010 .100 EHT0031
Nozzles
EHT2011 .080 EHT0032

STANDARD .750 EHN0016
EHT2012 .100 EHT0033
EHT2013 .080 EHT0034
1.000
E EHT2014 .100 EHT0035
375 .230
EHT2015 .080 EHT1330
.500
Hot
EHT2016 .100 EHT1331

EHT2017 .080 EHT1332
Hot One
WEAR RESISTANT .750 EHN0400

EHT2018 .100 EHT1333
ØO
Custom
ØT EHT2019 .080 EHT1334

1.000
EHT2020 .100 EHT1335
STANDARD EHT2021 EHN0019 EHT0036
625 1.000 .125 .250
WEAR RESISTANT EHT2022 EHN0402 EHT1336
Point Gate (Full Body Extended)

INCLUDES
NEEDLE RETAINER TIP
EHT2301 .060 EHT2326
.375
EHT2302 .080 EHT2327
STANDARD EHN0015
NEEDLE EHT2303
.500
.060 EHT2328
EHT2304 .080 EHT2329
250 .938
EHT2305 .060 EHT2326
.375
EHT2306 .080 EHT2327
RETAINER TIP WEAR RESISTANT EHN0401
EHT2307 .060 EHT2328
.500
EHT2308 .080 EHT2329
EHT2309 .080 EHT2330
.500
EHT2310 .100 EHT2331
EHT2311 .080 EHT2332
EHT2312 .100 EHT2333
EHT2313 .080 EHT2334
1.000
A EHT2314 .100 EHT2335
375 .980
EHT2315 .080 EHT2330
.500
EHT2316 .100 EHT2331
E EHT2317 .080 EHT2332
EHT2318 .100 EHT2333
0.750 EHT2319
1.000
.080 EHT2334
EHT2320 .100 EHT2335
STANDARD EHT2321 EHN0019
625 1.000 .125 1.000 EHT2336
WEAR RESISTANT EHT2322 EHN0402
5° PER SIDE ØO SERIES THREAD TYPE

250 1/2-24 UN
ØT 375 5/8-20 UN
625 1"-16 UN

Hot One Nozzles 29
Housing, Nozzle Plate and
Gate Machining Dimensions Detail
Manifold Housing, Nozzle Plate, “A” Plate and
Gate Machining Dimensions
LOCATING RING
F DIA. .261 DIA. HOLE THRU
WATER LINES ARE 5/16–18 TAP ITEM
F DIA. G DIA. H DIA. J DIA.
RECOMMENDED IN G DIA. NUMBER
HOUSING .34 DEEP
H DIA. 2-PLC'S. TYP. EHL0252 4.000 3.312 3.000 2.500
RISER PAD
J DIA. .219
HEIGHT EHL0253 5.500 4.625 4.000 3.750
EHL0254 4.000 3.312 3.000 2.500
EHL0255 5.500 4.625 4.000 3.750
Manifold housing and insulator sheet are to be same width and
.250 MIN.
length as mold base. Height of manifold housing to vary with
K DIA. .25 MIN. stackup of manifold, riser pads and spacer rings.
M DIA. HOUSING MUST BE EQUAL
MANIFOLD TO RISER PADS, SPACER
HEIGHT 1.000 RING AND MANIFOLD AT
N DIA.
NOZZLES
Hot One NozzlesCustom

(1.500 FOR ROOM TEMPERATURE
625 SERIES) .625 WIRE
CHANNEL
+.001 N DIA. MIN for
.250 MIN. N DIA. MIN for
+.001 SERIES K DIA. –.000 HIGH
.250 MIN. –.000 SQ. COIL
SPACER RING
1.875 NOZZLE PLATE
M DIA. PERFORMANCE
AND SUPPORT .250
PAD HEIGHT RECOMMENDED
RECOMMENDED 250 1.56 1.501 1.062 1.187
(.125 MIN.)
375 2.06 2.001 1.250 1.437
A + BE .31 MIN. WATER LINES ARE 625 3.06 3.001 1.875 2.125
RECOMMENDED IN
"A" PLATE AND
| Housing,
NOZZLE PLATE
.125 RAD. MAX.
Hot Runner
NOTE: The expansion factor must be taken into consideration prior to machining for, and installing, nozzle.
This expansion factor (BE) must then be added to the nominal “A” dimension.
Nozzle Plate
Formula for determining this expansion factor is as follows:
BE = “A” dimension x .00000633 x nozzle setpoint temp – 68°(assuming the mold is at 68˚F during
operation). If mold temperature is different, substitute 68˚F with actual mold temperature.
Systems
EXAMPLE: Given a 3 inch “A” dimension, with a nozzle setpoint temp. of 500°:
BE = 3 x .0000063 x (500-68) = .008… thus A + BE = 3.008.
and Gate
The above information is only given as an example. Variations may occur based on mold configurations
and cooling factor. In some instances, it may be necessary to obtain an empirical factor.
| New
250 & 375 SERIES 625 SERIES
SPRUE AND POINT GATE (FULL BODY) POINT GATE (BODILESS) POINT GATE (BODILESS)
Machining
MACHINING DIMENSIONS MACHINING DIMENSIONS MACHINING DIMENSIONS
80° Ø2.125 MIN
ProductsDimensions Detail
“R” RAD. .010 –.015 RAD. 80°
30°0' 30°0' 30°
3
+.0005
R0.125
–.0000
R0.010-0.015
0.005 LAND MAX
0.020 AT TANG.
0.125
0.235
.005
0.47
“S” DIA. “0” DIA. .180

.080 LAND LAND R0.312
MAX. .100
+.0005 ØO
–.0000 .020
NOTE: Extended sprue length “Q” DIA. AT TANGENT +0.0005
Ø0.6250 0.0000
will add .750 to land.
O DIA.
SERIES T DIA. S DIA. SERIES
UNFILLED FILLED Q DIA. R RAD.
NOZZLE
*.375 *.3755 RESIN RESIN
250 .500 .5005 250 .028 MIN. .060 MIN. .3750 .125
AND 375 .028 MIN. .060 MIN. .5000 .187
375 .750 .7505
1.000 1.0005 625 .080 MIN. .100 MIN. .6250 .312
625 1.000 1.0005
NOTE: The “O” diameter can be opened by the
*250 Point Gate (Full Body) only. customer to suit the application. Also the
land must be remachined to .005 max. after
increasing the gate diameter.

30 Hot One Nozzles
Replacement Nozzle Heater Detail
Replacement Square Coil 250, 375 AND 625 NOZZLE HEATER Replacement High Performance
Nozzle Heater 240 VAC, T/C TYPE “J”, 36" LONG D
Nozzle Heater
DIA
WIRING INFORMATION:
Power leads are black
Ground lead is green
Thermocouple leads are black and white L
LENGTH
L – White is negative (–) and constantan
(non-magnetic)
– Black is positive (+) and iron (magnetic)
D DIA.
D DIA. USED WITH D DIA. USED WITH

ITEM ITEM
SERIES NOMINAL L DIM. WATTS NOZZLE SERIES NOMINAL L DIM. WATTS NOZZLE
NUMBER NUMBER
NOZZLE SUB-ASSEMBLY NOZZLE SUB-ASSEMBLY
SCH0081 EHA0001 CIH0081S CIA0001S
2.000 300 2.000 300
SHC1081 EHA1001 CIH1081S CIA1001S
2.500 350 2.500 350
3.000 400 3.000 400
CIH1083S CIA1003S
Index Detail
SCH1083 EHA1003
250 .625 3.500 425 .625 3.500 425
SCH1084 EHA1004 250 CIH1084S CIA1004S
| Heater
4.000 500 4.000 425

5.000 500 5.000 500
CIH0087S CIA0007S
Nozzle
SCH0087 EHA0007 6.000 550

6.000 550 CIH1087S CIA1007S
SCH1087 EHA1007
Systems

2.125 400 2.125 400
Replacement

2.625 450 2.625 450
3.125 550
NozzlesHot| Runner
SCH1090 EHA1010 3.125 550

CIH1090S CIA1010S
3.625 700 3.625 700
375 SCH1091 EHA1011 CIH1091S CIA1011S
.875 375
SCH0092 EHA0012 CIH0092S .875 CIA0012S
4.125 800 4.124 800
5.125 900 5.125 900
SCH1093 EHA1013
Hot OneCustom
CIH1093S CIA1013S
6.125 1000 6.125 1000
7.125 1100 7.125 1100
4.000 1000 3.038 847
5.000 1030 4.038 1000
6.000 1100 5.038 1030
625 1.500 7.000 1000 6.038 1100
SCH0100 EHA0020 625 1.500
8.000 1200 CIH0099S CIA0019S
SCH1100 EHA1020 7.038 1000
CIH1099S CIA1019S
9.000 1200 8.038 1200
10.000 1200 9.038 1200
CIH0103S CIA0022S
10.038 1200
CIH1103S CIA1022S

Standard Global Manifold Replacement Heaters
Ceramic 321 Stainless Steel

Image not to scale.
~6mm
Unflexible Unheated Flexible Heated Length Unflexible Unheated
(min. 30mm) (min. 30mm)
~20mm Length (tolerance +/- 1.5%)
DME Manifold Flexible Replacement Heaters

8.0mm diameter. Operating voltage 240 Volt. Threaded pins on both ends.
HIGH-WATT FLEXIBLE TUBULAR HEATERS LOW-WATT FLEXIBLE TUBULAR HEATERS
Hot One Nozzles

ITEM NO. LENGTH (mm) WATTAGE ITEM NO. LENGTH (mm) WATTAGE
HFH8030 300 660 HFL8040 400 339
HFH8035 350 675 HFL8045 450 364
HFH8040 400 795 HFL8050 500 410
Custom Hot
HFH8045 450 910
HFL8055 550 458
HFH8050 500 1025
HFL8060 600 504
HFH8055 550 1145
HFL8065 650 552
HFH8060 600 1260
| Standard
HFL8070 700 598
HFH8065 650 1380
Runner Global
HFH8070 700 1495 HFL8075 750 646
HFH8075 750 1615 HFL8080 800 692
HFH8080 800 1730 HFL8085 850 738
Systems
HFH8085 850 1845 HFL8090 900 784
HFH8090 900 1960 HFL8095 950 832
HFH8095 950 2080 HFL8100 1000 878
Manifold
HFH8100 1000 2195
HFL8105 1050 926
HFH8105 1050 2316
| New
HFL8110 1100 972
HFH8110 1100 2430
HFL8115 1150 1018
Replacement
HFH8115 1150 2545
|
HFL8120 1200 1066
Products Heaters
HFH8120 1200 2665
Hot Runner Systems
HFH8125 1250 2780 HFL8125 1250 1112

HFH8130 1300 2895 HFL8130 1300 1158
HFH8135 1350 3015 HFL8135 1350 1206
HFH8140 1400 3130 HFL8140 1400 1252
HFH8145 1450 3245 HFL8145 1450 1298
HFH8150 1500 3365 HFL8150 1500 1346
Replacing a DME Manifold Flexible Tubular Heater may also OPTIONAL ITEM
require the replacement of retaining rings that hold the heater
in place. After installing the manifold heater, insert a retaining RR-472-13000-100 Manifold Heater Retainer Clips
ring into each of the existing undercut grooves in the manifold.
Use a brass hammer to lightly tap a small piece of brass and
each retaining ring to secure the manifold heater.
Heater Retainer Clips
Undercut Grooves

Image not to scale.

Ceramic 321 Stainless Steel
~6mm
Unflexible Unheated Flexible Heated Length Unflexible Unheated
(min. 30mm) (min. 30mm)
~20mm Length (tolerance +/- 1.5%)
DME Manifold Flexible Replacement Heaters

8.5mm diameter. Operating voltage 230 Volt. Threaded pins on both ends.
Hot Runner Systems | Standard Global Manifold Replacement Heaters
HIGH-WATT FLEXIBLE TUBULAR HEATERS LOW-WATT FLEXIBLE TUBULAR HEATERS
ITEM NO. LENGTH (mm) WATTAGE ITEM NO. LENGTH (mm) WATTAGE
HFH850300 300 650 HFL850500 500 700
HFH850350 350 750 HFL850550 550 780
HFH850400 400 900 HFL850600 600 860
Custom Hot Runner Systems | Index
HFH850450 450 1050 HFL850650 650 950

HFH850500 500 1150 HFL850700 700 1000
HFH850550 550 1300 HFL850750 750 1100
HFH850600 600 1450 HFL850800 800 1190
HFH850650 650 1600 HFL850850 850 1250
HFH850700 700 1750 HFL850900 900 1350
HFH850750 750 1900 HFL850950 950 1430
HFH850800 800 2050 HFL851000 1000 1500
HFH850850 850 2200 HFL851050 1050 1590
HFH850900 900 2350 HFL851100 1100 1650
HFH850950 950 2500 HFL851150 1150 1750
HFH851000 1000 2650 HFL851200 1200 1830
HFH851050 1050 2800 HFL851250 1250 1900
HFH851100 1100 2930 HFL851300 1300 1990
HFH851150 1150 3060 HFL851350 1350 2070
HFH851200 1200 3190 HFL851400 1400 2150
HFH851250 1250 3320 HFL851450 1450 2230
HFH851300 1300 3450 HFL851500 1500 2300
HFH851350 1350 3580
HFH851400 1400 3710
OPTIONAL ITEM
HFH851450 1450 3840
RR-472-13000-100 Manifold Heater Retainer Clips
HFH851500 1500 3970
Replacing a DME Manifold Flexible Tubular Heater may also

require the replacement of retaining rings that hold the heater
in place. After installing the manifold heater, insert a retaining
ring into each of the existing undercut grooves in the manifold.
Heater Retainer Clips
Use a brass hammer to lightly tap a small piece of brass and
each retaining ring to secure the manifold heater.
Undercut Grooves

Hot One Nozzles 33
Replacement Parts Detail
Terminal Mounting Box

For information on terminal mounting boxes, mold power and thermocouple connectors, see the DME Control Systems Catalog.
Nozzle Seat Locating Ring

Replaceable interface between manifold and machine nozzle. INCLUDES (2) 5⁄16 – 18 × 1⁄2" LG. FLAT HEAD CAP SCREWS
F DIA. D
X
C DIA.
D HEX.
(ACROSS FLATS) 1.500
SPH. RAD.
C
.218
L
.25 FOR EHN0011 & EHN0012 X
.38 FOR EHN0013 & EHN0014
Y
THREAD UNF E DIA. A
B
ITEM SPH. C D E F ITEM D X Y A B C
X L THREAD
NUMBER RAD. DIM. HEX. DIA. DIA. NUMBER DIA. DIA. DIA. DIM. DIA. DIM.
Custom
EHN0011 .500 EHL0252 2.990 2.000 2.500 3.312 3.990 2.875
Hot OneHot
.62 1.250 1.250 1.50 .363 .312 ⁄4 –16
3
EHN0012 .750 EHL0253 3.990 3.250 3.750 4.625 5.495 2.875
EHN0013 .500 EHL0254 2.990 2.000 2.500 3.312 3.990 4.500
.75 1.750 1.500 1.88 .457 .375 1–12
EHN0014 .750 EHL0255 3.990 3.250 3.750 4.625 5.495 4.500
Nozzles
Runner| Systems
Nozzle Seat Machining Locating Ring Machining
M THREAD SIZE Relief in top of manifold for locating ring.
Replacement
N DIA.
.50
.12
| New
PartsProducts
+.005
Detail
ITEM NUMBER M THREAD SIZE ITEM NUMBER N DIA. –.000
EHN0011 .687 DIA. HOLE × .56 DEEP EHL0252 2.505
EHN0012 3
⁄4–16 UNF TAP × .50 DEEP EHL0253 3.755
EHN0013 .922 DIA. HOLE × .69 DEEP EHL0254 2.505
EHN0014 1–12 UNF TAP × .62 DEEP EHL0255 3.755
Drool Rings
Used in conjunction with nozzle seat and locating ring to prevent A A
nozzle purging and drooling from entering manifold area.
ITEM B C
NUMBER DIA. DIA.
EHL1001 1.38
2.19
EHL1002 1.62 C DIA.
B DIA.
EHL1003 1.38
3.44 .12
EHL1004 1.62
See application information on the preceding page for appropriate use of nozzle seats, drool rings and locating rings.
U.S. 800-626-6653 Canada 800-387-6600

34 Hot One Components
Components for Externally Heated Manifold Systems
Used primarily with tubular heated manifolds, these components are made from
a non-magnetic material with low thermal conductivity. They provide the higher
efficiency and performance required for tubular manifold applications.
Riser Pads
Supports manifold opposite nozzles and prevents heat loss.
DRILLED & C'BORED FOR

¼-20 LOW HEAD SCREW
"X" DEEP
H ITEM
Index Manifold Systems
H X
NUMBER
.78 DIA. ERP1001 .500 .405
.19
1.41 DIA. ERP1002 .750 .655
.06
1.75 DIA.
Externally| Heated

¼-20 LOW HEAD SCREW
"X" DEEP
ITEM
H X
NUMBER
Systems
H
ERP1011 .500 .405
ERP1012 .750 .655
.78 DIA.
Hot Runnerfor
| Components
Center Support Pads and Tubular Dowels

Supports manifold center spacing, while minimizing heat transfer from manifold.
Custom
Hot One Components

1.06 DIA. ¼-20 LOW HEAD SCREW
.375 DIA. "X" DEEP 2 PLACES
H
ITEM
H X
.78 DIA. NUMBER
.19
.06 1.41 DIA. ECB1001 .500 .405
1.75 DIA. ECB1002 .750 .655
.375 DIA.
H
ITEM L
NUMBER LENGTH
3834TD .750
.250 DIA. 38114TD 1.250

Hot One Nozzles 35
Parts Detail
Riser Pad INCLUDES (2) #10–24 LOW HEAD CAP SCREWS

Supports manifold opposite nozzles. Prevents heat loss and ITEM NUMBER X DIM. +.010
–.000 L DIM. F DIM. G DIA. USED WITH
maintains spacing between manifold and clamping plate. ERP0163 .250 GATE-MATE 4,
ERP0167 .375 4.000 3.250 .625 250 SERIES AND
F ERP0164 .750 375 SERIES
1.125 G DIA.
ERP0165 .250
ERP0168 .375 5.000 4.000 .781 625 SERIES
X L
ERP0166 .750
Center Support Pad Spacer Ring

Aligns and supports manifold center while minimizing heat Maintains spacing between manifold and nozzle plate.
transfer from manifold.
.875
P DIA. DIA.
X FOR .250 DIA. DOWEL X A DIA.
+.010
ITEM NUMBER X DIM. +.010
–.000 P DIA. ITEM NUMBER X DIM. –.000 A DIA. USED WITH
ECB0161 .250 2.500 ESR0157 .250 GATE-MATE 4, 250
.406
Custom Hot
ECB0162 .750 2.500 ESR0158 .750 SERIES AND 375 SERIES
ECB0163 .250 1.500 ESR0159 .250
.531 625 SERIES
ECB0164 .750 1.500 ESR0160 .750
Hot One
Tapered Dowel Pin .193 DIA. .162 DIA.
ITEM NUMBER
Runner
Aligns and prevents end plug from rotating. Tapered
EDP0001
dowel pin must conform to ANSI B18.8.2-1978 standard. 1.50
Nozzles
Systems
End Plug End Plug Set Screw
Used to plug horizontal flow channels. Used to secure end plug into manifold (2 required). End plug
| Parts
Material : P–20 set screw must conform to the following standards.
ANSI B1.1. ANSI B18.3 and ASTM F912.
| New
Detail
H DIA. +.0000
<.0002 THREAD
J DIA.
Products
+.001
#10–24 TAP K <.000
M N
SERIES ITEM NUMBER H DIA. J DIA. K DIM. M DIM. SERIES ITEM NUMBER THREAD N DIM.
GATE-MATE 4 EEP0002 .5615 .800 .750 1.500 GATE-MATE 4 SSS7878 7
⁄8–14 UNF-3A .875
250 EEP0001 .4365 .675 .750 1.500 250 SSS3434 3
⁄4–16 UNF-3A .750
375 EEP0002 .5615 .800 .750 1.500 375 SSS7878 7
⁄8–14 UNF-3A .875
625 EEP0003 .6875 .894 1.125 1.875 625 SSS11 1–12 UNF-3A 1.000
Heater Stop Machining Heater Puller Machining

Used for ECH-Series cartridge heaters. Used for CHS-Series cartridge heaters recommended for
HEATER HOLE
heaters installed in blind holes.
.406
. 201 DIA. HOLE s .625 DEEP

1/4–20 UNC TAP s .50 DEEP
1/4–20 s .38 LG. BUTTON HEAD CAP SCREW .687 DIA. HOLE s .75 DEEP
3
MOLDMAKER TO SUPPLY /4 16 UNF TAP s .68 DEEP
U.S. 800-626-6653 Canada 800-387-6600

36 Hot One Nozzles
Cartridge Heaters & Thermocouples
240 VAC, 36" Leads with 6" of Lead Protection Although these heaters do not employ integral
thermocouples, they’re designed and constructed to run at
Cartridge Heater – Power Leads are multi-colored
higher molding temperatures and provide longer life than
conventional heaters.
L
Cartridge Heaters
Shoulder Style Cartridge Heater .500 DIAMETER NOMINAL
.500 DIA. NOMINAL
WATTS
ITEM LENGTH
WATTS PER
NUMBER L
LIN. IN.
L
ECH0103 4.0 500 125
ECH0119 4.0 750 188
Shoulder Style Cartridge Heaters
ECH0104 4.5 575 128
Cartridge Heaters ITEM
L
IN WATTS
WATTS
PER
* ECH0138 5.0 500 100
NUMBER
Can be installed through hole INCHES LIN. IN. ECH0105 5.0 650 130
or installed using retainer plate CHS0119 4.0 500 125 * ECH0139 5.0 750 150
construction. CHS0120 4.5 575 128 ECH0120 5.0 1000 200
CHS0121 5.0 650 130 * ECH0148 5.5 500 91
CHS0122 5.5 725 132 ECH0106 5.5 725 132
Shoulder Style Cartridge
Heaters &| Thermocouples
CHS0123 6.0 800 133 * ECH0140 6.0 750 125

Heaters CHS0124 6.5 875 135 ECH0107 6.0 800 133
These heaters are used in CHS0125 7.0 950 136 ECH0121 6.0 1000 167
conjunction with heater pullers CHS0126 7.5 1025 137 ECH0108 6.5 875 135
Index
CHS0127 8.0 1100 138 * ECH0141 7.0 600 86

to insure easy removal of blind
CHS0128 8.5 1175 138 ECH0109 7.0 950 136
or through hole installations. CHS0129 9.0 1200 133 ECH0122 7.0 1000 143
CHS0130 10.0 1350 135 * ECH0149 7.5 1000 133
CartridgeSystems
CHS0131 11.0 1500 136 ECH0110 7.5 1025 137

CHS0132 12.0 1650 137 * ECH0142 8.0 1000 125
CHS0133 15.0 2050 137 ECH0111 8.0 1100 138
| Runner
CHS0134 18.0 2500 139 ECH0123 8.0 1500 188

Heater puller to be ordered separately. ECH0124 8.0 2000 250
ECH0112 8.5 1175 138
Heater Puller (with Snap Ring) ECH0113 9.0 1200 133
NozzlesHot
PULLER WITH RING

ECH0114 10.0 1350 135
Provides trouble-free removal of ITEM NUMBER
Hot One Custom
ECH0125 10.0 1500 150

Shoulder Style Cartridge Heater. EHP0250 ECH0126 11.0 1000 91
ECH0115 11.0 1500 136
1.625 ECH0128 12.0 1000 83
REPLACEMENT
SNAP RINGS ECH0127 12.0 1500 125
Snap Ring .81
.500 (Included) ITEM NUMBER* ECH0116 12.0 1650 137
HEX
EHP0001 * ECH0144 12.0 2000 167
¾-16 THREAD .81 * ECH0146 14.0 1000 71
*Pkg. of 25
* ECH0145 14.0 2300 164
ECH0129 15.0 1500 100
Manifold Thermocouples 1/4 – 28 UNF ECH0117 15.0 2050 137
Installed in manifold to maintain precise temperature control. * ECH0147 18.0 1500 83
ECH0130 18.0 1700 94
Flat Washer Type .28 DIA. Threaded Type .375 ECH0118 18.0 2500 139
Utilized in limited Installed between heat NOTE: Sizes preceded by an * are the
space applications. source and flow channel newest additions.
for more precise control. See the Hot One Design and Machining
Guidelines at the end of this Hot One Nozzles
section for manifold size recommendation
ITEM NUMBER ITEM NUMBER and installation drawings.
ETC0168 ETC0251

Hot One Components 37
Cartridge Heaters
DME Standard Cartridge heaters employ a swaged NOTE: Lead wires can withstand temperatures up to 450°F.
If temperatures will exceed this amount, leads must
construction using the finest resistance wire and insulation be insulated.
available for optimum heating performance, long life and
maximum dependability. These heaters are furnished with
10" long flexible lead wires, ready for fast installation.
Thermocouple cartridge heaters are also available.
LENGTH LENGTH
DIA. (INCHES) VOLTS WATTS ITEM NUMBER DIA. (INCHES) VOLTS WATTS ITEM NUMBER
2 120 40 CU2021 2 120 100 CU5021
2 240 40 CU2022 2 240 100 CU5022
Custom
3 120 75 CU2031 3 240 200 CU5032
Hot One
3 240 75 CU2032 4 240 250 CU5042
1 /4
4 120 100 CU2041 5 120 300 CU5051
4 240 100 CU2042 5 240 300 CU5052
HotComponents
6 120 150 CU2061 6 120 375 CU5061
Runner Systems
6 240 150 CU2062 6 240 375 CU5062
5 /8
2 120 75 CU3021 8 120 500 CU5081
2 240 75 CU3022 8 240 500 CU5082
3 120 100 CU3031 10 120 650 CU5101
3 240 100 CU3032 10 240 650 CU5102
4 120 150 CU3041 12 120 775 CU5121
| Cartridge
4 240 150 CU3042 12 240 775 CU5122
3 /8
5 120 185 CU3051 14 240 900 CU5142
5 240 185 CU3052 16 240 1050 CU5162
| NewHeaters
6 120 225 CU3061 3 240 225 CU6032
6 240 225 CU3062 4 120 300 CU6041
8 120 300 CU3081 4 240 300 CU6042
Products
8 240 300 CU3082 5 120 375 CU6051
2 120 75 CU4021 5 240 375 CU6052
2 240 75 CU4022 6 120 450 CU6061
3 120 150 CU4031 6 240 450 CU6062
3 240 150 CU4032 3 /4 8 120 600 CU6081
4 120 180 CU4041 8 240 600 CU6082
4 240 180 CU4042 10 120 800 CU6101
5 120 200 CU4051 10 240 800 CU6102
5 240 200 CU4052 12 120 950 CU6121
6 120 300 CU4061 12 240 950 CU6122
1 /2
6 240 300 CU4062 14 240 1100 CU6142
8 120 400 CU4081 16 240 1250 CU6162
8 240 400 CU4082
10 120 500 CU4101
10 240 500 CU4102
NOTE: Special heaters are available on special order.
12 120 600 CU4121
12 240 600 CU4122
16 120 800 CU4161
16 240 800 CU4162
U.S. 800-626-6653 Canada 800-387-6600

High Watt Density Cartridge Heaters
Fit Tolerances DME High Watt Density Cartridge Heaters employ swaged
The cavity or hole, into which a cartridge heater is construction for maximum heat transfer and high watt density
inserted, should be reamed* to the nominal diameter of for more demanding applications. Recommended for use when
the heater. DME cartridge heater diameters are actually IJHIUFNQFSBUVSFTBSFSFRVJSFE VQUP¡'
PSXIFSFIFBUFST
.002 to .007 undersize. High Watt Density Cartridge will be subjected to vibration. Furnished with 10" long flexible
Heaters are .004 undersize, held to a tolerance of ±.002. lead wires. Special heaters are available on special order.
This sizing is maintained for easy installation and for best Thermocouple cartridge heaters are also available.
heat transfer. However, if close hole tolerances are not
Index Heaters
maintained, operating life of the heater may be drastically

LENGTH
reduced. Also make sure that the heated area of the DIA. (INCHES) VOLTS WATTS ITEM NUMBER
Density| Cartridge
1 120 100 CM1001

cartridge does not extend beyond the hole. 1 240 100 CM1002
11 /2 120 150 CM1121
Spacing of Heaters 11 /2 240 150 CM1122
As a general rule it is not recommended to space heaters 1/4
2 120 200 CM2021
2 240 200 CM2022
Systems
in a mold, die or platen any closer to each other than the 3 120 300 CM2031
diameter of the heater. 3 240 300 CM2032
| High Watt
4 240 375 CM2042

Contamination 5 240 450 CM2052
Custom Hot Runner
2 240 250 CM3022

Contamination consists of any foreign matter such as 3 240 350 CM3032
plastics, oil, grease, dirt or water entering through the 3 /8 4 240 500 CM3042
terminal end or the end opposite the terminal. Care must 5 240 550 CM3052
Hot One Components
6 240 600 CM3062

be taken to protect the heater or these contaminants will 2 240 250 CM4022
shorten the effective heater life. 3 240 300 CM4032
4 240 400 CM4042
Proper Care and Maintenance 1/2
5 240 800 CM4052
6 240 1000 CM4062
1. Heaters should be stored in a dry area, especially 8 240 1200 CM4082
during periods of excess humidity. 10 240 1500 CM4102
12 240 2000 CM4122
2. Protect leads from abuse, abrasion, fatigue, etc. 2 240 300 CM5022
4 240 700 CM5042
6 240 1000 CM5062
3. Maintain temperature controllers and accessories 5 /8 8 240 1200 CM5082
in good working condition to avoid an overheating 9 240 1400 CM5092
condition. 10 240 1500 CM5102
14 240 2000 CM5142
2 240 300 CM6022
4. Transferring heaters from one die or platen to another
4 240 750 CM6042
is not recommended. 3 /4 6 240 1200 CM6062
10 240 1600 CM6102
14 240 2200 CM6142
*See DME Equipment and Supplies Catalog for DME NOTE: Lead wires can withstand temperatures up to 450°F. If
machine reamers and DME straight shank long drills. temperatures will exceed this amount, leads must be insulated.

Nozzle Heaters for Injection Molds
Features This nozzle heater features a five-inch long unheated

Square coil design for improved heat transfer tail section, and the adapter is provided with a moisture-
High watt density on nozzle … up to 106 watts/in2 resistant seal. These two design advantages practically
eliminate failures in the adapter area due to overheating
Heat is conducted from entire heater circumference … 360˚ heat
and moisture contamination.
Unheated tail section reduces temperature at adapter
Moisture-resistant seal As with all DME heaters, these new nozzle heaters
are designed to give long life even when operated at
Low profile
¡'5IFTFBSFWFSZMPXQSPGJMFIFBUFSTUPGBDJMJUBUF
Hot One
¡'NBYJNVNPQFSBUJOHUFNQFSBUVSF easy installation in the tight environment of multiple
Available for same-day shipping gate molds.
Custom
Components
All units have a resistance tolerance of ±5% to provide
430 SS Band Rolled Over to Retain Coil
consistent operation and reduced adjustment time when
Hot Runner
5.00" No-Heat Section 3/16" Dia. it is necessary to replace a heater or bushing.
2F Style Lead A stainless steel clamping band is installed on all units.

Coil Orientation
| Nozzle
Identification
Width
Data on All units are stock coiled per the dimensions listed
Systems
Heat Shrink
below. All units have Teflon® covered power leads and
.28"
fiberglass thermocouple leads as indicated.
Heaters
| New
Reinforcing Clamp Tab Retainers
Brazed Connection
for Injection
.094" Dia. 304
SS Sheath
Coil I.D.
ProductsMolds
PVC Heat Shrink
with FEP Melt Liner 22 Ga. Type “E”
#6-32 Stainless Steel Teflon Leads
Socket Head Cap Screws
Nozzle Heaters (240 VAC)

COIL COIL COIL LEAD THERMO- ITEM
WATTS I.D. O.D. WIDTH LENGTH COUPLE NUMBER
125 .750 .980 1.0" 36" NO SCH0103
125 .750 .980 1.0" 72" NO SCH0104
250 .750 .980 1.0" 36" NO SCH0105
250 .750 .980 1.0" 72" NO SCH0106
125 .750 .980 1.0" 36" YES* SCH0107
250 .750 .980 1.0" 36" YES* SCH0108
125 .875 1.10 1.0" 36" NO SCH0109
250 .875 1.10 1.0" 36" NO SCH0110 This installation illustrates DME’s square coil design fit over
a nozzle. This heater was designed to fit any industry nozzle
*A thermocouple is externally spotwelded to the sheath. as a replacement for runnerless molding.
U.S. 800-626-6653 Canada 800-387-6600

High Watt Density Thermocouple Cartridge Heaters
These diagrams show typical installations of a

thermocouple replacement cartridge heater.
DME High Watt Density Thermocouple Cartridge
Heaters employ swaged construction for maximum
heat transfer and high watt density for more
demanding applications. Recommended for use
XIFOIJHIUFNQFSBUVSFTBSFSFRVJSFE VQUP¡'

or where heaters will be subjected to vibration.
Fit Tolerances
| Index Cartridge Heaters
The cavity or hole into which a cartridge heater is

inserted should be reamed* to the nominal diameter
of the heater. DME cartridge heater diameters are
actually .002 to .007 undersize. High Watt Density
Cartridge Heaters are .003 undersize, held to a
tolerance of ±.002. This sizing is maintained for easy
Thermocouple
installation and for best heat transfer. However, if

close hole tolerances are not maintained, operating
High Watt Density Thermocouple Cartridge Heaters
life of the heater may be drastically reduced. Also (240 VAC, Type J Thermocouple, 36" Long Leads)
Systems
make sure that the heated area of the cartridge does

LENGTHS
Watt Density
not extend beyond the hole. ITEM

DIAMETER IN CM VOLTS WATTS NUMBER
Hot Runner
Contamination 1 3 /4 4.445 240 200 TCH0001
Contamination consists of any foreign matter such 2 5.08 240 250 TCH0002
2 1 /2 6.35 240 250 TCH0003
as plastics, oil, grease, dirt or water entering through
| High
3 7.52 240 250 TCH0004

the terminal end or the end opposite the terminal.
3 1 /2 8.39 240 320 TCH0005
Custom
Care must be taken to protect the heater or these

4 10.15 240 370 TCH0006
contaminants will shorten the effective heater life.
Hot One Components
3 /8" 4 1 /2 11.43 240 420 TCH0007

(9.42mm) 5 12.70 240 470 TCH0008
Proper Care and Maintenance
5 1 /2 13.97 240 525 TCH0009
1. Heaters should be stored in a dry area,
6 15.24 240 575 TCH0010
especially during periods of excess humidity.
6 1 /2 16.51 240 625 TCH0011
2. Protect leads from abuse, abrasion, fatigue, etc. 7 17.78 240 675 TCH0012
3. Maintain temperature controllers and 7 1 /2 19.05 240 725 TCH0013

8 20.32 240 775 TCH0014
accessories in good working condition to avoid
3 1 /2 8.89 240 420 TCH0015
an overheating condition.
4 10.16 240 480 TCH0016
4. Transferring heaters from one die or platen to 4 1 /2 11.43 240 550 TCH0017
another is not recommended. 1/2" 5 12.70 240 625 TCH0018
(12.50mm) 5 1 /2 13.97 240 700 TCH0019
*See DME Equipment and Supplies Catalog for DME 6 15.24 240 775 TCH0020
machine reamers and DME straight shank long drills. 6 1 /2 16.51 240 850 TCH0021
7 1/ 2 19.05 240 975 TCH0022

Thermocouples
DME Bayonet Thermocouples are made of 20 gauge stranded DME Adjustable Bayonet Type Thermocouples fit hole depths
glass-insulated wires. The grounded hot junction is in the end up to 101/2" and will conform to any angle.
of a .188 O.D. stainless steel protecting tube for fast response
DME Spade Type Thermocouples are used between band
and long life. Tube features a round tip and is fitted with a
heaters and machine nozzles in applications where space will
stainless steel spring loaded bayonet fitting. Lead wires are
not permit bayonet-type thermocouples. The stainless steel
protected by rugged .188 I.D. flexible armor (lead wire
spade is only .025 thick and can be easily contoured to fit
calibration is ANSI Type J Iron/Constantan). Armor cable
various diameters.
is 47” long; spade lugs are attached at the end of the lead
wires for easy connection to terminal strip or plug.
Custom
1/32
Hot One
L DIMENSION Straight Type
1-11/16 47" ITEM NUMBER L
HotComponents
SPADE LUGS
TC2500 2 1 /2
Runner Systems
STAINLESS STEEL TC3500 3 1 /2
STAINLESS 4"
FLEXIBLE ARMOR
STEEL BAYONET FITTING TC6000 6"
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
| Thermocouples
45° BEND 1/2 47"
SPADE LUGS
45° Angle Type
| New Products
1- ON
STAINLESS STEEL ITEM NUMBER L

6
SI
/1
4"
11
EN
FLEXIBLE ARMOR TC2545 2 1 /2

IM
LD
STAINLESS STEEL TC3545 3 1 /2

BAYONET FITTING
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
1/2 47"
90° BEND SPADE LUGS 90° Angle Type
1/2 ITEM NUMBER L
STAINLESS STEEL 4"
FLEXIBLE ARMOR TC2590 2 1 /2
1-11/16
TC3590 3 1 /2
L DIMENSION
STAINLESS STEEL
BAYONET FITTING TC6090 6"
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
U.S. 800-626-6653 Canada 800-387-6600

42
Hot One Components
Thermocouples and Accessories
Hole Depth Chart

TAP DRILL AS REQ’D
A 3/16 O.D. TUBING FOR ADAPTER
L (.185 TO .191)
.265 O.D. SPRING
HOLE DEPTH FOR ADAPTER LENGTH
THERMOCOUPLE
LENGTH 7/ 13 /8
8
21 /2 1" TO 13 /8 1/
2 TO 7/8
9/32 DIA. (.281 DRILL SUGGESTED)
31 /2 2" TO 23 / 8 11 / 2 TO 17/8 A CAP
(HOLE DEPTH) BAYONET
6" 41 /2 TO 47/8 4" TO 43 /8 EDGE OF MOLD OR MACHINE ADAPTER
L
101 /2 ADJ. 1/
2 TO 101 / 2
1/
2 TO 10" (THERMOCOUPLE LENGTH)
By turning the adjustable

Adjustable Thermocouple bayonet fitting along the
BAYONET FITTING .384 O.D. spring, the DME Adjustable
HOT JUNCTION Thermocouple can be set for the
desired immersion length, from
1 / " to 101 / ". Spring will conform
2 2
to any angle. Hot junction of
ANSI Type J I/C calibrated leads
is inside round tip. Flexible metal
PROVIDES FOR HOLE DEPTHS FROM 1/2 TO 10-1/2 48"
ITEM NUMBER braid is 48" long with 21 /2" of lead
Accessories
wires at the end and spade lugs

TC8000
for ease of connection.
Threaded Type Thermocouple
Index
Systems | and
ITEM NUMBER Threaded type thermocouple is

spring loaded and supplied with
TCT4
| Thermocouples
cable and mini plug.

48"
Bayonet Adapters
Custom Hot Runner
The stainless steel bayonet adapters C ITEM

accommodate the spring loaded bayonet NUMBER A B C
fitting on the thermocouple, to bottom the 7/16
BA1007 7/ .465 1/
hot junction where temperature sensing 8 8-27 NPT
Hot One Components
is desired. Adapter requires tapped hole BA1013 13 / .934 1/

B 8 8-27 NPT
for mounting.
BA4007 7/ .465 3 / -24 NF
8 8
A
BA4013 13 /8 .934 3 / -24
8 NF
Spade Type Thermocouple

Used between band heaters and machine
nozzles in applications where space will
not permit bayonet type thermocouples.
Stainless steel spade measures 1” x 11/4
1-1/4" x .025 thick and can be easily contoured
to fit various diameters.
48" 4" ITEM Thermocouple is Type J I/C.
NUMBER Flexible stainless steel armor
1" TC9000 cable is 48” long with 4” of
lead wires at the end.
Plug (with Cable Clamp) Jack (with Cable Clamp) Mini Plug Mini Jack
ROUND PINS
AND FLAT PINS
SOCKETS AND
(3/16 & 1/8) SOCKETS
ITEM NUMBER ITEM NUMBER ITEM NUMBER ITEM NUMBER

PL10 PL20 M2MJ M2FJ

DME Meteor ®
Hot Runner Systems
CUSTOM-CONFIGURED,
ECONOMICAL SOLUTIONS
FOR QUICK DELIVERY
THE BEST SOLUTIONS FOR PRECISION
THERMOPLASTIC MICROMOLDING
44 Meteor® Hot Runner Systems
More Solutions. More Choices.Always Quick Delivery.
The Meteor Package

Each Meteor manifold kit includes the following standard items:
Manifold with pre-machined horizontal flow channel
Pre-installed, replaceable tubular heaters
End plugs
End plug set screws
Ancillary Components
More Solutions. More Choices. Always Quick Delivery.
A variety of ancillary components available include:

Locating rings
Drool rings
Nozzle seats
Riser pads and cap screws
Center support pads and dowel pins
Thermocouples
Nozzle Options METEOR

EHA AND CIA
SYSTEM 250 SERIES 375 SERIES
All nozzles have a selection of tip styles to suit METEOR 1 ✓ ✓
material flow and gate cosmetic requirements. METEOR 2 ✓ ✓
|
Meteor® Hot Runner Systems
Application Notes
250 Series nozzles to be used with manifold kits MEM0100K thru MEM0200K,
MCM0100K thru MCM0200K and MXM0100K thru MXM0200K. 375 Series
nozzles to be used with all other manifold kits.
All manifolds with suffix of 100K, 150K and 200K have a 9mm diameter flow
channel; all other manifolds have a 12mm diameter flow channel.
CIA High Performance nozzles are recommended for materials that process
BCPWF¡$¡'
For filled or abrasive materials, wear-resistant tips are recommended.
Meteor manifolds are not recommended for use with PVC material.
Contact DME for assistance.

Meteor® Hot Runner Systems 45
More Solutions. More Choices.
The Meteor® Manifold System provides a versatile yet economical solution

for many hot runner mold designs. Two-drop (in-line) and four-drop (X-style)
manifolds are available in sizes to suit a variety of applications.
Pre-engineered with accurately machined flow channels, nozzle ports can
be freely located anywhere within each manifold’s flow channel limits. Meteor
manifolds are supplied with replaceable, press-fit tubular heaters which are
stocked for quick delivery. A full complement of ancillary components are also
available to complete the system design and construction.
Advantages

Two levels of quick-delivery hot runner systems
In-line and X-style manifolds for 2- and 4-drop applications
Suitable for engineered and commodity resins
Cost-effective
Satisfaction 100% guaranteed
Meteor 1 manifold
Choose the Meteor System that’s right for you
DME offers two quick-delivery hot runner systems with varying levels of
|
customization – you pick the one that fits your needs.
Meteor manifolds are
More Solutions. More Choices. Always Quick Delivery.

Meteor 1
supplied with ■ Standardized manifolds with machined horizontal flow channel
replaceable, ■ Customer machines vertical flow channel locations and end plugs for
maximum configuration flexibility
press-fit tubular ■ Customer can easily order a Meteor 1 manifold kit and select nozzles,
heaters. supports, nozzle seat, locating ring, thermocouples and other necessary
items
Meteor 2
■ Manifold and components system, integrated with a Meteor 1 manifold kit

■ Customer specifies nozzles, supports, nozzle seat, locating ring,
thermocouples, etc.
■ DME performs vertical flow channel and end plug machining
Meteor 2 manifold and components

Meteor 1 In-Line and X-Style Manifolds
Meteor 1
Meteor 1 In-Line End Exit

THERMOCOUPLE LOCATION
A TC
50.0mm/
1.968in
NL MIN
46mm/1.81in
NL MAX
and X-Style Manifolds
O.A.L.
Meteor 1 In-Line Center Exit

31mm /1.22in
| Index
A
| Index
1 In-Line
12mm/.47in RAD
Systems
74.0mm/
| Systems
2.91in
Meteor
50.0mm/
1.968in
Hot Runner
Runner
46mm/1.81in NL MIN
Systems
NL MAX
THERMOCOUPLE
TC
LOCATION O.A.L.
Custom
Hot
Meteor® Hot Runner
MANIFOLD MANIFOLD KIT NL MIN. NL MAX. O.A.L. A B TC

TYPE ITEM NO. MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH
MEM0100K 55 2.165 100 3.937 195 7.677 44.5 1.75 — —
MEM0150K 100 3.937 150 5.906 245 9.646 44.5 1.75 — — 60 2.362
IN-LINE MEM0200K 150 5.906 200 7.874 295 11.614 44.5 1.75 — —
END
EXIT MEM0300K 200 7.874 300 11.811 395 15.551 44.5 1.75 — —
MEM0400K 300 11.811 400 15.748 495 19.488 50.8 2.00 — — 72.5 2.362
MEM0500K 400 15.748 500 19.685 595 23.425 50.8 2.00 — —
MCM0100K 55 2.165 100 3.937 195 7.677 44.5 1.75 — —
MCM0150K 100 3.937 150 5.906 245 9.646 44.5 1.75 — — 60 2.362
IN-LINE MCM0200K 150 5.906 200 7.874 295 11.614 44.5 1.75 — —
CENTER
EXIT MCM0300K 200 7.874 300 11.811 395 15.551 44.5 1.75 — —
MCM0400K 300 11.811 400 15.748 495 19.488 50.8 2.00 — — 72.5 2.854
MCM0500K 400 15.748 500 19.685 595 23.425 50.8 2.00 — —
MXM0100K 55 2.165 100 3.937 195 7.677 44.5 1.75 56.8 2.236 SEE X-STYLE
MXM0150K 100 3.937 150 5.906 245 9.646 44.5 1.75 51.3 2.020
X-STYLE 60 2.362
MXM0200K 150 5.906 200 7.874 295 11.614 50.8 2.00 51.3 2.020
MXCM0300K 200 7.874 300 11.811 395 15.551 50.8 2.00 51.3 2.020 72.5 2.854

Meteor 1 In-Line and X-Style Manifolds
Meteor 1 X-Style THERMOCOUPLE

LOCATION
THERMOCOUPLE
LOCATION FOR
MXM0100K NL MAX
74.2mm/2.921in NL MIN
TC
MOLD BASE
A CENTER LINE XY XY
MIN* MAX**
Meteor® HotCustom
B
12mm/
Runner
.47in RAD
Hot Runner
MOLD NL MIN
50mm/1.968in BASE NL MAX
Hot
Systems
CENTER
O.A.L. LINE O.A.L.
Runner
Systems
| Systems
Meteor
46mm/1.81in
X and Y Coordinates Cross-Reference Chart
| 1New
XY MIN* XY MAX**
MANIFOLD KIT
In-Line
| New
ITEM NO. MM INCH MM INCH
Products
MXM0100K 38.90 1.531 70.71 2.783
MXM0150K 70.71 2.783 106.07 4.176
and
Products
MXM0200K 106.07 4.176 141.42 5.568
X-Style Manifolds
MXM0300K 141.42 5.568 212.13 8.352
Meteor 1 Manifold Kit Includes:

In-Line System: X-Style System:
(1) Manifold (center or end heater exit) (1) Manifold
(2) Tubular heaters (installed) (2) Tubular heaters (installed)
(2) Tapered end plugs (4) Tapered end plugs
(2) Set screws (4) Set screws
MANIFOLD
TUBULAR HEATER
TAPERED END PLUG
SET SCREW

48
Meteor 1 & 2 Ancillary Component Options
Meteor 2
LOCATING RING
DROOL RING
NOZZLE SEAT
RISER PAD
L.H.C.S.
TOP
WIRING KIT METEOR 1 MANIFOLD KIT
CENTER THERMOCOUPLE
DOWEL
SUPPORT
| IndexComponent Options
PIN
BOTTOM PAD
DOWEL PIN
HOT RUNNER NOZZLES THAT

CAN BE USED WITH THE
METEOR 1 AND METEOR 2 KITS:
DESIGN CRITERIA t4&3*&4&)""/%$*"
V VERTICAL t4&3*&4&)""/%$*"
METEOR 1 METEOR 2
MANIFOLD MANIFOLD FLOW
MANIFOLD KIT KIT PLUS CHANNEL DIA.
1 & |2 Ancillary
TYPE ITEM NO. ITEM NO. NOZZLE OPTIONS MM INCH

MEM0100K MEM0100KP Meteor 1 Manifold Kit includes manifold, tubular heaters
Index
250, EHA & CIA

MEM0150K MEM0150KP 9 .354
IN-LINE MEM0200K MEM0200KP
SERIES installed, two end plugs, and two set screws. The customer
END EXIT MEM0300K MEM0300KP machines the vertical flow channel locations and end plugs
Systems
375, EHA & CIA

MEM0400K MEM0400KP 12 .472
MEM0500K MEM0500KP
SERIES for maximum configuration flexibility.
Systems
MCM0100K MCM0100KP
250, EHA & CIA Meteor 2 Manifold Kit Plus includes the machining of the
| Meteor
MCM0150K MCM0150KP 9 .354

IN-LINE SERIES
MCM0200K MCM0200KP vertical flow channels and the installation of the end plugs
Hot Runner
CENTER
EXIT MCM0300K MCM0300KP
375, EHA & CIA and set screws by DME.
MCM0400K MCM0400KP 12 .472
SERIES
Hot Runner
MCM0500K MCM0500KP The customer provides DME with the gate locations on a
MXM0100K MXM0100KP
250, EHA & CIA Meteor 2 Criteria Form.
Systems
MXM0150K MXM0150KP 9 .354

SERIES
X-STYLE MXM0200K MXM0200KP
375, EHA & CIA
Custom
MXM0300K MXM0300KP 12 .472

SERIES
Meteor® Hot Runner
ANCILLARY COMPONENT OPTIONS

METEOR 1 METEOR 2 CTR.
MANIFOLD MANIFOLD THERMO- LOCATING DROOL NOZZLE RISER SUPPORT DOWEL 1/4-20 X .50 WIRING
MANIFOLD KIT KIT PLUS COUPLE RING RING SEAT PADS PADS PINS LG. L.H.C.S. KIT ITEM
TYPE ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. NO.
MEM0100K MEM0100KP
MEM0150K MEM0150KP MNS0009 ERP1001 DP820
MEM0200K MEM0200KP ETC0252 ERP1002 ECB0468 MWK1001
EHL0253 DP828
IN-LINE ERP1011 ECB0469 1412LH
MEM0300K MEM0300KP EHL0255 EHL1003 DP832
END EXIT ERP1012 ECB0503 (2 OF (2 REQ’D.)
MEM0400K MEM0400KP (1 REQ’D.) SAME
MNS0012 (2 OF SAME (1 REQ’D.) REQ’D.)
MEM0500K MEM0500KP (2ETC0252 REQ’D.) MWK1002
REQ’D.)
MCM0100K MCM0100KP
MCM0150K MCM0150KP MNS0009 ERP1001 DP820
MCM0200K MCM0200KP ETC0252 ERP1002 ECB0468 MWK1001
IN-LINE EHL0253 DP828
ERP1011 ECB0469 1412LH
CENTER MCM0300K MCM0300KP EHL0255 EHL1003 DP832
ERP1012 ECB0503 (2 OF (2 REQ’D.)
EXIT MCM0400K MCM0400KP (1 REQ’D.) SAME
MNS0012 (2 OF SAME (1 REQ’D.) REQ’D.)
MCM0500K MCM0500KP (2ETC0252 REQ’D.) MWK1002
REQ’D.)
MXM0100K MXM0100KP ERP1001
ETC0252 DP820 MWK1001
MXM0150K MXM0150KP EHL0253 MNS0009 ERP1002 ECB0468 DP828
MXM0200K MXM0200KP ERP1011 ECB0469 1412LH
X-STYLE EHL0255 EHL1003 DP832
ETC0252 (1 REQ’D.) ERP1012 ECB0503 (2 OF (2 REQ’D.)
SAME MWK1002
MXM0300K MXM0300KP (2 REQ’D.) MNS0012 (4 OF SAME (1 REQ’D.) REQ’D.)
REQ’D.)

Locating Rings
00 D
ITEM NO. ØD ØX ØY A ØB C
C
101 MM 82.5 MM 95 MM 117 MM 139.5 MM 73 MM
EHL0253
3.990 IN 3.250 IN 3.750 IN 4.625 IN 5.495 IN 2.875 IN
.218
101 MM 82.5 MM 95 MM 117 MM 139.5 MM 114 MM
EHL0255
3.990 IN 3.250 IN 3.750 IN 4.625 IN 5.495 IN 24.500 IN
Y Includes (2) 1/2 inch long, 5/16 Flat Head Cap Screws.
BOLT CIRCLE
A
B
Meteor® Hot Runner

Machine Nozzle Seats
CustomSystems
6.82mm/ SPH RAD.
.269in
E FLOW CHANNEL SPHERICAL
ITEM NO. MM IN RADIUS
Hot Runner
MNS0009 9 MM .354 IN 1/2 + 3/4 IN
28.58mm/ M20 X 1.5
1.125in MNS1009 9 MM .354 IN 15.5 MM
E THREAD
MNS0012 12 MM .472 IN 1/2 + 3/4 IN
31.75mm/1.25in
| Meteor
22.1mm /
.870in MNS1012 12 MM .472 IN 15.5 MM
Systems
NOTE: Machine nozzle tip orifice to be matched properly with
nozzle seat flow channel.
1 & |2 Ancillary
38.1
New Products
HEX
Component Options
Center Support Pads
O.D. H
ITEM NO. MM IN MM IN
ECB0468 30 1.181 20 .787
ECB0469 30 1.181 10 .394
ECB0503 40 1.575 10 .394
NOTES:
H +.13 1. The M10 X 1.5 tapped hole is used to screw the center support
–.00
pad to a plate for machining the pad to the correct height.
2. An 8mm dia. dowel pin is required for assembly.
O.D.
M10 X 1.5 THRU

Dowel Pins
L
Ø 8mm/.315in ITEM NO. MM IN
DP820 20 .787
DP828 28 1.102
L DP832 32 1.260
| IndexComponent Options
Drool Ring
.12
ITEM NO.
EHL1003
Ø 1.38
Ø 3.44
1 & |2 Ancillary
Systems Index
Manifold Thermocouple
Systems
| Meteor
M6 THREAD ITEM NO.

Hot Runner
ETC0252
Hot Runner
Systems
Custom
Meteor® Hot Runner
Riser Pads and Screws H X

ITEM NO. MM IN MM IN
ERP1001 12.7 .500 10 .405
DRILLED AND C’BORED FOR 1/4-20 ERP1002 19 .750 16.6 .655
LOW HEAD SCREW “X” DEEP
H X
H ITEM NO. MM IN MM IN
ERP1011 12.7 .500 10 .405
ERP1012 19 .750 16.6 .655
9
.06
Ø 1.41 Ø 1.75 NOTE: For maximum support, use riser pads ERP1001 or ERP1002 whenever possible.
Ø .78 Only use riser pads ERP1011 or ERP1012 when there are space constraints.
DRILLED AND C’BORED FOR 1/4-20

LOW HEAD SCREW “X” DEEP
ITEM NO. 1/4-20 x 1/2 lg. LOW HEAD
CAP SCREW (L.H.C.S.)
H 1412LH
Ø .78

D M E H o t S p ru e Bu s h ings
52 Hot Sprue Bushings
Table of Contents
D-MAX High Performance Hot Sprue Bushings.......... 53-59

Capability with engineered and
commodity-grade resins
Gate-Mate® Hot Sprue Bushings .............................. 60-67

Ideal for direct part gating,
single-cavity molds
Straight-Shot™ Hot Sprue Bushings ......................... 70-78

Reduce cycle times and
save material costs
Integrally Heated Hot Sprue Bushings.....................79-84

Advanced heat transfer capability promotes
a more uniform heat profile
Hot Runner Services....................................................85-90

Total support for your hot runner systems
U.S. 800-626-6653 Canada 800-387-6600

D -MA X High Per formance
Hot Sprue Bushings
HIGH-PERFORMANCE CAPABILITY
D-MAX High Performance Hot Sprue Bushings

WITH ENGINEERED AND
COMMODITY-GRADE RESINS
54 D-MAX Hot Sprue Bushings
Plastic Materials and Specifications
Large number of bushing and tip combinations High performance capability

Three flow channel sizes Standard and wear-resistant tips
Lengths up to 190mm Precise thermal control
PLASTIC MATERIAL PROCESS CONDITIONS
PROCESS MOLD HOT RUNNER DENSITY SOLID

STANDARD
TEMPERATURE TEMPERATURE TEMPERATURE MELTING DENSITY
MATERIAL RESIN
SYMBOL
[°C] [°F] [°C] [°F] [°C] [°F] [g/cm3] [Ibs/inch3] [g/cm3] [Ibs/inch3]
Styrene Butadiene SB 210 410 70 158 230 446 0.93 0.0366 1.02 0.0369
Polyurethane PUR 220 428 45 113 240 464 0.93 0.0366 1.11 0.0401
Styrene-acrylonitrile SAN 230 446 80 176 255 491 0.99 0.0358 1.08 0.0390
Plastic Materials and Specifications
Polystyrene PS 210 410 45 113 230 446 0.95 0.0343 1.05 0.0379
Polycarbonate PC 300 572 80 176 330 626 1.08 0.0390 1.20 0.0434
Polyphenylene Oxide-
PPO 260 500 80 176 300 572 0.99 0.0358 1.13 0.0408
Styrene
Polyethylene PE 200 392 25 77 225 437 0.74 0.0267 0.96 0.0347

Polypropylene PP 225 437 40 104 245 473 0.73 0.0264 0.91 0.0329
Polyether-etherketone PEEK 330 626 165 329 370 698 1.13 0.0408 1.37 0.0495
Polyphenylene Sulfide PPS 300 572 110 230 330 626 1.53 0.0553 1.70 0.0614
Polyebutylene Terephthalate PBT 265 509 60 140 290 554 1.44 0.0520 1.57 0.0567
Polyamide 6 PA 6 220 428 90 194 250 482 0.98 0.0354 1.14 0.0412
Polyamide 66 PA 66 255 491 90 194 280 536 1.09 0.0394 1.26 0.0455
Thermal Plastic Elastomers TPE 240 464 35 95 265 509 0.78 0.0282 0.90 0.0325
|
D-MAX Hot Sprue Bushings
Polyoxymethylene
POM 180 356 100 212 200 392 1.16 0.0419 1.42 0.0513
(Polyacetal)
Polymethyl Methacrylate PMMA 235 455 70 158 250 482 1.09 0.0394 1.18 0.0426
Acrylonitrile Butadiene
ABS 225 437 70 158 250 482 0.95 0.0343 1.08 0.0390
Styrene
NOTE: Temperature and density values shown above are

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

D-MAX Hot Sprue Bushings 55
High Performance Hot Sprue Bushing 250 Series
NOTE: Dimensions shown in inches unless specified otherwise. For selection of gate diameter it is important to take into
consideration the material flow characteristics, share rate
Ø4.000 LOCATING RING BORE Ø2.165 HEAD HEATER BORE of resin, molding conditions, fill time requirements, gate
vestige, wall thickness and configuration of parts to be
R0.24 molded. Situations requiring high injection velocities must
CENTRAL
be considered when selecting small gate diameters. High

1.57
R0.38
injection rates may require larger gates due to shear heat
0.33
build up (e.g. high weight thin wall applications). See material
0.75
manufacturer’s literature for further information regarding

material to be molded.
To compensate for nozzle’s growth when heat is applied, the
linear expansion of the nozzle (BE) at a given temperature
0.33
1.656
3.50 must be added to the nominal “A” dimension. The formula

below shows how to figure boring depth (dimension “A” + BE).
The tip of the nozzle will now be flush with the cavity line at
1.50
processing temperature.
+ 0.001 0.49
Ø1.575 0.000 Head Bore
(2) 5/16-18 UNC Tap Formula for determining this expansion factor is as follows:
0.717
+ 0.001
0.000
BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF
(assuming the mold is at 68ºF during operation). If mold
temperature is different, substitute 68ºF with actual mold

temperature.
NOTE: R0.50
MATCH MACHINE
NOZZLE TIP ORIFICE
Ø0.31
R0.75
EXAMPLE: Given a 4.134 inch “A” dimension, with a set point
5 of 500ºF:
INSULATION SHEET
(OPTIONAL) BE = 4.134 x 0.00000633 x (500 - 68) = 0.011
3 Thus “A” + BE will be 4.145
NOTE: The above information is only given as an example;
+0.001
0.000
variations may occur based on mold configurations and

4
0.22 Min. - .55 Max.
cooling factor. In some instances, it may be necessary to

1.299
obtain an empirical factor.

R0.016 MAX
“O” DIA.
“S” DIA.
0.16
0.12
Ø1.187 Min. - UNFILLED RESIN FILLED RESIN

.50 MIN
Ø1.250 Max.
2 A + BE
*0.3750
1 0.5005
0.028 Min. 0.062 Min.
|
0.7505
0.31 MIN 1/2-24 UN
D-MAX High Performance Series 250

WATER LINES
TORQUE TO 30 FT/LBS 1.0005
* Point Gate (Full Body) only.
BUSHING AND COMPONENT SPECIFICATIONS

ASSEMBLY COMPONENTS
“A”
ASSEMBLY BUSHING BODY HIGH PERFORMANCE HEAD HEATER THERMOCOUPLE
DIMENSION WATTAGE WATTAGE
DETAIL #1 HEATER DETAIL #2 DETAIL #3 DETAIL #4 * Locating
DMAX06055 2.165in (55.00mm) DEP06055 CIH0081S 440 rings must
DMAX06067 2.657in (67.50mm) DEP06067 CIH0082S 350 be ordered
DMAX06080 3.150in (80.00mm) DEP06080 CIH0083S 400
DMAX06092 3.642in (92.50mm) DEP06092 CIH0084S 565 RDP38021 500 DTC38001 separately.
POINT GATE STD. SPRUE AND EXTENDED SPRUE AND EXTENDED SPRUE AND
(BODILESS) POINT GATE EXTENDED POINT GATE EXTENDED POINT GATE
(FULL BODY) (FULL BODY) RUNNER DESIGN (FULL BODY) ANGLE DESIGN
Ø1.187 MIN
80° Ø1.187 MIN Ø1.187 MIN Ø1.187 MIN
30°
30° 30° 30°
R0.010-0.015 +0.0005 25° MAX

0.080 MIN.
0.080 MIN.
R0.125 ØS CUSTOMER
0.080 MIN.
0.0000
0.100
0.180
RADIUS TO
0.020 AT TANG.
.005 LAND MAX
ØO SUIT +0.0005
+0.0005 +0.0005 ØS
Ø0.3750 0.0000
0.0000 ØS 0.0000
U.S. 800-626-6653 Canada 800-387-6600dme@milacron.comwww.milacron.com

NOTE: Dimensions shown in inches unless specified otherwise. For selection of gate diameter it is important to take into
consideration the material flow characteristics, share rate
Ø4.000 LOCATING RING BORE Ø2.913 HEAD HEATER BORE of resin, molding conditions, fill time requirements, gate
1.77 vestige, wall thickness and configuration of parts to be
CENTRAL molded. Situations requiring high injection velocities must
R0.25
R0.38
injection rates may require larger gates due to shear heat
1.57
0.37
0.75
manufacturer’s literature for further information regarding

1.656
0.37
must be added to the nominal “A” dimension. The formula
3.50
+ 0.001 0.71
Head Bore Ø2.008 0.000 (2) 5/16-18 UNC Tap Formula for determining this expansion factor is as follows:
0.933
+ 0.004
0.000
NOTE:
D-MAX High Performance Series 375
MATCH MACHINE
Ø0.47
R0.50 temperature.
NOZZLE TIP ORIFICE R0.75
INSULATION SHEET
EXAMPLE: Given a 2.362 inch “A” dimension, with a set point
5 (OPTIONAL) of 500ºF:
BE = 2.362 x 0.00000633 x (500 - 68) = 0.0064
3 Thus “A” + BE will be 2.368
+0.001
0.000

4
0.22 Min. - .55 Max.

1.299

R0.016 MAX obtain an empirical factor.
0.12
0.16
Ø1.437 Min. -
“O” DIA.
0.50 MIN
Ø1.625 Max.
“S” DIA.
2 UNFILLED RESIN FILLED RESIN
A + BE
0.5005
1 0.028 Min. 0.062 Min. 0.7505
0.31 MIN 5/8-20 UN
1.0005
WATER LINES
TORQUE TO 30 FT/LBS
|

ASSEMBLY COMPONENTS
“A”
ASSEMBLY BUSHING BODY HIGH PERFORMANCE HEAD HEATER THERMOCOUPLE
DETAIL #1 HEATER DETAIL #2 DETAIL #3 DETAIL #4
* Locating
DMAX10072 2.854in (72.50mm) DEP10072 CIH0089S 450 rings must
DMAX10085 3.346in (85.00mm) DEP10085 CIH0090S 550 be ordered
DMAX10097 3.839in (97.50mm) DEP10097 CIH0091S 700 separately.
RDP50021 750 DTC38001
POINT GATE STD. SPRUE AND EXTENDED SPRUE AND EXTENDED SPRUE AND
(BODILESS) POINT GATE EXTENDED POINT GATE EXTENDED POINT GATE
(FULL BODY) (FULL BODY) RUNNER DESIGN (FULL BODY) ANGLE DESIGN
Ø1.437 MIN
Ø1.437 MIN Ø1.437 MIN Ø1.437 MIN
80°
30°
30° 30° 30°
R0.010-0.015 +0.0005
0.080 MIN.
25° MAX
0.080 MIN.
0.080 MIN.
ØS 0.0000 CUSTOMER
0.020 AT TANG.
R0.187
0.005 LAND MAX
0.100
0.180
RADIUS TO
ØO SUIT +0.0005
+0.0005 +0.0005 ØS0.0000
Ø0.5000 0.0000 ØS 0.0000


NOTE: Dimensions shown in inches unless specified otherwise.
+0.001 For selection of gate diameter it is important to take into
Ø4.000 LOCATING RING BORE Ø2.756 0.000 HEAD BORE
consideration the material flow characteristics, shear rate
of resin, molding conditions, fill time requirements, gate
Ø2.125 HEATER BORE vestige, wall thickness and configuration of parts to be
molded. Situations requiring high injection velocities must
Ø8.00 DWL
BUSHING HEATER
CABLE EXIT
(OPTIONAL FOR injection rates may require larger gates due to shear heat
ANTI-ROTATION)
0.75 manufacturer’s literature for further information regarding
1.174
(4) 5/16-18 UNC
must be added to the nominal “A” dimension. The formula
3.50 1.174
1.378
Formula for determining this expansion factor is as follows:

Ø8 X18LG DWL BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF
(OPTIONAL FOR
NOTE: MATCH MACHINE ANTI-ROTATION)
NOZZLE TIP ORIFICE R 0.750 temperature is different, substitute 68ºF with actual mold
6
INSULATION SHEET temperature.
4 Ø0.625 (OPTIONAL)
5
EXAMPLE: Given a 3.543in “A” dimension, with a set point of
500ºF and mold temperature 68ºF:
1.743
BE = 3.543 x 0.00000633 x (500 - 68) = .010

Thus “A” + BE will be 3.553
2
0.633 Min. - 1.283 Max.

obtain an empirical factor.
0.469 -0.001 HEAD C’BORE
R0.030
0.06 X 45˚
0.06 X 45˚
0.06 X 45˚
0.375
MIN. WIRE CHANNEL 2.125

MIN.
“O” DIA.
“S” DIA.
0.000
|
A + BE UNFILLED RESIN FILLED RESIN

1
0.080 Min. 0.100 Min. 1.0005
WATER LINES 0.31 MIN. 1"-16 UN

TORQUE TO 30 FT/LBS

ASSEMBLY COMPONENTS
“A”
ASSEMBLY BUSHING BODY BUSHING HEAD CAST-IN HEATER HEAD HEATER THERMOCOUPLE
DETAIL #1 DETAIL #2 DETAIL #3 DETAIL #4 DETAIL #5
DMAX16090 3.543in (90.00mm) DEP16090 CIH0104-S 847 * Locating
DMAX16115 4.528in (115.00mm) DEP16115 CIH0096-S 1000
rings must
be ordered
DMAX16190 7.480in (190.00mm) DEP16190
DBP16001
CIH0099-S 1000
RDP38021 500 DTC62501 separately.
POINT GATE STD. SPRUE AND EXTENDED SPRUE

(BODILESS) POINT GATE RUNNER DESIGN EXTENDED SPRUE AND
(FULL BODY) ANGLE DESIGN
Ø2.125 MIN Ø2.125 MIN Ø2.125 MIN Ø2.125 MIN
80°
30° 30°
30° 30°
R0.125
0.08 MIN.
25° MAX.
0.08 MIN.
R0.010-0.015 +.0005 CUSTOMER +.0005

0.08 MIN.
0.005 LAND MAX
0.020 AT TANG.
0.125
0.235
-.0000 -.0000 +.0005

RADIUS TO
0.47
R0.312 ØS ØS -.0000
SUIT ØS
ØO
+0.0005
Ø0.6250 0.0000

Gate Tip Detail

Sprue Gate/Extended Sprue Gate
SERIES GATE TIP ITEM NUMBER B DIA. T DIA. L C
EHT0010 .500
.250 .375
Ø2.03 SPRUE GATE EHT0011 .750
EHT0012 1.000 .100
250 .080
EHT0013 .500
1.000 1.125
A EXTENDED SPRUE GATE EHT0014 .750
EHT0015 1.000 .850
EHT0016 .500
SPRUE GATE EHT0017 .750 .250 .375
C EHT0018 1.000
375 .125
L EHT0019 .500
EXTENDED SPRUE GATE EHT0020 .750 1.000 1.125
EHT0021 1.000
ØT
SPRUE GATE EHT0022 .250 .500
625 .187 1.000
5° PER SIDE EXTENDED SPRUE GATE EHT0023 1.000 1.250
(Add .750 to A dimension for extended sprue gate tips.)
Point Gate (Bodiless)

INCLUDES
SERIES GATE TIP ITEM NUMBER T DIA.
NEEDLE RETAINER TIP
EHT0005 EHT0024
STANDARD EHN0015
NEEDLE EHT1314 EHT0324
250 .375
EHT1308 EHT0324
EHT1313 EHT1324
A EHT0039 EHT0025
STANDARD EHN0016
RETAINER TIP EHT1312 EHT0325
375 .500
EHT1303 EHT0325
EHT1309 EHT1325
EHT1306 EHT1354
STANDARD EHN0019
EHT1311 EHT0326
625 .625
EHT1307 EHT0326
EHT1310 EHT1354
Gate Tip Detail
ØT
Point Gate (Full Body)

INCLUDES
NEEDLE RETAINER TIP
EHT2001 .060 EHT0026
.375
EHT2002 .080 EHT0027
STANDARD EHN0015
EHT2003 .060 EHT0028
.500
EHT2004 .080 EHT0029
250 .187
|
EHT2005 .060 EHT1326

NEEDLE .375
EHT2006 .080 EHT1327
EHT2007 .060 EHT1328

.500
EHT2008 .080 EHT1329
EHT2009 .080 EHT0030
.500
RETAINER TIP EHT2010 .100 EHT0031
A EHT2011 .080 EHT0032
EHT2012 .100 EHT0033
EHT2013 .080 EHT0034
1.000
EHT2014 .100 EHT0035
375 .230
EHT2015 .080 EHT1330
E .500
EHT2016 .100 EHT1331
EHT2017 .080 EHT1332
EHT2018 .100 EHT1333
EHT2019 .080 EHT1334
1.000
ØO EHT2020 .100 EHT1335
ØT STANDARD EHT2021 EHN0019 EHT0036
625 1.000 .125 .250
WEAR RESISTANT EHT2022 EHN0402 EHT1336
Point Gate (Full Body Extended)

INCLUDES
NEEDLE RETAINER TIP
EHT2301 .060 EHT2326
.375
NEEDLE EHT2302 .080 EHT2327
STANDARD EHN0015
EHT2303 .060 EHT2328
.500
EHT2304 .080 EHT2329
250 .938
EHT2305 .060 EHT2326
.375
EHT2306 .080 EHT2327
RETAINER TIP WEAR RESISTANT EHN0401
EHT2307 .060 EHT2328
.500
EHT2308 .080 EHT2329
EHT2309 .080 EHT2330
.500
EHT2310 .100 EHT2331
EHT2311 .080 EHT2332
EHT2312 .100 EHT2333
EHT2313 .080 EHT2334
1.000
EHT2314 .100 EHT2335
A 375 .980
EHT2315 .080 EHT2330
.500
EHT2316 .100 EHT2331
EHT2317 .080 EHT2332
E WEAR RESISTANT .750 EHN0400
EHT2318 .100 EHT2333
0.750 EHT2319 .080 EHT2334
1.000
EHT2320 .100 EHT2335
STANDARD EHT2321 EHN0019
625 1.000 .125 1.000 EHT2336
WEAR RESISTANT EHT2322 EHN0402
ØO SERIES THREAD TYPE

5° PER SIDE
250 1/2-24 UN
375 5/8-20 UN
ØT 625 1"-16 UN
U.S. 800-626-6653 Canada 800-387-6600

250, 375 & 625 High Performance Locating Rings
DRILLED AND C’BORED

5/16-18 TAPPED THRU (2) FOR 5/16 DIA. SOCKET
HEAD CAP SCREW (4)
Ø84.12 [3.312]

DRILLED AND C’BORED
FOR 5/16 DIA. SOCKET 36.0 [1.42]
HEAD CAP SCREW (2)
A
15.88 [0.625]
34.00 [1.339]
5/16-18 TAPPED THRU (2) A

Ø84.12 [3.312]
Ø101.35 [3.990]
|
45° 9.9 [0.39]

Ø101.35 [3.990]
44.28 [1.743]
29.39 [1.157]
ØD Ø38.2 [1.50] 32.00 [1.260]

17.0 [0.67]
PML2505 & PML3751 PML6251
SECTION A-A
ITEM NUMBER ØD
PML2505 34.00 (1.34")
PML3751 46.00 (1.81")
PML6251 63.00 (2.48")

NOTE: Dimensions shown in millimeters, inches in parentheses

DME Gate-Mate ®
Hot Sprue Bushings
IDEAL FOR DIRECT

PART GATING,
SINGLE-CAVITY MOLDS
Gate-Mate® Hot Sprue Bushings 61
Gate-Mate® Applications and Benefits
DME Gate-Mate® Hot Sprue Bushings

The DME Gate-Mate® Hot Sprue Bushing is designed for direct part gating in
single-cavity molds, eliminating the conventional cold sprue. The unique design
of the bushing provides minimal gate vestige, without the objectionable witness
lines so commonly found on direct gated parts.
The bushing transfers molten plastics from the machine nozzle to the mold
cavity via a direct channel in the body. The plated copper alloy tip provides
an improved temperature profile in the gate area.
The DME Gate-Mate® Hot Sprue Bushing utilizes an advanced design square coil
heater and independent thermocouple, strategically located for precise temperature
control. The bushing is available in three sizes to suit a variety of applications.
Gate-Mate® Hot Sprue Bushings

Mini and Jumbo Style Gate-Mate
See the DME Control Systems Catalog for Smart Series® Single Zone Temperature Controllers. Bushings Shown
Typical Applications BODY
SQUARE
TOP OF
COIL HEATER
MOLD
TIP
PART
|
THERMOCOUPLE
Gate-Mate® Applications and Benefits

CORE
NOTE: Mini Gate-Mate is also available with a
cast-in heater with integral thermocouple.
CAVITY
Advantages
LOCATION Direct part gating eliminating a cold sprue to trim and no witness
RING
lines on the molded part
Minimal gate vestige resulting in better part appearance
Benefits Faster start-ups providing positive temperature control of gate area
Eliminates sprues, reduces cycle time, improves
part quality, increases production Reduced cycle times because the bushing allows cooling channels
to be placed closer to the gate area
Provides optimum gate cosmetics
Cooler cavities with no direct contact between bushing tip and cavity
Plated copper alloy tip improves temperature
profile in gate area Improved part quality with a shorter injection path and elimination
of sprue, meaning no regrind
Self insulating material layer surrounds tip for
better tip control and part cooling Increased production with faster cycles and no sprue trimming
Square coil heater and independent thermocouple Easy installation and operation, and available in three standard
provide precise temperature control sizes suitable for most applications
Optional cast in heater available for Mini Positive temperature control with J-Type thermocouple and
Gate-Mate bushing DME Smart-Series® (and G-Series) controllers

62 Gate-Mate® Hot Sprue Bushings
Mini Gate-Mate®
The Mini Gate-Mate Bushings are ideal for fast cycling single cavity
molds. The compact design permits shorter overall stack-up of the
“A” side mold plates. The Mini Gate-Mate Bushings are provided with
either a square coil heater or a cast-in heater. Thermocouple placement
Radius Type
provides better heater control, and the overall body design improves
Flat Type
thermal insulation. Square coil heater, thermocouple and tip are
all replaceable.
Sub-assemblies include square coil heater and thermocouple or cast-in

heater with integral thermocouple. Tip to be ordered separately.
1⁄2 " SPH. Radius Type Bushing
1.500 Flat Type Bushing

Mini Gate-Mate®
.625 .250
1.187
HEATER
|
1.375
.281
.6250 DIA. Dimensions same as radius type bushing
1
/2 SPH. RADIUS BUSHING FLAT BUSHING
SUB-ASSEMBLY SUB-ASSEMBLY
ITEM NUMBER HEATER TYPE ITEM NUMBER HEATER TYPE
GMB0116 SQUARE COIL GMB0117 SQUARE COIL
GMB0111 CAST-IN GMB0112 CAST-IN
Mini Gate-Mate® Tips
ITEM TIP
NUMBER STYLE
1
2 -20
GMT0100 STANDARD
1.086
GMT4101 WEAR RESISTANT
Contact for DME for tip recommendations

and assistance with your application.
.010 DIA.

Mini Gate-Mate® Machining Dimensions
Machining Dimensions for Bushings

+.001
1.501 –.000 DIA.
1.125 DIA.
.219 MIN. .625 WIRE CHANNEL 118˚
.719 MAX. .125 RAD.
4.000 DIA. +.0005
–.0000
.6250 DIA.
.80˚
+.0005
–.0000 INCL
.125 RAD.
.6250 DIA. .125
1.375 + BE
.125 RAD. SEE NOTE
.030
.125 MIN. .030 MIN.
.005 LAND (MAX.)
.407 MAX.

.400 .187 SPH. RAD.
.31 MIN. DISTANCE BETWEEN WATERLINE AND DROP
NOTE:
The expansion factor must be taken into
consideration prior to machining for and installation
of the bushing. This factor (BE) must then be added
to the A dimension. The formula for determining this
expansion factor is as follows:
BE = “A” dimension x 0.00000633 x nozzle set
Replacement Parts
point - 68ºF (assuming the mold is at 68ºF during
operation). If mold temperature is different, SUB-ASSEMBLY BODY HEATER TYPE THERMOCOUPLE
substitute 68ºF with actual mold temperature. REFERENCE TYPE (240 VAC, 250 WATT) (36" LEADS)
GMB0111 1
⁄2 RADIUS (CAST IN) N/A
EXAMPLE:
CIH0100 (INTEGRAL TO HEATER)
|
Given a setpoint of 500°F: BE = 1.375 × .0000063 × GMB0112 FLAT
(500 – 68) = .004 thus 1.375 + .004 = 1.379.
Mini Gate-Mate® Machining Dimensions

GMB0116 1
⁄2 RADIUS (SQUARE COIL)
Please note that the above information is given as TCG0100
an example. Variations may occur based on mold GMB0117 FLAT SCH0004
configuration and cooling factor. In some instances,
it may be necessary to obtain an empirical factor.
Mini Gate-Mate Bushing Locating Ring

1.500
5
16 -18 TAPPED THRU
ITEM
NUMBER
2.375 6548
NOTES:
.53
1. Two (2) 5⁄16-18 S.H.C.S. are included with Locating Ring
1.250 2. Two (2) Drilled and C’bored holes for 5⁄16-18 S.H.C.S. are
1.50 DIA. 3.990 DIA.
on a 1.656 circle radius in Locating Ring
.218 3. C’bore depth in Top Clamp Plate and C’bore depth in
Locating Ring can be altered to suit application
7
16 -18 S.H.C.S.
32 5

Medium Gate-Mate®
The Medium Gate-Mate Bushing is designed for direct part gating in single cavity molds,
eliminating the conventional cold sprue. The unique design of the bushing provides
minimal gate vestige, without the objectionable witness lines so commonly found
on direct gated parts.
The bushing transfers molten plastics from the machine nozzle to the mold cavity
via a direct channel in the body. The bushing, in conjunction with the recommended
tip and gate configuration, controls gate vestige height.
The Medium Gate-Mate Bushing utilizes an advanced design square coil heater and
an independent thermocouple, strategically located for precise temperature control.
Bushing Assembly Bushing Sub-Assembly

2.156 DIA. 2.156 DIA.
BUSHING ASSEMBLY
(INCLUDES GMT2 TIP)
Medium Gate-Mate®
.250 .250
1.062 1.062 ITEM DUAL
A L
.562 .562 NUMBER SPH. RAD.
GMB5232 2.375 3.437 1
/2 & 3/4
GMB5332 3.375 4.437
L L
BUSHING SUB-ASSEMBLY
A A (ORDER TIP SEPARATELY)
|
ITEM DUAL
A L
NUMBER SPH. RAD.
.730 .730
GMB0020 2.375 3.437 1
⁄2 & 3⁄4
GMB0030 3.375 4.437
.024 DIA.
7500 DIA. 7500 DIA.
Medium Gate-Mate® Tips TIP TIP ITEM O TIP TIP HOLE

STYLE NUMBER DIA. LENGTH DIA. DIA.
STANDARD
WEAR RESISTANT STANDARD GMT2 .044 MIN.
SUPER SHARP THRU HOLE .024
WEAR RESISTANT GMT0400 .055 MIN.
SUPER SHARP WEAR RESISTANT NO HOLE THRU HOLE WEAR RESISTANT
SUPER SHARP GMT0301 .030 MIN. 1.730 N/A
SUPER SHARP .010
GMT0401 .055 MIN.
2 -20 WEAR RESISTANT
1
(typ.)
.030 MIN.
TIP THRU HOLE GMT0302*
.050 MAX
LENGTH 1.690 .090 .050
THRU HOLE
GMT0402* .055 MIN.
WEAR RESISTANT
NO HOLE GMT0303 .044 MIN. 1.730 .024 N/A
TIP DIA. TIP DIA. TIP DIA.
NOTES:
.118 HOLE DIA.
1. Thru-hole tip is designed .040 shorter in length to be a direct
10˚ ˚0" replacement for the standard tip; use a .030 to .060 diameter gate
TYPICAL .125 DIA. HOLE 2. A .030 minimum diameter gate is recommended when using the
MOLDMAKER TO MACHINE super sharp tip
3. Contact DME for tip recommendations and assistance with
*Contact DME for details to modify thru-hole tips for larger “O” diameters. your application

Medium Gate-Mate® Machining Dimensions

2.187 DIA.
Improved tip insulation, elimination of material degradation in
+.002
2.157 –.000 DIA. threaded area of tip, and faster color changes can be achieved
1.625 DIA. through use of a Gate Shell Insulator.
.563 .625 WIRE CHANNEL
.219 .125 RAD.
4.000 DIA.
90˚
+.0005
+.0005 –.0000
–.0000 .140
.7500 DIA.
.7500 DIA.
A + BE
.125 RAD. .80˚
SEE NOTE
INCL
30˚ .375 RAD.

.875
TO SUIT .030
.044 MIN. .005 LAND (MAX.)
(.030 MIN. FOR
.31 MIN. DISTANCE BETWEEN .187 SPH. RAD.
SUPER SHARP TIP)
WATERLINE AND DROP
NOTE:
The expansion factor must be taken into consideration prior to machining for, and
installing bushing. This factor (BE) must then be added to the nominal A dimension. ITEM NUMBER
Formula for determining this expansion is as follows: BE = “A” dimension x 0.00000633 REFERENCE
x nozzle set point - 68ºF (assuming the mold is at 68ºF during operation). If mold
BUSHING BUSHING
A
temperature is different, substitute 68ºF with actual mold temperature.
ASSEMBLY SUB-ASSEMBLY
EXAMPLE:
Given a 2.375 inch A dimension, with a Bushing Set Point temp. of 500°F: GMB5232 GMB0020 2.375
BE = 2.375 × .0000063 × (500 – 68) = .006 thus A + BE will be 2.381. GMB5332 GMB0030 3.375
Please note that the above information is given as an example. Variations may occur
based on mold configurations and cooling factor. In some instances, it may be necessary
|
to obtain an empirical factor.
Medium Gate-Mate® Machining Dimensions

Replacement Parts
ITEM NUMBER SQUARE COIL HEATERS THERMOCOUPLE
REFERENCE (240 VAC) (TYPE J, 36" LEADS)
BUSHING BUSHING ITEM ITEM

WATTS LENGTH LENGTH
ASSEMBLY SUB-ASSEMBLY NUMBER NUMBER
GMB5232 GMB0020 SCH3142 315 1.70 TC9600 1.35

GMB5332 GMB0030 SCH3242 315 2.70 TC9700 2.35
Medium Gate-Mate Locating Ring

1.781
5
16 -18 TAPPED THRU
ITEM
NUMBER
2.375
6545
.53 NOTES:
1.250 1. Two (2) 5⁄16 -18 S.H.C.S. are included with
2.216 DIA. 3.990 DIA. Locating Ring
.218 2. Two (2) Drilled and C’bored holes for
5
⁄16 -18 S.H.C.S. are on a 1.656 circle radius
in Locating Ring
3. C’bore depth in Top Clamp Plate and C’bore
depth in Locating Ring can be altered to
suit application
7
16 -18 S.H.C.S.
32 5

Jumbo Gate-Mate®
The Jumbo Gate-Mate Bushing is designed for direct part gating in single
cavity molds, eliminating the conventional cold sprue. The unique design of
the bushing provides minimal gate vestige, without the objectionable witness
lines so commonly found on direct gated parts.
The bushing transfers molten plastics from the machine nozzle to the mold
cavity via a direct channel in the body. The bushing, in conjunction with the
recommended tip and gate configuration, controls gate vestige height.
The Jumbo Gate-Mate Bushing utilizes an advanced design square coil

heater and an independent thermocouple, strategically located for precise
temperature control.
Bushing Assembly Bushing Sub-Assembly
2.625 DIA. 2.625 DIA.

Jumbo Gate-Mate®
BUSHING ASSEMBLY
(INCLUDES GMT0004 TIP)
.500 .500 ITEM
1.062 1.062 A L
NUMBER SPH. RAD.
.562 .562
GMB0008 2.500 3.562 1
/2 & 3/4
GMB0009 3.500 4.562
L L
BUSHING SUB-ASSEMBLY
|
(ORDER TIP SEPARATELY)

A A
ITEM
A L
NUMBER SPH. RAD.
.855 GMB0113 2.500 3.562
.855 1
/2 & 3/4
GMB0114 3.500 4.562
.030 DIA.
1.2500 DIA. 1.2500 DIA.
Jumbo Gate-Mate® Tips

STANDARD THRU HOLE TIP ITEM TIP TIP HOLE
WEAR RESISTANT THRU HOLE WEAR RESISTANT STYLE NUMBER LENGTH DIA. DIA.
STANDARD GMT0004
1.855 .030 N/A
WEAR RESISTANT GMT0406
3
4 -16 THRU HOLE GMT0007
(typ.) 1.815 .140 .100
THRU HOLE
GMT0407
TIP WEAR RESISTANT
LENGTH
NOTES:
1. Thru-hole tip designed .040 shorter in length to be a
direct replacement for the standard tip; use a .080 to .125
diameter gate
TIP DIA. TIP DIA. 2. Contact DME for tip recommendations and assistance with
HOLE DIA. your application

Jumbo Gate-Mate® Machining Dimensions
90˚
+.0005
–.0000
2.750 DIA.
+.002 1.2500 DIA.
2.626 –.000 DIA.
2.000 DIA. .80˚
INCL
.563 .625 WIRE CHANNEL. .375 RAD.
.219 .125 RAD.
4.000 DIA.
.030
+.0005 TO SUIT
–.0000 .140 .005 LAND (MAX.)
.070 MIN.
1.2500 DIA.
A + BE .187 SPH. RAD.
.125 RAD. SEE NOTE

30˚ ITEM NUMBER REFERENCE
1.000 BUSHING BUSHING A
ASSEMBLY SUB-ASSEMBLY
.31 MIN. DISTANCE BETWEEN GMB0008 GMB0113 2.500

WATERLINE AND DROP GMB0009 GMB0114 3.500
NOTE: EXAMPLE:
The expansion factor must be taken into consideration prior to machining Given a 2.500 inch A dimension, with a Bushing Set Point temp. of 500°F:
for, and installing bushing. This factor (BE) must then be added to BE = 2.500 × .0000063 × (500 – 68) = .007 thus A + BE will be 2.507.
the nominal A dimension. Formula for determining this expansion is
as follows: BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF Please note that this information is given as an example. Variations
(assuming the mold is at 68ºF during operation). If mold temperature is may occur based on mold configurations and cooling factor. In some
different, substitute 68ºF with actual mold temperature. instances, it may be necessary to obtain an empirical factor.
Replacement Parts
|
Jumbo Gate-Mate® Machining Dimensions
Improved tip insulation, ITEM NUMBER SQUARE COIL HEATERS THERMOCOUPLE
elimination of material REFERENCE (240 VAC) (TYPE J, 36" LEADS)
degradation in threaded area
BUSHING BUSHING ITEM ITEM
of tip, and faster color changes ASSEMBLY SUB-ASSEMBLY NUMBER
WATTS LENGTH
NUMBER
LENGTH
can be achieved through use GMB0008 1.18
GMB0113 SCH0002 600 1.70 TC0002
of a Gate Shell Insulator. GMB0009 GMB0114 SCH0001 800 2.70 TC0001 2.18
Jumbo Gate-Mate Locating Ring

1.50
5
16 -18 TAPPED THRU
ITEM
NUMBER
GMB0007
NOTES:
2.687 DIA. 3.990 DIA. 1. Two (2) 5⁄16 -18 S.H.C.S. are included
.218 with Locating Ring
2. Two (2) Drilled and C’bored holes for
5
⁄16 -18 S.H.C.S. are on a 1.656 Circle
radius in Locating Ring
3. C’bore depth in Top Clamp Plate and
C’bore depth in locating ring can be
DRILLED & C'BORED FOR altered to suit application
7
16 -18 S.H.C.S.
32 5

DME Straight-Shot ™
Hot Sprue Bushings
REDUCE CYCLE TIMES

AND SAVE MATERIAL COSTS
Straight-Shot Hot Sprue Bushings 69
High-Performance Series Straight-Shot™
High-Performance
Straight-Shot bushings “S” Type (Standard Tip Configuration)
are available as S-type
.062 or .125 DIA. Tips with .08 Land area
Seven shoulder lengths from 7⁄8 to 37⁄8
.500 And .750 Spherical radius for machine nozzle
NOTE:
The expansion factor must be taken into consideration prior
Replaces conventional cold sprue bushings to reduce
to machining for and installation of the bushing. This factor cycle time and save material costs
(BE) must then be added to the A dimension. The formula for
determining this expansion factor is as follows:
Efficiently processes commodity or engineering grade resins
Provides low vestige gate cosmetics (.062 or .125 Gate
temperature. diameters available)
Straight-Shot
EXAMPLE: High-watt density heater with distributed wattage
Hot RunnerHot
Given a setpoint of 500°F:
BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 + .004 = 1.379. to help prevent tip freeze-offs
Please note that the above information is given as an example.
Variations may occur based on mold configuration and cooling
factor. In some instances, it may be necessary to obtain an
empirical factor. +.000
1.995 DIA.
Systems
−.005 .08
5.00
Sprue Bushings
(S-TYPE)
1.995 DIA. +.000 .08
–.005
.312 DIA.
| 4-Zone and
R.750
R.500
| High-Performance
1.000 DIA. .17
"0" DIA. .015 RELIEF
8-Zone Timer-Based
A= 7 8 .62 1.000 DIA.
TO 3 7 8 A= 7 8
"0" DIA. TO 3 7 8
BUSHING ASSEMBLY REPLACEMENT PARTS

BUSHING SHOULDER
SHOULDER TIP RETAINER BODY SPACER HEATER THERMOCOUPLE
O ASSEMBLY BUSHING
LENGTH ITEM ITEM ITEM ITEM ITEM ITEM
DIA. ITEM ITEM
Series
A NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER
NUMBER NUMBER
Sequencers
7
⁄8 HPS0607S2 HPS1007
Straight-Shot
1 ⁄8
3
HPS0613S2 HPS1013
17⁄8 HPS0617S2 HPS1017
.062 23⁄8 HPS0623S2 HPS1023 HPT0001 HPT0601 HPS0001 HPT1001 HPS2001 HPS3001
27⁄8 HPS0627S2 HPS1027
33⁄8 HPS0633S2 HPS1033
37⁄8 HPS0637S2 HPS1037
7
⁄8 HPS1207S2 HPS1007
13⁄8 HPS1213S2 HPS1013
17⁄8 HPS1217S2 HPS1017
.125 2 ⁄8
3
HPS1223S2 HPS1023 HPT0002 HPT1201 HPS0001 HPT1001 HPS2001 HPS3001
27⁄8 HPS1227S2 HPS1027
33⁄8 HPS1233S2 HPS1033
37⁄8 HPS1237S2 HPS1037
NOTE: High-Performance Series Straight-Shot Hot Sprue Bushings heater has voltage of 240 VAC, 700 watts. Thermocouple is “J” type.

70 Straight-Shot Hot Sprue Bushings
High-Performance Series Straight-Shot™
High-Performance “E” Type (Extended Tip Configuration)

Straight-Shot Bushings
are available as E-type Replaces conventional cold sprue bushings to reduce cycle time and save material costs
Efficiently processes commodity or engineering grade resins
High-watt density heater with distributed wattage to help prevent tip freeze-offs
.062 or .125 DIA. Tips with .36 Land area for machining of molded part details
Seven shoulder lengths from 7⁄8 to 37⁄8
.500 And .750 Spherical radius for machine nozzle
.277 MAX. Always machine runner or part contour to the .277 maximum depth at centerline of gate. However,
DEPTH do not weaken the bushing face by exceeding this maximum dimension (Figures 1 and 2). Always
machine part contour to the .277 maximum depth at edge of retainer, with 15° maximum angle.
Machine a 3° minimum taper to the gate diameter. This will result in a small sprue on the part being
Straight-Shot
molded (Figure 3). Machine a 3° minimum taper to the gate for a reverse taper sprue on the part being
FIG. 1 molded (Figure 4). Retainer material is H-13 steel 46-52 HRC.
Sequencers
NOTE:
.277 MAX. The expansion factor must be taken
DEPTH R.750 into consideration prior to machining
E-TYPE (EXTENDED TIP
R.500 for and installation of the bushing.
.17 CONFIGURATION)
This factor (BE) must then be added
Series
to the A dimension. The formula for

determining this expansion factor is
8-Zone Timer-Based
FIG. 2
as follows:
BE = “A” dimension x 0.00000633
| High-Performance
FIG. 3 15° MAX.

.312 DIA. x nozzle set point - 68ºF (assuming
the mold is at 68ºF during opera-
.277 MAX. MAX.
tion). If mold temperature is
5.28 different, substitute 68ºF with
(E-TYPE) actual mold temperature.
.015 RELIEF
.62 EXAMPLE:
3° MIN.
CUSTOMER MAY ALTER Given a setpoint of 500°F:
GATE
| 4-Zone and
(.500 MAX.) TO ACCOMMODATE BE = 1.375 × .0000063 × (500 – 68) =

NON-STANDARD "A" LENGTHS .004 thus 1.375 + .004 = 1.379.
FIG. 4
.36 A = 7 8 TO 3 7 8 Please note that the above
Sprue Bushings
information is given as an example.

Variations may occur based on mold
"0" DIA.
configuration and cooling factor. In
3° MIN. 1.000 DIA.
1.995 DIA. +.000 some instances, it may be necessary
– .005
GATE to obtain an empirical factor.
Systems
BUSHING ASSEMBLY REPLACEMENT PARTS

BUSHING
SHOULDER SHOULDER TIP RETAINER BODY SPACER HEATER THERMOCOUPLE
Hot RunnerHot
O ASSEMBLY
LENGTH BUSHING ITEM ITEM ITEM ITEM ITEM ITEM
DIA. ITEM
A ITEM NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER
Straight-Shot
NUMBER
7
⁄8 HPS0607E2 HPS2007
13⁄8 HPS0613E2 HPS2013
17⁄8 HPS0617E2 HPS2017
.062 23⁄8 HPS0623E2 HPS2023 HPT0001 HPT0602 HPS0001 HPT1001 HPS2001 HPS3001
27⁄8 HPS0627E2 HPS2027
33⁄8 HPS0633E2 HPS2033
37⁄8 HPS0637E2 HPS2037
7
⁄8 HPS1207E2 HPS2007
13⁄8 HPS1213E2 HPS2013
17⁄8 HPS1217E2 HPS2017
.125 23⁄8 HPS1223E2 HPS2023 HPT0002 HPT1202 HPS0001 HPT1001 HPS2001 HPS3001
27⁄8 HPS1227E2 HPS2027
33⁄8 HPS1233E2 HPS2033
37⁄8 HPS1237E2 HPS2037
NOTE: High-Performance Series Straight-Shot Hot Sprue Bushings heater has voltage of 240 VAC, 700 watts. Thermocouple is “J” type.

S-Series Straight-Shot™
Larger Shots – Extended Heater Life

DME developed Straight-Shot Hot Sprue Bushings to
eliminate sprues, permit larger shots and faster fills,
and greatly extend heater life.
U.S. Patent No. 4,273,525 The bushings feature an unrestricted “straight-

shot” channel to feed the part or runner. Material
in the channel is heated by a special helical tubular
5.09
heater which surrounds the melt stream. This heater
+.000
A= 7
TO 3 7
1.995 DIA. –.005 .19
8 8
distributes heat uniformly throughout the bushing
.19 and is virtually impervious to moisture, gases and
plastics contamination.
Hot Straight-Shot
.16
1.000 DIA.
Runner Systems
.31 DIA. R The helical tubular heater (120 or 240 volt) is
DIA.
thermocouple equipped so temperature can be
.015 closely controlled using a DME single-zone Closed
RELIEF Loop Temperature Controller.
.62 .015 .340
RELIEF
Hot Sprue
NOTE: The standard S-Series Straight-Shot is designed
The expansion factor must be taken into consideration prior to machining for direct part gating or for feeding half-round or
| 4-Zone
for and installation of the bushing. This factor (BE) must then be added to the
A dimension. The formula for determining this expansion factor is as follows: trapezoidal runners. It is supplied with a .16 diameter
BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF (assuming
gate and no gate land. Available in seven standard
Bushings
the mold is at 68ºF during operation). If mold temperature is different,
substitute 68ºF with actual mold temperature. shoulder lengths with either a 1⁄2" or 3⁄4" spherical
and 8-Zone
EXAMPLE: radius and 120 or 240 volt heater. The S-Series
Given a setpoint of 500°F: Straight-Shot can be retrofitted to almost any mold
BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 + .004 = 1.379.
| S-Series
Please note that the above information is given as an example. Variations that uses a conventional sprue bushing.
may occur based on mold configuration and cooling factor. In some
Timer-Based
instances, it may be necessary to obtain an empirical factor. NOTE: 5° heater lead is standard. For 90° lead, add “90”
to end of item number (e.g., SSBT4507S190).
WITH 120 VOLT WITH 240 VOLT
Straight-Shot
HEATER SHOULDER HEATER
R LENGTH Typical Applications
ITEM NUMBER A ITEM NUMBER
Sequencers
SSBT4507S1 ⁄8
7
SSBT4507S2
SSBT4513S1 1 ⁄83
SSBT4513S2
SSBT4517S1 17⁄8 SSBT4517S2
1
⁄2 SSBT4523S1 23⁄8 SSBT4523S2
SSBT4527S1 27⁄8 SSBT4527S2
SSBT4533S1 33⁄8 SSBT4533S2
SSBT4537S1 3 ⁄87
SSBT4537S2
SSBT6507S1 ⁄8
7
SSBT6507S2
SSBT6513S1 13⁄8 SSBT6513S2
SSBT6517S1 17⁄8 SSBT6517S2
3
⁄4 SSBT6523S1 23⁄8 SSBT6523S2
SSBT6527S1 2 ⁄87
SSBT6527S2
SSBT6533S1 33⁄8 SSBT6533S2
SSBT6537S1 37⁄8 SSBT6537S2
DIRECT PART GATING FEEDING A TRAPEZOIDAL RUNNER

E-Series Straight-Shot™
DME standard E-Series Straight-Shot Hot Sprue Bushings

(Long and Short Styles) provide a .25 inch extra stock
allowance on the front face to permit machining of runner
profiles or part contours into that face. They are supplied
with a .06 diameter gate and a .25 inch gate land. The
gate diameter can be enlarged to suit the particular
Long Style
molding application. See DME Control Systems Catalog for temperature controllers.
E-Series (Long Style)

NOTE: .25 LAND 5.34
Sequencers
Must always be
altered as shown A= 7
8 TO 3 7
8 1.995 DIA. +.000
.19
Straight-Shot
–.005
in Figures 1 thru 6
(see next page). .44
.06 DIA.
.06
Timer-Based
1.000 DIA. .31 DIA. R

DIA.
| E-Series
.25 .015
RELIEF
and 8-Zone
ENLARGED VIEW AS SUPPLIED .62 .015 .340

RELIEF
Bushings
NOTE:
The expansion factor must be taken into consideration prior to machining
for and installation of the bushing. This factor (BE) must then be added to the
A dimension. The formula for determining this expansion factor is as follows:
| 4-Zone
BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF (assuming

Hot Sprue
the mold is at 68ºF during operation). If mold temperature is different,

substitute 68ºF with actual mold temperature. E-Series Straight-Shot (Long Style)
Hot Sprue Bushings
EXAMPLE:
Runner Systems
Given a setpoint of 500°F: WITH 120 VOLT WITH 240 VOLT

BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 + .004 = 1.379.
Hot Straight-Shot
R LENGTH
Please note that the above information is given as an example. Variations may ITEM NUMBER A ITEM NUMBER
occur based on mold configuration and cooling factor. In some instances, it
may be necessary to obtain an empirical factor. SSBT4507E1 7
⁄8 SSBT4507E2
SSBT4513E1 13⁄8 SSBT4513E2
The DME standard E-Series Straight-Shot (Long Style) is SSBT4517E1 1 ⁄8

7
SSBT4517E2
available in seven standard shoulder lengths with either

1
⁄2 SSBT4523E1 23⁄8 SSBT4523E2
SSBT4527E1 27⁄8 SSBT4527E2
a ½" or ¾" spherical radius and 120 or 240 volt heater. The
SSBT4533E1 33⁄8 SSBT4533E2
E-Series Straight-Shot (Long Style) can be retrofitted to suit
SSBT4537E1 37⁄8 SSBT4537E2
the particular molding application.
SSBT6507E1 7
⁄8 SSBT6507E2
NOTE: 5° heater lead is standard. For 90° lead, add “90” to end of item SSBT6513E1 13⁄8 SSBT6513E2
number (e.g., SSBT4507E190). SSBT6517E1 17⁄8 SSBT6517E2
3
⁄4 SSBT6523E1 23⁄8 SSBT6523E2
SSBT6527E1 27⁄8 SSBT6527E2
SSBT6533E1 33⁄8 SSBT6533E2
SSBT6537E1 3 ⁄8
7
SSBT6537E2

E-Series Straight-Shot™
The DME standard E-Series Straight- E-Series Straight-Shot Hot

Shot (Short Style) is intended to suit Sprue Bushings (Short Style)
the requirements of smaller injection
WITH 240 VOLT
molding machines and is supplied with HEATER A
R
a 7/8" A dimension. The A dimension can DIMENSION
ITEM NUMBER
be altered to suit the particular molding
SSBT4407E2 1
⁄2
application. SSBT0407E2 NONE
7
⁄8
NOTE: 5° heater lead is standard. For 90° lead, Short Style NOTE:
add “90” to end of item number (e.g., See the DME Control Systems Catalog for The expansion factor must be taken
SSBT4407E290). temperature controllers. into consideration prior to machining
for and installation of the bushing.
This factor (BE) must then be added
to the A dimension. The formula for
E-Series (Short Style) 3.22
determining this expansion factor is
A = 78 +.000 as follows:
1.995 DIA. –.005 .19
.25 LAND BE = “A” dimension x 0.00000633
x nozzle set point - 68ºF (assuming
.015 RELIEF
HotStraight-Shot
the mold is at 68ºF during
operation). If mold temperature
is different, substitute 68ºF with
Runner Systems
.06 DIA. .06
1.000 DIA. actual mold temperature.
.25 DIA. R
DIA.
EXAMPLE:
.25 BE = 1.375 × .0000063 × (500 – 68) =
.004 thus 1.375 + .004 = 1.379.
.44
Hot Sprue
.340 Please note that the above
information is given as an example.
ENLARGED VIEW AS SUPPLIED SSBT4407E2 SSBT0407E2 Variations may occur based on mold
| 4-Zone
configuration and cooling factor. In
NOTE: Must always be altered as shown in Figures 1 thru 6 (see below). some instances, it may be necessary
Bushings
and 8-Zone
Design Guidelines for Altering E-Series Straight-Shot Hot Sprue Bushings
(Long and Short Styles)
| E-Series
Always remove the .25 extra stock allowance and alter the Maximum stock removal of .268 provides an approximate
A dimension to suit whenever gating into a flat part surface. .08 gate diameter (Figure 2). Maximum stock removal of
Timer-Based
Minimum stock removal of .25 provides an approximate .06 .268 is recommended for gate diameters larger than .08
gate diameter (Figure 1). (Figures 3 and 4).
Straight-Shot
.25 .268 .268 .268
MIN. MAX. MAX. MAX.
DEPTH DEPTH DEPTH DEPTH
Sequencers
.06 DIA. .08 DIA. .09 DIA. .12 DIA.
FIG. 1 FIG. 2 FIG. 3 FIG. 4
.268 .268
Always machine runner profile or part contour to the MAX. MAX.
.268 maximum depth at centerline of gate (Figures 5 DEPTH DEPTH
and 6). However, do not weaken the bushing face by *GATE DIA. *GATE DIA.
exceeding this maximum dimension.
* Resultant gate diameter may be enlarged to suit the particular
molding application.
FIG. 5 FIG. 6

ER-Series Straight-Shot™
The DME standard ER-Series Straight-Shot Hot Sprue

Bushings (Long and Short Styles), like the standard E-Series,
are supplied with a .25 inch extra stock allowance on the
front face to permit machining of runner profiles or part
contours into that face. These bushings feature a “reverse
taper” design that originates from under the heat source,
providing easier start-ups.
The ER-Series design can also be used when a reverse taper
will benefit a particular application. These bushings are supplied (Long Style)
with a .12 diameter orifice and a .50 long reverse taper. The
orifice may be enlarged and the taper increased to suit.
NOTE:
The expansion factor must be
taken into consideration prior to
ER-Series (Long Style) machining for and installation
Sequencers
of the bushing. This factor (BE)

5.34
™
must then be added to the A

Straight-Shot
A = 7 8 TO 3 7 8 1.995 DIA. +.000 dimension. The formula for

–.005 .19
determining this expansion
.12 .50 factor is as follows:
DIA. BE = “A” dimension x
Timer-Based
0.00000633 x nozzle set point

- 68ºF (assuming the mold is
1.000 R at 68ºF during operation). If
.31 DIA.
DIA.
| ER-Series
mold temperature is different,

5˚ substitute 68ºF with actual
mold temperature.
.44 .015
and 8-Zone
RELIEF EXAMPLE:
.62 .015 .340
ENLARGED VIEW AS SUPPLIED RELIEF
BE = 1.375 × .0000063 × (500
Bushings
– 68) = .004 thus 1.375 + .004

NOTE: For minimum projection on runner/part, = 1.379.
alter the bushing face (See figures 1 thru 3 on next page). Please note that the above
| 4-Zone
information is given as an
example. Variations may occur
based on mold configuration
Hot Sprue
ER-Series Straight-Shot (Long Style) and cooling factor. In some

Hot Sprue Bushings instances, it may be necessary
Runner Systems

HotStraight-Shot
R LENGTH
ITEM A ITEM
NUMBER NUMBER
SSBT4507ER1 7
⁄8 SSBT4507ER2
SSBT4513ER1 1 ⁄8
3
SSBT4513ER2 The DME standard ER-Series Straight-Shot
SSBT4517ER1 1 ⁄8
7
SSBT4517ER2 (Long Style) is available in seven standard
1
⁄2 SSBT4523ER1 23⁄8 SSBT4523ER2 shoulder lengths with either a 1/2" or 3/4"
SSBT4527ER1 27⁄8 SSBT4527ER2 spherical radius and 120 or 240 volt heater.
SSBT4533ER1 33⁄8 SSBT4533ER2 The ER-Series Straight-Shot (Long Style)
SSBT4537ER1 3 ⁄8
7
SSBT4537ER2 can be retrofitted to suit the particular
SSBT6507ER1 7
⁄8 SSBT6507ER2 molding application.
SSBT6513ER1 13⁄8 SSBT6513ER2
NOTE: 5° heater lead is standard. For 90°
SSBT6517ER1 17⁄8 SSBT6517ER2 lead, add “90” to end of item number
(e.g., SSBT4507ER190).
3
⁄4 SSBT6523ER1 23⁄8 SSBT6523ER2
SSBT6527ER1 2 ⁄8
7
SSBT6527ER2

ER-Series Straight-Shot™
The DME standard ER-Series Straight-Shot (Short Style) is intended to suit Short Style
the requirements of smaller injection molding machines and is supplies with
a 7/8" A dimension. The A dimension can be altered to suit the particular
molding application.
NOTE: 5° heater lead is standard. For 90° lead, add “90” to end of item number
(e.g., SSBT4407ER290).
NOTE:
The expansion factor must be taken into consideration prior to machining for and installation of
the bushing. This factor (BE) must then be added to the A dimension. The formula for determining
this expansion factor is, as follows: BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF
(assuming the mold is at 68ºF during operation). If mold temperature is different, substitute 68ºF ER-Series Straight-Shot
with actual mold temperature. Hot Sprue Bushings (Short Style)
EXAMPLE: WITH 240 VOLT
Given a setpoint of 500°F: BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 + .004 = 1.379. HEATER R A
Please note that the above information is given as an example. Variations may occur based DIMENSION
on mold configuration and cooling factor. In some instances, it may be necessary to obtain an ITEM NUMBER
empirical factor. SSBT4407ER2 1
⁄2
HotStraight-Shot
⁄8
7
SSBT0407ER2 NONE
3.22
ER-Series (Short Style)
Runner Systems
A= 7
8 1.995 DIA. +.000
–.005 .19
.015 RELIEF
NOTE:
For minimum
projection on runner/
Hot Sprue
1.000
.25 DIA. R part, alter the bushing
DIA. face (See figures
5˚ 1 through 3 below).
| 4-Zone
.12 .44
Bushings
DIA.
.50 .340
and 8-Zone
ENLARGED VIEW AS SUPPLIED SSBT4407ER2 SSBT0407ER2
Design Guidelines for Altering ER-Series Straight-Shot Hot Sprue Bushings
| ER-Series
(Long and Short Styles)
Timer-Based
.25 FIG. 1 FIG. 2
.25
.25 .25
MIN. MIN.
Straight-Shot
Sequencers
™
RUNNER
PART
.25
.25
MIN.
FIG. 3 For minimum projection on runner/part, machine the runner
profile or part contour .25 inch deep into the bushing face at
the centerline of the orifice (See Figures 1 and 2). When gating
into a flat surface, remove the .25 inch extra stock allowance
on the bushing face (See Figure 3). However, do not weaken
the bushing face by exceeding the .25 inch dimension. The A
dimension can be altered by removing stock from the front face
RUNNER/PART
of the 2.00 diameter bushing shoulder.

T-Series Straight-Shot™
The DME standard “T” Series Straight-Shot improves the

performance of three-plate molds by virtually eliminating the
sprue from the runner system. It is available with either 1/2" or
3
/4" spherical radius, 120 or 240 volt heater and a 7/8" or 13/8" long
stripper plate bushing to suit the application.
NOTE: 5° heater lead is standard. For 90° lead, add “90” to end of item
number (e.g., SSBT4517T10790).
NOTE:
5.09 The expansion factor must be taken into consideration prior
to machining for and installation of the bushing. This factor
A = 178 +.000 (BE) must then be added to the A dimension. The formula for
1.995 DIA. –.005
No. 10-24 × 1 2 LONG determining this expansion factor is as follows:
.19
F H S (2) INCLUDED BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF
Sequencers
.16
.97 +.0000 DIA. temperature.
™
–.0005
R
Straight-Shot
1.4995 .31 DIA.

EXAMPLE:
DIA.
.97 Given a setpoint of 500°F:
BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 +
.004 = 1.379.
Timer-Based
Please note that the above information is given as an

.25 1.69 DIA. .340 example. Variations may occur based on mold configuration
and cooling factor. In some instances, it may be necessary
| T-Series
L to obtain an empirical factor.

and 8-Zone
T-Series Straight-Shot Hot Sprue Bushings

Bushings
HEATER HEATER
Typical Application R L
ITEM ITEM
| 4-Zone
NUMBER NUMBER
SSBT4517T107 7
⁄8 SSBT4517T207
Hot Sprue
1
⁄2 SSBT4517T113 13⁄8 SSBT4517T213
SSBT6517T107 7
⁄8 SSBT6517T207
3
⁄4
Runner Systems
SSBT6517T113 13⁄8 SSBT6517T213

HotStraight-Shot
MOLD Replacement
OPEN Stripper Bushings
ITEM
L
NUMBER*
SSSB07 7
⁄8
SSSB13 1 ⁄83
*Includes mounting screws.
X-2 X-1 A-CLAMPING

PLATE PLATE PLATE
For Improved Performance
and Increased Productivity:
Use DME standard T-Series (3-Plate) Mold Bases
(See DME Mold Bases and Plates Catalog)
U.S. 800-626-6653 Canada 800-387-6600


TR-Series Straight-Shot™
The DME standard TR-Series Straight-Shot Hot Sprue Bushing,

like the standard T-Series, improves the performance of three-
plate runner molds by minimizing the length of protrusion on the
NOTE: runner system. This bushing features a “reverse taper” design that
The expansion factor must be taken into consideration prior to
machining for and installation of the bushing. This factor (BE) must originates from under the heat source, providing easier start-ups.
then be added to the A dimension. The formula for determining this
expansion factor is as follows:
BE = “A” dimension x 0.00000633 x nozzle set point - 68ºF The TR-Series design can also be used when a reverse taper will
(assuming the mold is at 68ºF during operation). If mold benefit a particular application. The bushing is supplied with a .12
temperature. diameter orifice and a .25 long reverse taper. The orifice may be
EXAMPLE: enlarged and the taper increased to suit. The bushing is available
Given a setpoint of 500°F: with either 1/2" or 3/4" spherical radius, 120 or 240 volt heater and a
BE = 1.375 × .0000063 × (500 – 68) = .004 thus 1.375 + .004 = 1.379.
7
Please note that the above information is given as an example. /8" or 13/8" long stripper-plate bushing to suit the application.
Variations may occur based on mold configuration and cooling
HotStraight-Shot
factor. In some instances, it may be necessary to obtain an
empirical factor.
Runner Systems
5.09
TR-Series Straight-Shot Hot Sprue Bushings +.000
A =1 7
8 1.995 DIA. –.005
WITH 120 VOLT WITH 240 VOLT No. 10-24 x 1 2 LONG .19
HEATER HEATER F H S (2) INCLUDED
R L
ITEM ITEM
.97 .12
Hot Sprue
NUMBER NUMBER +.0000
–.0005 DIA.
SSBT4517TR107 7
⁄8 SSBT4517TR207 1.4995 .31 DIA. R
1
⁄2 DIA.
| 4-Zone
SSBT4517TR113 1 ⁄8
3
SSBT4517TR213 5˚
.97
SSBT6517TR107 7
⁄8 SSBT6517TR207
3
⁄4
Bushings
SSBT6517TR113 13⁄8 SSBT6517TR213
NOTE: .25 1.69 DIA. .340
and 8-Zone
5° heater lead is standard. For 90° lead, add “90” to end of .25
item number (e.g., SSBT4517TR10790). L
| TR-Series
Typical Application Important:
To prevent “pushback” of the hot sprue
Timer-Based
bushing due to injection pressure – and
assure a positive tapered seal with the
Straight-Shot
stripper plate bushing – secure the hot sprue
bushing to the A-Clamping Plate. A dowel
Sequencers
MOLD
OPEN or flat key installed under the locating ring
(shown) or clamping-type locating ring may ™
be used.
For Improved Performance and

.25
Increased Productivity:
X-2 MIN. X-1 A-CLAMPING Use DME standard T-Series (3-Plate)
PLATE PLATE PLATE
Mold Bases (see DME Mold Bases and
Plates Catalog)

Straight-Shot™ Bushings Replacement Parts
Replacement Heaters for Straight-Shot Hot Sprue Bushings Standard

ITEM
VOLTS WATTS L BUSHING SERIES
NUMBER*
SSTC31 120 300 45⁄8 S, E & ER (Long Style), T & TR

5˚ 5˚ heater lead, with 48"
SSTC32 240 300 4 ⁄8
5
S, E & ER (Long Style), T & TR
long shielded leads
SSTC42 240 250 21⁄2 E & ER (Short Style)
* Includes installation wrench.
5˚
Sequencers Parts
Straight-Shot Heater Installation ITEM

Available On Request:
and Removal Wrench USED WITH Heaters with 90° exit leads. Add
NUMBER
Bushings Replacement
“90” to item number.

(Included with heaters above). WR0875 SSTC31 & 32 Series Example: SSTC3190
WR0874 SSTC42 Series
L L
8-Zone Timer-Based
ID OD
1 3
/2 /4
Straight-Shot
90˚
5˚
| 4-Zone| and
Sprue Bushings
Replacement Parts for Discontinued Hot Sprue Bushings (HBT6630 through 6636),
Temperature Controllers (PFC5) and Control Modules (FC5)
HotSystems
Cartridge Heaters Thermocouple Cartridge Heaters

ITEM ITEM
DIA. LENGTH WATTS VOLTS DIA. LENGTH VOLTS WATTS
NUMBER NUMBER
Hot Runner
1
1/
4 21/2 240 200 HBC2022* /4 21/2 240 200 HBTC2022*
Straight-Shot
1
1/
4
3
3 /4 240 300 HBC2032** /4 33/4 240 300 HBTC2032**
* Used with Hot Sprue Bushings 5 3⁄16 long; heater
supplied with leads 48" long.
** Used with Hot Sprue Bushings 6 3⁄16 long; heater
supplied with leads 46" long. THERMOCOUPLE
48"
Threaded type thermocouple is

ITEM Replacement Fuses for Temperature spring loaded and supplied with ITEM
AMPS cable and mini plug. NUMBER
NUMBER Control Modules (FC5) and Temperature
ABC5 5
Controllers (PFC5) TCT4
13X5 5 See the DME Control Systems Catalog for new controllers.

Integrally Heatedtext
Hot Sprue Bushings 79
Integrally Heated Sprue Bushings .750" SERIES
The Integrally Heated Sprue Bushing is uniquely designed for high performance and reliability for direct gating
applications, even with the most demanding molding cycles and plastic resins.
The product’s advanced heat transfer capability is attributed to its integrally heated design, resulting in a more
uniform heat profile. Maximum heat 600ºF.
A replaceable thermocouple is strategically located near the melt flow channel to optimize processing conditions
with all thermoplastics.
Features and Benefits:

Distributed watt density – maintains a more uniform heat profile.
High refractory insulation – provides superior heat transfer.
Streamlined flow channel – minimizes pressure loss.
Fully sealed construction – maintains highest product reliability.
HotIntegrally
High-grade alloy steel construction – increases durability and longer life.
Runner Systems
Replaceable thermocouple – allows for Type “J” or “K”.
Tip Styles and Flow Diagrams
Heated Hot| Sprue

4-ZoneBushings
Maximum heat 600ºF
and 8-Zone| Timer-Based

Recommended for
Sprue Tip Extra Stock Sprue Tip
Commodity Resins
Only
Direct Gating Diagram
Features andSequencers
Insulating Washer Locating Ring
Wire Channel
Benefits
Power & T/C Bushing Leads
Insulating Washer
Water Line

80 Integrally Heated Hot Sprue Bushings
Integrally Heated Sprue Bushings .750" SERIES USER GUIDE
Integrally Heated Sprue Bushings

The DME Integrally Heated Sprue Bushing is an exclusive medium volume bushing with the ability to
process a wide range of resins. Its streamlined flow channel terminates in a reverse taper gate, providing
minimal pressure loss and allowing for rapid gate freeze. The formation of a small gate stub on the part
or runner results in a machine hold-time reduction, with no increase in sink marks on the part.
The Sprue Bushing’s superior heat transfer capacity is attributed to its integrally heated design. To optimize
processing conditions for all thermoplastics, a replaceable thermocouple is strategically located near the
flow channel. The Integrally Heated Sprue Bushing has a .187" flow diameter, and is offered in two
head styles and two gate styles to suit a broad range of applications.
Gating Options for Sprue Bushings

SPRUE GATE
Suitable for most applications, the Sprue Gate is provided as standard on the Heated Sprue Bushing.
(Please note that this gate style is not intended for machining.) The press fit areas are held
User’s Guide
to ± .0005".
EXTRA STOCK SPRUE GATE
The Extra Stock Sprue Gate is available for applications requiring machining of the gate area for runner
profiles, part contours, or adjustment of the bushing height. The .750" diameter bushing has .500” of
|
extra stock. The press fit areas are held to ± .0005”.

Integrally Heated Hot Sprue Bushings
Head Options for Sprue Bushings

.500" Radius*
Provided with a 0.500" radius to mate with 0.500" radius machine nozzles.
Reinforced contact area for improved strength and heat transfer.
.750" Radius*
Provided with a 0.750" radius to mate with 0.750" radius machine nozzles.
Reinforced contact area for improved strength and heat transfer.
*Other radii are available by special request.
Gating Options Gate Diameters

Sprue .080" to .125"* max. (2mm to 3.2mm* max.)
Extra Stock Sprue .080" to .125"* max. (2mm to 3.2mm* max.)
* Re-machine gate diameter, if necessary, for larger shot weights. Maintain gate angle and remove all machine marks.
.750" Series Maximum Shot Weights (0.080" Gate) .750" Series Resin Compatibility
Resin Viscosity Gating Commodity
Gating Options High Medium Low Options Resin
Sprue
a a
Sprue 50g 150g 300g

Extra Stock Sprue 50g 150g 300g Extra Stock Sprue
Contact DME when exceeding minimum shot weight and process heat = Recommended
a
temperature at 600ºF.
Reference: High Viscosity = Melt Flow (0.02 – 6); Medium Viscosity = Melt Flow (7 – 15); Low Viscosity = Melt Flow (16 – up). The values expressed in grams
are for reference purposes only. Part dimensions, wall thickness, mold condition, and molding parameters must also be considered.

Integrally Heated Hot Sprue Bushings 81
Head Options
.500 Radius Style .750 Radius Style

1.9900 dia. .750 R
(50.55mm) (19.1mm) .125
.190 .500 R (3.2mm)
(4.8mm) .440
(12.7mm) 1.060 dia. (11.2mm)
(26.9mm)
.635 dia.
(16.1mm)

.8750 .190
(22.23mm) (4.8mm) 1.9900 dia.
(50.55mm)
Gating Options / Bushing Dimensions
Sprue Gate Extra Stock Sprue Gate
L dim.
|
.740 dia. Note*
Options and Dimensions

L dim. (18.8mm)
L2 dim.
L2 dim. .187 dia. Note*
.080 dia. (4.7mm)
(2.0mm) Flow Channel
.25 .187 .75

(6.3mm) (4.7mm) .375 (19.1mm)
(9.5mm)
Note***
Note**
.7500 dia.
(19.05mm) .500 (12.7mm)
6° Extra Length
.7500 dia.
(19.05mm)
* Dimensions include extra length.

** This surface cannot be machined, modified or altered. Dimensions are in inches; millimeters are in parentheses.
*** Maximum machining stock; only this area can be machined. Note: For additional gate dimensions see page 82

Integrally Heated Sprue Bushings .750" SERIES SPECIFICATIONS
Gate Style L Dim. L2 Dim. .500 Radius Head .750 Radius Head Watts Thermocouple
Sprue 2.375" (60.3) 1.500" (38.1) SB031000 SB031001 315 MT020020
2.875" (73.0) 2.000" (50.8) SB031008 SB031009 370 MT020020
3.375" (85.7) 2.500" (63.5) SB031016 SB031017 425 MT020020
3.875" (98.4) 3.000" (76.2) SB031024 SB031025 480 MT020020
4.375" (111.1) 3.500" (88.9) SB031032 SB031033 535 MT020021
Gate Style L Dim. L2 Dim. .500 Radius Head .750 Radius Head Watts Thermocouple
Extra Stock Sprue 2.875" (73.0) 2.000" (50.8) SB031004 SB031005 315 MT020020
3.375" (85.7) 2.500" (63.5) SB031012 SB031013 370 MT020020
3.875" (98.4) 3.000" (76.2) SB031020 SB031021 425 MT020020
4.375" (111.1) 3.500" (88.9) SB031028 SB031029 480 MT020020

Specifications
4.875" (123.8) 4.000" (101.6) SB031036 SB031037 535 MT020021
All specifications are subject to change without notification.

Dimensions are in inches; millimeters are in parentheses.
Right (Standard)*
|
* Standard Lead exit –

60" (1.52m) wrapped - 600 volt leads;
right angle lead exit; and 6" (15.2cm)

stainless steel, square-lock armored cable.
ITEM NUMBER Mold Power-Thermocouple Input Connector

CKPTIC1 A Single-Zone Power-Thermocouple Input Connector is
available for mounting in or on the mold to accept the power-
thermocouple cable from the mainframe. The water-resistant Recommended Mold Pocket Layout
connector has an integral retaining latch for a secure cable For Mold Power-Thermocouple
connection and numbered screw-type terminals for power Input Connector (CKPTIC1)
and thermocouple lead wires.
*Can be mounted on top of mold 3.50
1.50
1.36
0.91
0.46 0.14
REF
0.32
ITEM NUMBER Armored Mold Power-Thermocouple Cables 2.00

1.45
1.00
MPTC10 Single-Zone Mold Power-Thermocouple Cables are NO. 4-40 NC-2B TAP
.50 DEEP MIN. (2) PLACES
0.25 R 0.55
MPTC20 constructed of special lead wire for use in high temperature 1.180
0.90
REF
0.25 R
MOLD SURFACE
environments, and are available to connect the mainframe to

the input connector on the mold. Available in lengths of 10 or 2.00 MOUNTING SURFACE
20 feet. Integral retaining latches on the mainframe and mold 4.00 MIN.
connections provide secure cable connections. Connector

configurations ensure proper insertion of cable.
For complete information on temperature controls, please see DME Control Systems Catalog.

Integrally Heated Hot Sprue Bushings 83
.750" Series Bore & Gate Dimensions
Insulating Washer Specifications Insulating Washer Option Standard Bore

Top Bottom 2.05 dia.
(52.1mm) a
Item Number MAX10015 MAX10027 .8752
a
.860 dia. (22.23mm)
O.D. 1.99 1.99
(50.5mm) (50.5mm) Top Washer (21.8mm)
I.D. 1.07 .810 .760

Bottom Washer .125 (19.3mm)
(27.2mm) (20.6mm) (3.2mm)
Thickness .125 .125 .110
(3.2mm) (3.2mm) 1.125
(2.8mm)
(28.6mm)
Note: Insulating Washers are not required,
but are recommended for high tem- .125
perature applications. .235 (3.2mm) .080
.125

(3.2mm) (6.0mm) (2.0mm)
b
1.9910 dia.
b
L2 dim. – .125 + Exp. (50.57mm)
L2 dim. – (3.2mm) + Exp. Water Line
{See page 4 for L2 dim.} L2 dim. + exp.
(See page 4 for L2 dim.)
Thermal Expansion (Exp.) Formulas .500 min.

-6
Exp. in = L2 in. × 6.88 × 10 × (Processing Temp. – 70°F) Gate (12.7mm)
Exp. mm = L2 mm × 13 × 10-6 × (Processing Temp. – 21°C)
Ref: 10-6 = 0.000001
All specifications are subject to change without notification.
Sprue Gate Extra Stock Sprue Gate

.860 dia. .860 dia.
(21.8mm) (21.8mm)
|
Machining Dimensions
.118 min.
(3.0mm)
.118
(3.0mm)
.493 max.
(12.5mm)
30° max.
a a
.7505 dia. .7505 dia.
a a
(19.06mm) (19.06mm)
Bore & Gate Tolerances

Tol. “a” Table Tol. “b” Table
in: + 0.0005 in: + 0.0010
–0 –0
mm: + 0.01 mm: + 0.02
–0 –0
Dimensions are inches. Millimeters are in parentheses.

Operating & Servicing Instructions

The Integrally Heated Sprue Bushing bodies are identical in design, but differ in length and head style. All Sprue Bushings
feature an integrated heater; Type “J” thermocouple; 60” wrapped - 600 volt leads; right angle lead exit; and 6” stainless
steel, square-lock armored cable.
Start-Up/Operating Procedures
If the temperature controller does not utilize “soft start” technology, set the controller to 200°F (93.3°C) in automatic mode
or 10% in manual mode. Allow bushing to “soak” for 15 minutes before increasing to processing temperature. This step will
allow the unit to dissipate potential moisture and prolong heater life.
Power Requirements
240 Volts AC – 15 amp fuse
Grounding – Integrally Heated Bushings utilize the direct contact of the bushing, mold plates, and machine platens to establish a path for grounding.
Locating Ring & Keying Options
*WARNING*
There must be a ground present between the mold “hot half” and the temperature control system or damage may occur to the bushing, thermocouple
and/or temperature control system.
Maximum heat 600ºF 1.135

(28.8mm)
Locating Ring Dimensions 5/16 - 18 THD
Jack Screw location
(2 places)
ITEM L.R.D.
NUMBER
ML010012 3.990”
(101.3mm)
5.490 dia.
(139.4mm)
|
3.990" dia
(101.3mm)
For 5/16 - 18 SHCS

(2 places)
1.625 R
(41.3mm) .510
(12.9mm)
Customer to machine counterbore.
Machining Options for Keying

.83 R min.*
(21.1mm)
.75 R min.
(19.1mm)
Dowel Pin Socket Head

Cap Screw
*Centerline for #10 Screw
Dimensions are in inches; millimeters are in parentheses.

D M E H o t Ru n n e r S e rvices
TOTAL SUPPORT FOR YOUR

HOT RUNNER SYSTEMS
86 Hot Runner
textServices
Moldflow Services — Optimize Part and Mold Design
Comprehensive Analysis and Modeling

With today’s shrinking time-to-market window, development speed is
essential. As part of its commitment to the molding industry, DME is now
offering Moldflow™ analysis to help optimize part and mold design –
especially for hot runner molds. DME is the first mold technologies
supplier to earn Moldflow’s silver certification in this advanced technology.
A Competitive Advantage
Predictive analysis, utilizing Moldflow software, yields tremendous
benefits, including:
Mold Design
Optimize part design

Sequencers
Reduce time-to-market
Save cost and time on mold tryouts
Lower development and production costs
Part and
Provide a framework to establish reputable processes

Timer-Based
Improve product quality

Decrease cycle times
— Optimize
What is Moldflow?
and 8-Zone
DME uses Moldflow Plastics Insight™ (MPI) software which is an

| 4-ZoneServices
integrated suite of analysis tools that utilize CAD files and apply advanced
Finite Element Analysis (FEA) techniques to quickly and easily enable a
virtual “what if” design environment before initiating mold construction.
| Moldflow
MPI provides in-depth part/mold design and process parameter optimization.

This is in contrast to Moldflow Plastics Advisor™ (MPA) which is primarily
useful for parts with low to medium complexity, conceptual designs,
Systems
and quick part design validation. DME is a certified, licensed provider of

Moldflow analysis services.
Services
Grill stack Mold Fill Analysis

Runner
mold
The Mold Fill module uses predictive technology to simulate the filling
Runner
process. Key analyses include:

Hot Hot
Optimize the number, size, and location of gates

Balance the runner system design
Reduce material stress levels
Predict weld line locations
Validate pressure and temperature distribution within the mold
Optimize processing conditions – including melt temperature, injection
rate, and cavity pressure
U.S. 800-626-6653 Canada 800-387-6600

Hot Runner
textServices 87
Moldflow Services — Optimize Part and Mold Design
Hot Hot
Runner
Runner
Mold Pack Analysis Warp Analysis
Services
Systems
Building on the results of a Mold Fill analysis, the Mold Pack Using the results from the Fill and Cool analyses,
module optimizes the packing phase to ensure a uniform packing the Warp Analysis module enables prediction of
condition. As an indication of part warpage, volumetric shrinkage plastic part shrinkage and warpage. Warp Analysis
| Moldflow
is evaluated and the pack pressure profile is optimized. The result diagnoses the cause(s) of warping and recommends
| 4-ZoneServices
is minimized warpage with an improved surface appearance. the appropriate solution, such as gate location
changes, design parameter changes, and reduction
of wall thickness variations.
and 8-Zone
Mold Cool Analysis
The Cool Analysis module assesses an existing cooling layout
MPI 3D
— Optimize
to determine potential molding problems. Steel types, cooling
MPI 3D addresses a class of problems previously
Timer-Based
channel sizes, bubblers, baffles, coolant temperatures, and flow
rates are all evaluated. Using this analysis, the Mold Cool module unsolvable using traditional Finite Element Analysis
recommends practical tooling design changes to ensure uniform techniques. In thick-walled parts, molten plastic can
Part and
cooling. Mold Cool takes into account: flow in all directions. Using a proven methodology
based on a solid tetrahedral, finite element volume
Sequencers
Number, location, depth, and pitch of cooling channels mesh, MPI 3D enables true, three-dimensional
Mold Design
Steel types simulations on thick-walled parts.
Cooling circuit layouts
Coolant temperatures and flow rates Where Do I Start?
Cycle times Contact your DME representative for more
information regarding Moldflow Services. The
DME Applications Engineering Department is
available to provide a customized Moldflow
analysis and assist you in maximizing the results
of your next application.

88 Hot Runner
textServices
Mold Filling/Mold Cooling Analysis Quote Request Form
THIS FORM IS REQUIRED FOR ALL ANALYSIS WORK FOR EACH PART
NOTE: Changes made after this form is received require written confirmation
Fax completed form to 248-544-5707 or

email dme_appl_eng@milacron.com
Runner Systems
HotServices
Hot Runner Request
| 4-Zone
| Customer Data – Timer-Based
for8-Zone
and Cooling Analysis
Sequencers
Mold Filling/Mold
U.S. 800-626-6653 Canada 800-387-6600

Hot Runner Services 89
DME Hot Runner Service Center
Ensuring the Productivity of every Hot Runner System

Full-Service Hot Runner Support
Mold technology leader DME - known for servicing its customers every step of the way - provides total support for your
hot runners. No matter what brand of hot runner you have, DME will repair, reconfigure or even totally rebuild it to ensure
maximum uptime and performance of your system.
A Dedicated Center for Hot Runner Systems

Our new Hot Runner Service Center, located in Madison Heights, Mich., is exclusively dedicated to supporting your hot runner
systems. Staffed by a team whose sole focus is hot runner systems, we’re quickly able to get your system operating at maximum
efficiency. This group has over three decades of experience installing, assembling, and repairing hot runner systems. And,
because we’re centrally located, we can get your system back in your shop quickly and cost-effectively.
Hot Runner
Hot Runner Services Overview
Hot Runner
Unrivaled Support When and Where You Need It
Since the 1970s, DME has developed and marketed a full spectrum of hot
Systems
runner systems and components. From Moldflow analysis to turnkey hot half
systems and everything in between, the DME family of hot runner products
Services
and services offers a comprehensive array of solutions for a wide range of
| 4-Zone
applications. Whether your need is for standard, off-the-shelf components,
customer engineered manifolds, or fully assembled systems ready for bolt-on
| DME
installation, DME has a proven solution to match your application.
and Hot
Moldflow Services
8-Zone
As the first mold technologies supplier to earn Moldflow’s silver certification,
The DME family of
Runner
DME is highly adept at applying Finite Element Analysis (FEA) techniques to
help optimize part and mold design. Whether you need Mold Fill, Mold Pack,
Timer-Based
hot runner products Mold Cool or Warp analyses, DME can assist you in maximizing the results of
Service Center
your next application.
and services offers
Applications Engineering and Technical Service
a comprehensive
Sequencers
Our dedicated and experienced team of mold designers and applications
engineers assists DME customers with product selection, system design, per-
array of solutions formance analysis and technical advice. DME technical service representatives
are globally located for complete coverage and quick availability no matter
for a wide range
g of where your hot runner production takes place. Technical experts employed
applications. worldwide are available for start-ups, personnel training or system service.
Comprehensive Hot Runner Service

Staffed by a team whose sole focus is hot runner systems, the DME Hot
Runner Service Center offers a single source for hot runner system
optimization and maintenance. Our services include expedited repairs,
system cleaning, system rebuilds, re-configuration and mold tryouts for
virtually any type of hot runner system.

90 Hot Runner
textServices
DME Hot Runner Service Center
A Wide Range of Services Rebuilds Ensure Performance

We recognize the value of your time - that’s why we’ve After tens of thousands of cycles you may have noticed your
developed a comprehensive suite of hot runner ser- system just doesn’t perform the way it used to. Or maybe you’ve
vices to provide a single source for maintenance and run high-temperature engineered materials and the tolerances
optimization of your system, even our competitor’s just aren’t as tight. Key benefits of system rebuilds include:
systems. Cost savings of at least 40% as compared to new systems
Key services include:
Extended life for your tool
t System evaluations
t Repairs Maximizing system uptime and performance
t System cleaning and rewiring of all hot runner Improved finished part quality
systems - including complete bake-out
t Total system rebuild Whether you need a total system rebuild, or a simple cleaning
t Total restoration of flooded systems and inspection DME can help. System rebuilds can be performed
t Re-configuration on any brand of hot runner system and typically include:
Sequencers
t Operating training t Complete bake-out cleaning

t All machining capabilities
Service Center
t Check and replace heaters and thermocouples

t Inspect and correct wiring
Cost-Effective Reconfiguration
Timer-Based
t Replace seals and bushings

When your process needs change, without a significant t Clean or replace nozzle components
tooling change, we can adapt your hot runner to the new t Check all dimensions and re-assemble system
Runner
process. Whether it’s a material switch, or a part design

8-Zone
change, DME can help reconfigure your existing system.

Repairs Get You Back Up Quickly
and Hot
Time is money. When a critical tool is out of commission,

Training Maximizes Productivity, Speeds Set-Up
| DME
productivity is lost and production schedules can be

The DME Hot Runner Service Center can provide threatened. We understand this at DME. That’s why our
| 4-Zone
comprehensive operator training in start-up or prototyping. team of hot runner repair specialists are always available
Services
Our hands-on programs help your operators get up-to-speed, to get you back in service.
or stay current on hot runner technology.
Whether you’re experiencing leaks, heating issues, flow
Systems
problems, or would simply like a system bake-out, we’ll repair

Preventative Maintenance (PM)
Hot Runner
your system quickly and cost-effectively.

It is important to protect and update your hot runner
Standard turnaround for repairs on systems from 1-12 drops
Hot Runner
system to ensure it is running at the highest efficiency.

The PM Program is designed to prevent system equip- (depending on parts availability for non-DME systems) is
ment failure before it occurs. We will enhance equip- 5 working days or less. If your system has over 12 drops,
ment reliability by replacing worn components before contact us for an estimated turnaround time. And, we offer
they fail. emergency 24-hour turnaround service.
t Maximizes system performance Mold Tryouts

t Reduces cost of replacement
t Ensures peak part quality We also offer mold tryouts at the Hot Runner Service Center.
t Decreases system downtime Injection molding machines from 85 to 250 tons are available
t Protects your investment to run your mold and ensure proper performance.
The PM Program can be set up either by system cycles

or by scheduled PM

DM E Obsolete R eplacement Parts
REPLACEMENT PARTS FOR OBSOLETE

HOT RUNNER SYSTEMS & NOZZLES
Obsolete Replacement Parts
92
Obsolete Replacement
text Parts 92
page content
content
Mini page
Gate-Mate® Nozzles
NOZZLE INCLUDES 1
/2 SPH. RADIUS BUSHING FLAT BUSHING
SUB-ASSEMBLY SUB-ASSEMBLY SUB-ASSEMBLY
(ORDER TIP SEPARATELY) 1 2 3 4
ITEM NUMBER HEATER TYPE ITEM NUMBER HEATER TYPE
ITEM HEATER NOZZLE THERMO- SEAL GMB0116 SQUARE COIL GMB0117 SQUARE COIL
HEATER WATTS
NUMBER TYPE BODY COUPLE RING
GMB0111 CAST-IN GMB0112 CAST-IN
N/A
GMB0110 CAST-IN GMB0105 CIH0100 250
(INTEGRAL) EHR7155
GMB0118 SQUARE COIL GMB0105 SCH0004 250 TCG0100
Mini Gate-Mate® Tips ITEM TIP Mini Gate-Mate Bushing Locating Ring
Contact DME for tip NUMBER STYLE
recommendations and assistance ITEM
with your application. GMT0100 STANDARD
NUMBER
GMT4101 WEAR RESISTANT
6548
Gate-Mate® 4 Nozzles and Tips

INCLUDES
NOZZLE NOZZLE SUB
ASSEMBLY ASSEMBLY 1 2 3 4
A (INCLUDES (TIP ORDERED NOZZLE
SQUARE
THERMO- SEAL
GMT2 TIP) SEPARATELY) COIL WATTS
BODY COUPLE RING
HEATER
2.000 GMB0050 GMB0150 GMB0060 SCH0060 250 TCG0060 NOTES:
1. Items 1 thru 4 are available separately
2.500 GMB0051 GMB0151 GMB0061 SCH0061 300 TCG0061 for replacement purposes
3.000 GMB0052 GMB0152 GMB0062 SCH0062 350 TCG0062 2. Items 2 is 240 VAC, 36" leads, 34" fiberglass
Gate-Mate® Nozzles
lead protection
3.500 GMB0053 GMB0153 GMB0063 SCH0063 400 TCG0063 EHR7155 3. Item 3 is type J, with 36" leads, 34"
4.000 GMB0054 GMB0154 GMB0064 SCH0064 425 TCG0064 fiberglass lead protection
5.000 GMB0055 GMB0155 GMB0065 SCH0065 500 TCG0065 4. Item 4 (for replacement) is sold in packs
of 4 only
6.000 GMB0056 GMB0156 GMB0066 SCH0066 500 TCG0066
INCLUDES Gate-Mate® 4 Tips

1 2 3
NOZZLE FRONT LOAD SEAL Replacement TIP TIP ITEM O TIP TIP HOLE
WATTS STYLE NUMBER DIA. LENGTH DIA. DIA.
BODY HEATER RING Seal Rings
GMB0060 SCH1060 250 STANDARD GMT2 .044 MIN.
ITEM NUMBER .024
SCH1061 WEAR RESISTANT GMT0400 .055 MIN.
GMB0061 300 EHR7155
SCH2061 SUPER SHARP GMT0301 .030 MIN. 1.730 N/A
SCH1062 SUPER SHARP .010

GMB0062 350 GMT0401 .055 MIN.
WEAR RESISTANT
SCH2062
SCH1063 .030 MIN.
GMB0063 400 THRU HOLE GMT0302*
.050 MAX
SCH2063 EHR7155 1.690 .090 .050
SCH1064 THRU HOLE
GMB0064 425 GMT0402* .055 MIN.
WEAR RESISTANT
SCH2064
SCH1065 NO HOLE GMT0303 .044 MIN. 1.730 .024 N/A
GMB0065 500
SCH2065
NOTES:
SCH1066
GMB0066 500 1. Thru hole tip is designed .040 shorter in length to be a direct
SCH2066 replacement for the standard tip; use a .030 to .060 diameter
gate
NOTES: 2. A .030 minimum diameter gate is recommended when using
1. Items 1, 2 and 3 are available separately for the super sharp tip
replacement purposes 3. Contact DME for tip recommendations and assistance with
2. Item 2 is 240 VAC, type J thermocouple, 36" leads, 34" your application
Teflon lead protection *Contact DME for details to modify thru hole tips for larger “O”
3. Item 3 (for replacement) is sold in packs of 4 only diameters

Obsolete Replacement Parts 93
Gate Shell Insulators
Gate Shell Insulators

Improves insulation in the tip area
Provides seal-off to eliminate material degradation in threaded area of tip
Minimizes material in gate area to allow for faster color changes
Withstands temperatures up to 550° F
Hot RunnerCustom
Systems
Typical Application
Hot| Runner
D DIA.
Gate
4-Zone
Shell
Systems
andInsulators
8-Zone
GATE SHELL
INSULATOR
| Timer-Based
New ProductsSequencers
FOR BUSHING OR ITEM D ITEM
FOR TIP STYLE
NOZZLE STYLE NUMBER DIA. NUMBER
Gate-Mate 4 Standard, Super Sharp, No Hole GSI0001 GSI0001

.748
Nozzle Thru Hole GSI0002 GSI0002
Jumbo Gate-Mate Standard GSI0003 GSI0003
1.248
Bushing or Nozzle Thru Hole GSI0004 GSI0004
Medium Gate-Mate Standard, Super Sharp, No Hole GSI0005 GSI0005
.748
Bushing Thru Hole GSI0006 GSI0006
APPLICATION NOTES:
1. Use only with bushings, nozzles and tip styles shown in the reference chart above
2. Gate machining must be done according to DME specifications
3. Nozzle tip cannot be altered in any way for the Gate Shell Insulator
to perform properly
4. If dissimilar resins are to be processed in the same mold, it is recommended that
their processing temperatures be within a similar range
5. For best results, the outer surface of the tip should be free from all resin before
the Gate Shell Insulator is installed or used

94
94
94 Obsolete Replacement
text Parts
page
page
Components for Micro Cool Onecontent
content
®
Split Plate/Solid Block Designs
Thermocouple (T/C) Distributor Tube Heaters (240 VAC, T/C Type J, 34" Leads)
Distributed wattage heater design for more uniform temperature control. Sealed, flexible teflon covered leads
to prevent lead damage and improve moisture resistance.
DIA OVERALL HEATED DIA OVERALL HEATED
ITEM NUMBER WATTS ITEM NUMBER WATTS
(AMPS)* LENGTH LENGTH (AMPS)* LENGTH LENGTH
HCTC034 5.000 4.000 320 HCTC0375 8.500 7.500 515
HCTC0345 5.500 4.500 340 HCTC038 9.000 8.000 550
HCTC035 6.000 5.000 400 HCTC039 10.000 9.000 650
.375 .375
HCTC0355 6.500 5.500 430 HCTC0310 11.000 10.000 710
(10 AMP) (10 AMP)
HCTC036 7.000 6.000 450 HCTC0311 12.000 11.000 720
HCTC0365 7.500 6.500 470 HCTC0312 13.000 12.000 760
HCTC037 8.000 7.000 480 HCTC0313 14.000 13.000 810
*(AMPS) = Amperage requirement for temp. control module.
Cool One®
Distributor Tubes End Cap

Sequencers
ITEM NUMBER LENGTH ITEM NUMBER

MATERIAL: AISI 4140 STEEL HT050312 11.82 MATERIAL: AISI 4140 STEEL EC1105
HARDNESS: 28-35 HRC HT050316 15.76
| Indexfor Micro
Timer-Based
Components for Micro Cool One®

| Components
Solid Block Designs

andSystems
8-Zone
Auto-fixed® “Integral Heater” Micro Probes (240 VAC, T/C Type J, 48" Leads)
MATERIAL: AISI D-2 STEEL
HARDNESS: 50-55 HRC
Systems
Runner
ITEM NUMBER* A B WATTS

| Hot4-Zone
AFIP331090 3.095 2.720 110

AFIP336090 3.595 3.220 130 NOTE: Probes are special order only
AFIP341090 4.095 3.720 150
Runner
AFIP346090 4.595 4.220 170

Custom
A
Systems
.312 DIA
Hot
Replacement Thermocouple
Heated
ITEM NUMBER LEAD LENGTH

Hot Runner
TC9900 48"
B .375
Internally
Register Ring
MATERIAL: AISI H-13 STEEL ITEM NUMBER*
HARDNESS: 48-52 HRC RAF3062
I.D. = .313 *Package of 10.
O.D.= 1.000

text Parts 95
95
The Cool One – Heated Nozzle

page Locator Replacement Parts
content
Heated Nozzle Locator Assemblies R

ITEM
NUMBER
HNL462 and HNL662 assemblies include: HNL462
1⁄
2
HNC46 or HNC66 core, respectively HNL472
3⁄4
HNL662
SSTC6290 heater HNL672
HNS67 spacer
HNL472 and HNL672 assemblies include:

HNC47 or HNC67 core, respectively
SSTC7290 heater Cores
Internally
ITEM
R CORE
HNS67 spacer NUMBER
HNC46
Hot Heated
1⁄
2
HNC47
RunnerCustom
3⁄4
HNC66
HNC67
Hot
Systems
Runner
Hot| Runner
Thermocouple Heaters
Systems
4-ZoneSystems
(240 VAC, 250 WATTS T/C type J 36" leads)
ITEM USED WITH
NUMBER CORES HEATER
SSTC6290 HNC46 & 66
and
| The
SSTC7290 HNC47 & 67
8-Zone
Cool
| Timer-Based
New
OneProducts
– Heated
Spacer SPACER
Sequencers
ITEM
NUMBER
HNS67 Nozzle Locators
ITEM NUMBER R
NL6702 1⁄
2
NL6703 3⁄4

text Parts 96
page
The Cool One – End content
Caps and Distributor Tubes
End Caps (for use with solid distributor block designs)
MATERIAL: AISI 4140 STEEL
End caps provide concentricity between distributor tube and distributor bore. Thread
accommodates heater stop or lead wire protector.
END CAPS FOR SPLIT PLATE DESIGNS: Moldmaker to supply to suit.
1.50
.56
ITEM DIA. DIA. USED WITH

The Cool One – End Caps & Distributor Tubes
THREAD
NUMBER A B DIST. BORE/TUBE
EC1207 1.249 0.875 5⁄

8"- 11 1.25 DIA./.87 O.D.
+ .000 + .002
– .002 – .000
A DIA. B DIA. EC2015 1.999 1.625 3⁄4"- 10 2.00 DIA./1.62 O.D.
THREAD
Distributor Tubes
MATERIAL: AISI P-20 STEEL
HARDNESS: 28-35 HRC
LENGTH
.03 × 45° TYP.
|
Internally Heated Hot Runner Systems
O.D. I.D.
USED WITH 1.25 DIAMETER USED WITH 2.00 DIAMETER

DISTRIBUTOR BORE/CHANNEL DISTRIBUTOR BORE/CHANNEL
I.D. = .50 O.D. = .87 I.D. = .62 O.D. = 1.62
LENGTH LENGTH
ITEM NUMBER ITEM NUMBER
6" HT07046 10" HT150510
10" HT070410 18" HT150518
16" HT070416 24" HT150524
20" HT070420 29" HT150529
24" HT070424 34" HT150534
29" HT070429 40" HT150540
34" HT070434 46" HT150546
NOTES:
Stainless Steel Distributor Tubes available on special order for molding highly
corrosive plastics materials.

text Parts 97
page content
The Cool One – Thermocouple Distributor Tube Heaters
Thermocouple (T/C) Distributor Tube Heaters

(240 VAC, T/C type J, 34" leads)
DIA. ITEM DIA. ITEM
Internally Heated
LENGTH WATTS LENGTH WATTS
(AMPS)* NUMBER (AMPS)* NUMBER
HCTC044 4" 380 HCTC0511 11" 1430

HCTC045 5" 500 HCTC0512 12" 1570
HCTC046 6" 600 HCTC0513 13" 1700
HCTC047 7" 700
Hot Runner
.625 HCTC0514 14" 1840
HCTC048 8" 820 (10 AMP) HCTC0515 15" 1980
HCTC049 9" 920 HCTC0516 16" 2110
Hot Runner
HCTC0410 10" 1030 HCTC0517 17" 2250
HCTC0411 11" 1140 HCTC0518 18" 2390
Custom
Systems
HCTC0412 12" 1250 HCTC0519 19" 2520
HCTC0413 13" 1350 HCTC0520 20" 2660
HCTC0414 14" 1460
Systems
HCTC0521 21" 2800
Hot| Runner
HCTC0415 15" 1570 .625 HCTC0522 22" 2930
HCTC0416 16" 1680 (15 AMP) HCTC0523 23" 3070
.500
HCTC0417 17" 1780
4-Zone
(10 AMP) HCTC0524 24" 3200
HCTC0418 18" 1900 HCTC0525 25" 3340
| The
HCTC0419 19" 2010 HCTC0526 26" 3480
Systems
HCTC0420 20" 2110
and
HCTC0527 27" 3620
Cool
HCTC0421 21" 2220 HCTC0528 28" 3750
8-Zone
HCTC0422 22" 2330 HCTC0529 29" 3900
One
HCTC0423 23" 2400 HCTC0530 30" 4020
| –Timer-Based
HCTC0424 24" 2400 HCTC0531 31" 4160
New
HCTC0425 25" 2400 HCTC0532 32" 4300
Thermocouple
HCTC0426 26" 2400 HCTC0534 34" 4570
ProductsSequencers
HCTC0427 27" 2400 HCTC0535 35" 4710
HCTC0428 28" 2400 .625
HCTC0536 36" 4840
(30 AMP)
HCTC0429 29" 2400 HCTC0537 37" 4980
HCTC0430 30" 2400 HCTC0538 38" 5120
HCTC055 5" 620
Distributor Tube Heaters
HCTC0539 39" 5250
HCTC056 6" 750 HCTC0540 40" 5390
.625 HCTC057 7" 880
HCTC0541 41" 5520
(10 AMP) HCTC058 8" 1020
HCTC0542 42" 5520
HCTC059 9" 1160 HCTC0543 43" 5520
HCTC0510 10" 1300
HCTC0544 44" 5520
*(AMPS) Amperage requirement for temperature control module.
NOTE: Heaters should be at least 2" shorter than distributor tube length in mold design.

text Parts 98
page
The Cool Onecontent
– Components
Auto-Fixed™ “Integral Heater” Probes (240 VAC, T/C Type J Grounded, 48" Leads)
MATERIAL: AISI D-2 STEEL HARDNESS: 50-55 HRC
STRAIGHT
A
.720 DIA.
.312 R.
.030 R
AVAILABLE WITH NOTE: Probes are special order only
45° STRAIGHT OR 90°
EXIT HEATER LEADS
20° + .000
– .001
.005 DIA. .384 DIA. 90°
.157 (.490 DIA.) + .000
– .001 .500 REF.
.394 DIA. These probes feature a swaged in heating element which
(.500 DIA.) is an integral part of the probe. A separate replaceable
.625 thermocouple is installed in each probe as supplied. The
B .500
integral heater design provides highly efficient heat transfer,
Important: Dimensions shown in parentheses apply to larger probes uniform heat distribution and is guaranteed for one year.
The Cool One – Components
AFIP5372 thru 622 only. Tolerances shown also apply to dimensions in paren-
theses. AFIP5 SERIES PROBES
ITEM NUMBER**
AFIP4 SERIES PROBES .500 (12.9 mm) DIAMETER
ITEM NUMBER**
.394 (10 mm) DIAMETER STRAIGHT 90° EXIT A B
WATTS
STRAIGHT 90° EXIT A B EXIT LEADS LEADS DIM. DIM.
WATTS
EXIT LEADS LEADS DIM. DIM. AFIP5372 AFIP537290 3.720 3.220 200
AFIP4322 AFIP432290 3.220 2.720 135 AFIP5422 AFIP542290 4.220 3.720 230
**lncludes probe, integral heater, thermocouple, adjustment ring and AFIP5622 AFIP562290 6.220 5.720 360
hold down nut.
|
Replacement Thermocouples ITEM NUMBER LEAD LENGTH Adjustment Rings

(ALL PROBES) TC9900 48" (Packaged with all probes)
+ .005
.062
Gate Inserts – .000
O.D.
I.D.
(GRIND TO SUIT)
MATERIAL: AISI S-7 STEEL (pre-hardened)
HARDNESS: 30-34 HRC
I.D.
Hardness can be increased to a higher
value by heat treatment, if desired.
2.500 .375 ITEM NUMBER† I.D. USED WITH
R. RAF4062 .469 AFIP4 SERIES
ITEM
O.D. I.D. USED WITH RAF5062 .565 AFIP5 SERIES
NUMBER
AFGI04N 1.625 .875 AFIP4 SERIES 45° .187 †Bag of 5 rings.
.625
AFGI10N 1.750 1.000 AFIP5 SERIES SPH. R.
Hold-Down Nut
Register Rings 15° TYP. .06 TYP.
(Packaged with all probes)
MATERIAL: AISI H-13 STEEL THICKNESS = .500
THREAD = 1"- 8
HARDNESS: 48-52 HRC HEX FLAT = 9⁄16
+ .000
– .001
A DIA. .125 ITEM NUMBER

120° TYP.
AFN100
+ .001
– .000
C DIA.
B DIA.
+ .000
– .001 Hold-Down Nut Wrench*
ITEM NUMBER
ITEM NUMBER A DIM. B DIM. C DIM. USED WITH
WR916
AFRR04N 1.062 .865 .387 AFIP4 SERIES
AFRR05N 1.187 .937 .493 AFIP5 SERIES *Required for straight exit leads only.

99 99
text Parts
The Cool Onepage

page content
content
– Probes and Probe Heaters
Auto-Fixed™ Probes (3" to 6" long)

HARDNESS: 50-55 HRC
LENGTH
ITEM NUMBER **
A
2.893 AFP310 A .250
3.625 AFP410
4.625 AFP510
5.609 AFP610
**Includes probe, stop sleeve
and hold down nut only.

These finned style Auto-Fixed probes employ a precision heater chart below. Gate inserts (shown on next page),
engineered tip configuration that automatically “fixes” the pre-machined for use with these probes, can save
relationship between probe tip and gate, centering the probe valuable machining time and help assure optimum
and limiting tip protrusion into the gate. Thermocouple probe performance.
heaters are guaranteed for one year as detailed under the
Auto-Fixed™ Finless Probes (3" to 6" long)

HARDNESS: 50-55 HRC
LENGTH
ITEM NUMBER **
A
2.893 AFPN310 A .250
3.625 AFPN410
4.625 AFPN510
|
5.609 AFPN610
The Cool One – Probes and Probe Heaters

**Includes probe, stop sleeve
and hold down nut only.
These finless style Auto-Fixed probes are available in the NOTE: Due to minimum distance requirements specified, the AFPO310
and AFPN310 probes cannot be used in a Cool One system. They
same sizes as the finned probes above and also in lengths may, however, be used in an insulated runner system.
up to 10". An optional register ring is available to provide
added stability at the probe tip if desired. As with the finned
probes, thermocouple heaters are guaranteed for one year
and pre-machined gate inserts are available.
Thermocouple (T/C) Probe Heaters† Non-Thermocouple Probe Heaters

(.250 diameter, 240 VAC, T/C type J grounded, 34" leads) (.250 diameter, 240 VAC, 34" leads)
ITEM NUMBER FOR PROBE WATTS LENGTH ITEM NUMBER FOR PROBE WATTS LENGTH
AFTC2132 AFP(N)310 150 3.00 AFC2132 AFP(N)310 150 3.00
†Thermocouple (T/C) Probe Heaters are guaranteed for one year from date of shipment.

text Parts 100
page content
The Cool One – Accessories and Replacement Parts
Accessories/Replacement Parts for 3" to 6" Long Auto-fixed Probes

See design and machining guidelines at the end of this Internally Heated Hot Runner Systems section.
Hold-Down Nut Stop Sleeve Register Ring

(Packaged with all probes) (Packaged with all probes) (For Finless Probes Only)
Thickness = .50 Length = 1.375 AISI H-13 STEEL
Thread = 1"-8 Thread = 3⁄8"-24 48-52 HRC
Hex Flat = 9⁄16 Dia. = .375 I.D. = .562
O.D. = 1.375
Thickness = .125

ITEM NUMBER
AFN100 AFSS38
AFRR10N
Gate Inserts Adjustment Rings

MATERIAL: AISI S-7 STEEL (pre-hardened)
For simplified counterbore depth adjustment
HARDNESS: 30-34 HRC
(No change from previous rings).
Hardness can be increased to a I.D. = .687 O.D. = .868
higher value by heat treatment, if
desired.
I.D. = 1.000 O.D. = 1.750 Height = 2.500
ITEM NUMBER FOR PROBE

AFGI10 AFP310 thru 610
AFGI10N AFPN310 thru 610 ITEM NUMBER* THICKNESS
RAF002 .002
RAF003 .003
RAF005 .005
Gate inserts are RAF007 .007
|
supplied premachined.
See design and machining RAF032 .032

guidelines at the end of this
Internally Heated Hot Runner RAF062 .062
Systems section. RAF125 .125
*Package of 10.
AFGI10 AFGI10N
Replacement Thermocouple (T/C) And Non T/C Heaters

FOR DISCONTINUED AUTO-FIXED PROBES AFP300, 400, 500, 600
(.250 diameter, 240 VAC, T/C type J grounded, 36" leads)
While the original Auto-Fixed probes (AFP300, 400, 500, 600) have been replaced
with the AFP310 thru 610 series, replacement heaters for these previous probes are
still available as detailed here.
T/C NON T/C
HEATERS HEATERS FOR
WATTS LENGTH
ITEM ITEM PROBE
NUMBER NUMBER
AFTC2022 AFC2022 AFP300 200 2"
AFTC2032 AFC2032 AFP400 300 3"
AFTC2042 AFC2042 AFP500 375 4"
AFTC2052 AFC2052 AFP600 475 5"

101 101
101 text
page
page content
content
Auto-Fixed™ Finless Probes (7" to 10" long)

HARDNESS: 50-55 HRC
These longer probes are ideal for larger molds or gating into deeper
cavity configurations. The optional register ring shown below
may be used to provide added stability at the probe tip if desired.
Thermocouple heaters are guaranteed for one year as detailed
under the heater chart below.
LENGTH ITEM
A NUMBER**
7.000 AFPN720
8.000 AFPN820
9.000 AFPN920
10.000 AFPN1020 A .375
**Includes probe, stop sleeve and hold down nut only.
Hold-Down Nut Stop Sleeve Register Ring

(Packaged with all probes) (Packaged with all probes) AISI H-13 STEEL
Thickness = .50 Length = 1.375 48-52 HRC
Thread = 1¼"-12 Thread = 1⁄2"-20 I.D. = .693
Hex Flat = 5⁄8 Dia. = .500 O.D. = 1.500
ITEM NUMBER
AFRR20N
AFN125 AFSS12
Thermocouple (T/C) Probe Heaters† Gate Insert

(.375 diameter, 240 VAC, T/C type J grounded, 46" leads) MATERIAL: AISI S-7 STEEL (pre-hardened)
HARDNESS: 30-34 HRC
Hardness can be increased to a

higher value by heat treatment, if
desired.
ITEM NUMBER FOR PROBE WATTS LENGTH
I.D. = 1.125 O.D. = 2000 Height = 2.500
AFTC3272 AFPN720 645 7.15
AFTC3282 AFPN820 760 8.15
ITEM NUMBER
AFTC3292 AFPN920 870 9.15
AFGI20N
AFTC32102 AFPN1020 980 10.15
†Thermocouple (T/C) Probe Heaters are guaranteed for one year from date
of shipment. Adjustment Rings
Moldmaker to supply to suit (.990 O.D., .820 I.D.)
U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.com.net www.dme.net

Modular Components Deliver High-Performance Solutions
Today’s increasingly feature-packed plastic products benefit tremen-

dously from the right hot runner solution. Increasing resin costs and
the complexity of engineered materials only compound this challenge.
From hot sprue bushings to turnkey hot halves, DME offers a wide
range of solutions to almost any molding application.
Get the modular advantage with DME hot runner systems

DME’s newest family of hot runner systems are built on an architec-
ture of modular components so we can quickly custom configure a
system that is ideal for your application. With the tremendous time
Modular Components Deliver High-Performance Solutions
pressures on moldmakers today, our modular architecture enables

industry-leading delivery times. This modular approach shortens
delivery, improves cost-effectiveness and optimizes performance.
DME’s Meteor and Stellar hot runner systems offer standardized
products, custom-configured to each application in only a few days.
Our dedicated team of application engineers

works to understand the critical variables of
your molding equation.
Here are a few areas in which our global capabilities make hot runner
solutions more efficient and more economical.
Micromolding solutions
As plastic parts get smaller and more complex, micromolding solutions
become more challenging. DME Stellar Hot Runner Systems were
designed for the demands of very small part molding with engineered
or commodity materials. The Stellar hot runner system is available for
applications with center-to-center dimensions as close as 17mm.
|
Hot Runner Systems
Application engineered solutions

As an industry leader in hot runner systems, DME is able to offer our
customers a comprehensive resource for hot runner solutions. Our
dedicated team of application engineers works to understand the
critical variables of your molding equation and engineer a hot runner
system solution that is optimal for your project.
Powerful custom manufacturing capabilities

For more complex, custom and even high cavitation applications,
DME offers extensive manufacturing capabilities enabling complete,
custom solutions. For example, turnkey hot half systems — fully
assembled, wired, and electrically tested — are ready to drop in
with no machining and minimal installation demands.
U.S. 800-626-6653 Canada 800-387-6600
DME CONTROL SYSTEMS
104 Control Systems
Table of Contents
TSP and TSP Plus Temperature

Control System ........................................105-110
Touch Screen Panel, Powerful, flexible and affordable
Smart Series® Temperature

Control Systems ..................................111 to 155
RoHS/WEEE-compliant temperature
controls for hot runner systems
Valve Gate Controls................................156-162

Energy efficient, reliable and compact
hydraulic and pneumatic controls
Technical Support ..................................163-164

Customer power requirement worksheet
Breaker wattage size table
Control system repairs and returns

Smar t Series ® TSP ™
Temperature C ontrol System
Series
POWERFUL, FLEXIBLE
AND AFFORDABLE
106 TSP Temperature Control System
TSP Features and Benefits
The TSP™ Temperature Control System optimizes injection molding performance of any hot runner
system with the advanced features of a touch screen unit but within a minimal footprint.
Benefits
TSP USER-FRIENDLY PERFORMANCE
■ Intuitive, leading edge touch screen display with adjustable viewing angle
■ Automatically employed diagnostics to ensure optimal hardware configuration
and performance
■ Advanced micro controller technology
TSP Features and Benefits
■ Continuous ground fault and current measurement
PLUG-AND-PLAY SYSTEM ARCHITECTURE

■ Patented “all-in-one” control card designed for reliability
■ Modular 6-zone cards; 15 amps per zone
■
Field calibration mode
■ Universal power supply
|
TSP Temperature Control System
OPTIMIZES PERFORMANCE FOR ALL HOT RUNNER SYSTEMS

■ Unique low voltage soft-start feature maximizes heater life
■ Uniform startup feature reduces scrap and energy usage
■ Proprietary adaptive auto-tuning control algorithm
■ Phase angle or burst firing modes (time proportional, zero-crossing)
ROBUST, HIGH-QUALITY DESIGN

■ Compact solid metal enclosure with heavy-duty industrial connectors
■ Mold and controller protection features
■ On-board heater and thermocouple fuses
■ Portable stand available
OPTIONAL 7" DISPLAY WITH ADVANCED FEATURE SET NOW AVAILABLE!
IMPORTANT NOTICE: TSP Controllers are not designed to control all zones as manifold zones.
Doing so will cause the main circuit breaker to trip.

text
TSP Temperature Control System 107
TSP Specifications
Specifications
TSP™ TEMPERATURE CONTROL SYSTEM SPECIFICATIONS
User Interface Full-color LCD touch screen on all HMI models
Display Size 5.7" QVGA
Calibration Accuracy 0.5˚C / 1˚F
Control Accuracy +/- 0.5˚C / 1˚F
Power Response Time 8.3 ms at 60 Hz
Control Algorithm Adaptive PID 2 with auto-tuning

Degree (F or C) Software selectable
Thermocouple J- or K-Type, software selectable
Operating Range 0 - 472˚C or 32 - 882˚F
Output Voltage Maximum 264 VAC
Supply Voltage 200/240 Delta or 380/440V 3Ø Star
40A 3-phase breaker for 6- and 12-zone control units
Supply Breaker
63A 3-phase breaker for 18- to 48-zone control units
Frequency 50 - 60 Hz automatic switching
Ambient Temperature Range 5 - 45˚C (41 - 113˚F)
Humidity Range Up to 95% non-condensing
Ground Fault Detection 40mA per zone
Power Control Phase angle or burst firing modes (time proportional, zero-crossing)
Overload Protection Semi-conductor fuses on both heater legs
Control Modes Closed loop (auto), open loop (manual), standby, boost mode and slave mode
|
TSP Specifications
Alarm Output Closing contact relay, max. 5A, 230V
T/C and Power Connector HAN 24e or 3
LED Indicators Fault, Scan
Soft-Start with Auto-Tune Unique low voltage method for heater safety
Input Protection Plug-in nano fuses on both TC legs
Port (optional) USB
ITEM NUMBER SLOTS # OF ZONES AVAILABILITY

ITS-06-15 1 6 Special order; contact DME
ITS-12-15 2 12 In stock

text
108 TSP Temperature
textControl System
TSP Component Ordering Information
Mold Power Cables (15 AMP Max)

ITEM ITEM ITEM NUMBER FROM 15 AMP TO POWER INPUT
MPC12C10G NUMBER NUMBER NUMBER OF ZONES FRAME (S) CONNECTOR
(MAX.)
10 FOOT LONG 20 FOOT LONG 30 FOOT LONG FOR CONNECTIONS
MPC12C10G MPC12C20G MPC12C30G 12 12 ZONE PIC12G
TO FRAME TO MOLD
Thermocouple Cables (for 15 or 30 AMP Mainframes)

ITEM ITEM ITEM NUMBER FROM 15 AMP TO THERMOCOUPLE
TC12C10G NUMBER NUMBER NUMBER OF ZONES FRAME (S) CONNECTOR
(MAX.)
TC12C10G TC12C20G TC12C30G 12 12 ZONE MTC12G
Ordering Information
TO FRAME TO MOLD
ZONES CONTROLLER CABLES TERMINAL MOUNTING BOX
MPC12C10G
12 ZONES
OF CONTROL
+ (1 each)
+ PTC12TBTS (1 each)
| TSP |Component
(15 AMP)
blank
TC12C10G
ITS-12-15
Systems
MPC12C10G
24 ZONES
+ +
System
OF CONTROL (2 each) PTC12TBTS (2 each)

Control
(15 AMP)
TC12C10G
TSP Temperature Control
ITS-24-15
MPC12C10G
48 ZONES
OF CONTROL
(15 AMP)
+ (4 each) + PTC12TBTS (4 each)
TC12C10G
ITS-48-15
Module Replacement Fuses

(sold in packs of 5)
RPM0124
ITEM ITEM NUMBER DESCRIPTION AMPS

ITSTROLLEY RPM0123 POWER FUSE 15
RPM0124 TC FUSE .062

109
TSP Temperature Control System Series
TSP Plus Temperature Control System
Everything you loved about the original TSP controller with new enhanced features
for optimal control.
t Automatic Leak detection
t Enhanced 7” Color Touch screen
t Storage : up to 100 Tools
t Full IO function card with 4 input + 4 output for communication
t Optional Thermocouple to monitor steel temperature and alarm if cooling is off
t Accuracy 0.01 oF
t Ability to control Small Mass / High Watt density nozzles
t Field selectable PID (parameters) to optimize control process
t APS technology (Adaptive Process System)
t SPI communication Protocol via RS232/RS485 included
ITEM NUMBER SLOTS # OF ZONES

ITSP-12-15 2 12
ITSP-24-15 4 24

ITSP-48-15 8 48
Custom zone configurations available upon request
ITEM NUMBER DESCRIPTION

PCB replacement card, 6
ITSCGR-A
zones @ 15 AMP
See reverse side for accessories 7”
SMART SERIES USER-FRIENDLY PERFORMANCE OPTIMIZES PERFORMANCE FOR ALL HOT
t *OUVJUJWF MFBEJOHFEHFUPVDITDSFFOEJTQMBZXJUIBEKVTUBCMF RUNNER SYSTEMS
|
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TSP Plus
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PLUG-AND-PLAY SYSTEM ARCHITECTURE

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ROBUST, HIGH-QUALITY DESIGN
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t 1PSUBCMF TUBOE BWBJMBCMF
IMPORTANT NOTICE: Smart Series Controllers are not designed to control all zones as manifold zones.
Doing so will cause the main circuit breaker to trip.

text
110 TSP Temperature
textControl System
TSP Plus Component Ordering Information

ITEM ITEM ITEM NUMBER FROM 15 AMP TO POWER INPUT
MPC12C10G NUMBER NUMBER NUMBER OF ZONES FRAME (S) CONNECTOR
(MAX.)
MPC12C10G MPC12C20G MPC12C30G 12 12 ZONE PIC12G
TO FRAME TO MOLD
Thermocouple Cables (for 15 or 30 AMP Mainframes)

ITEM ITEM ITEM NUMBER FROM 15 AMP TO THERMOCOUPLE
TC12C10G NUMBER NUMBER NUMBER OF ZONES FRAME (S) CONNECTOR
(MAX.)
TC12C10G TC12C20G TC12C30G 12 12 ZONE MTC12G
TO FRAME TO MOLD
ZONES CONTROLLER CABLES TERMINAL MOUNTING BOX
MPC12C10G
| blank| TSP Plus
12 ZONES
OF CONTROL
(15 AMP) + (1 each)
+ PTC12TBTS (1 each)
TC12C10G
Control System
ITSP-12-15
Control Systems
MPC12C10G
24 ZONES
OF CONTROL
TSP Temperature
(15 AMP)
TC12C10G
ITSP-24-15
MPC12C10G
48 ZONES
OF CONTROL
(15 AMP)
TC12C10G
ITSP-48-15
ITEM ITEM
ITSPTROLLEY ITSPALRMLT
Module Replacement Fuses
(sold in packs of 5)
RPM0124
ITEM NUMBER DESCRIPTION AMPS
RPM0123 POWER FUSE 15
RPM0124 TC FUSE .062

Smar t Series ®
ROHS/WEEE-COMPLIANT
TEMPERATURE CONTROLS
FOR HOT RUNNER SYSTEMS
112 Smart Series®
RoHS/WEEE Compliant
Advanced Temperature Control for Hot Runner Systems
Capability/RoHS and WEEE Compliant

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Electrical Noise Immunity

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|
Smart Series®

Smart Series® 113
CE COMPLIANT! DME Mainframes and Modules comply with

Electromagnetic compatibility and low voltage directives
Control Modules
SSM (15 and 30 AMP): 5IF44.NPEVMFQSPWJEFTBDDVSBUFUFNQFSBUVSFDPOUSPM JODMVEJOH4NBSU4UBSU®
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USBOTGFS5IJTNPEVMFJTBMTPGVMMZDPNQBUJCMFXJUIUIF5"4NPEVMFGPSTUBOECZIFBUBOEBMBSNGVODUJPOT
Accessory Modules
TAS: 5IF5"4NPEVMFQSPWJEFTPWFSVOEFSWJTVBMBOEBVEJCMFBMBSNT CPPTU BOETUBOECZIFBUDPOUSPM
XJUIDPOUSPMNPEVMFTBTTUBUFEBCPWF5IF5"4NPEVMFDBOBDDPNNPEBUFVQUP[POFTPGDPOUSPM
SSM1512 "MBSNJTBDUJWBUFEBU¡'4FFQBHFTGPSEFUBJMT
NOTE: 5IF5"4BDDFTTPSZNPEVMFSFRVJSFTUIFVTFPGi.'$wTUZMFDPNNVOJDBUJPOTNBJOGSBNFT
Smart Series®
/PODPNNVOJDBUJPOTGSBNFTNBZCFVQHSBEFEPOTJUFXJUIJOTUBMMBCMFLJUT
|
CE COMPLIANT! Control Modules
Simplified Power Hook-Up
Concern for user convenience didn’t stop with improved operation features. DME
went one step beyond
DSS1512 to ensure that the power hook-up procedure goes smoothly as well. For this reason,
detailed schematics
for various hook-ups are provided directly on all mainframe back panels. If it is ever
necessary to change
the configuration, these diagrams will help ensure safe and proper connections. All
wiring diagrams can
be referenced at the end of this section.
SSH Controller (10 AMP)

5IF44)JTBTUBOEBMPOFTJOHMF[POFDPOUSPMMFSJEFBM
GPSVTFXJUIIPUTQSVFCVTIJOHTPSNBDIJOFOP[[MFT
SSH1022

114 Smart Series®
Smart Series® Temperature Control Systems
1 Mainframe
2 Circuit Breaker/Disconnect
3 Mold Power Cable
4 Thermocouple Cable
5 Mold Power Input Connector
6 Insulated Crimp Connector
7 Thermocouple Connector
8 Terminal Mounting Boxes
9 Mainframe Blank Panels
10 Module Replacement Fuses
TABLE OF CONTENTS PAGE
11 Control Modules
Introduction................................................................................................................................ 112-113
Typical System Configurations .......................................................................................................115
SSH Single Zone Controller ..................................................................................................... 116-117
Single and Two-Zone Mainframes and Accessories.......................................................... 118-121
Single Zone High Power Mainframes............................................................................................121
Smart Series Mainframes........................................................................................................ 122-124
Digital Current / Voltage Monitor ...................................................................................................125
Smart Series Accessories ...............................................................................................................126
Standard Mainframe Connector Wiring........................................................................................127
Wiring Diagram for Hot Runner Molding System
and Smart Series / G-Series Mold Connectors .........................................................................128
Wiring Diagram for Hot Runner Molding System
|
and High Power Smart Series / G-Series Mold Connectors ...................................................129

Smart Series®
Cables and Connector Kits ...................................................................................................... 131-132

Mold Connector Pocket Layouts ............................................................................................ 133-134
Terminal Mounting Boxes ........................................................................................................ 135-136
SSM Temperature Control Modules ...................................................................................... 137-138
DSS Temperature Control Modules ....................................................................................... 139-140
TSM Temperature Control Module with Color Touch Screen ........................................... 141-142
TAS Temperature Alarm / Standby Heat Modules .............................................................. 143-144
Replacement Parts and Service Items .................................................................................. 145-147
Input Power Wiring Diagrams ................................................................................................ 148-150
Alternate Cable Configuration ................................................................................................ 151-153
Terminal Box Detail & Mold Connectors – European .................................................................154
Cable Storage Basket.......................................................................................................................155

Smart Series® 115
Typical System Configurations

SSM1512
DSS1512 5 Zones of Control (15 AMP)
+ + MPC5C10G + PTC5TBTS +
MFP5G
MFS512G
X5 TC5C10G
SSM1512 8 Zones of Control (15 AMP)

DSS1512
+ + MPC8C10G
+ PTC8TBTS +
MFP8G
MFS512G
X8 TC8C10G
Smart Series®
SSM1512
DSS1512
12 Zones of Control (15 AMP)
+ + MPC12C10G
+ +
|
PTC12TBTS
Typical System Configurations

MFP12G
TC12C10G MFS512G
X12
SSM3012 2 or 3 Zones of High Power Control (30 AMP)
DSS3012
MTC5G
+ + MPCH23C10G + + +
MFHP2G
MFHP3G
PTCH23TBG
MFS512G
TC5C10G PICH23G
X2 or 3X
SSM3012 5 Zones of High Power Control (30 AMP)
DSS3012
MTC5G
+ + MPCH5C10G
+ + +
MFHP5G
PTCH5TBG
MFS512G
X5 TC5C10G PICH5G

116 Smart Series®
RoHS/WEEE Compliant
®
Smart Series Single Zone Temperature Controller
SSH1022/21 (10 AMP)
t $PNQBDU
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Key Features Operational Refinements

t Large Digital Display t Improved SmartStart®
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t Shorted Thermocouple Sensitivity Adjustment t Third Fuse
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t Switchable °C/°F Operation
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t K Type Thermocouple Support
|
t Cut Feature
Smart Series®
(BJODVUGFBUVSFGPSTNBMMOP[[MFTBOEIFBUFSTXJUI
VOHSPVOEFEJOUFSOBMUIFSNPDPVQMFT
Front Panel Digital LED Indicators
BACKWARD SHORTED OPEN BUMPLESS FRONT PANEL TEMP MODE TEMP MODE PROCESS MANUAL LOCKOUT
THERMOCOUPLE THERMOCOUPLE THERMOCOUPLE TRANSFER LOCKOUT FAHRENHEIT CENTIGRADE TEMP % POWER ERROR

Smart Series® 117
RoHS/WEEE Compliant
®
SSH1022/21 (10 AMP)
$POUSPMMFSJODMVEFTGPPUQPXFSDPSE NBUJOHNPMEQPXFSBOEUIFSNPDPVQMFDPOOFDUPS
$,15.
BOEUXPTQBSFGVTFT "#$
"EEJUJPOBMDBCMFTBOEPSDPOOFDUPSTNVTUCF
CONTROLLER VOLTS PSEFSFETFQBSBUFMZ4FF1BHFGPSEFUBJMFEJOGPSNBUJPOPODBCMFTBOEDPOOFDUPST
ITEM NUMBER (VAC) Warranty: Two year (excluding triac and fuses).
SSH1022 240 4
SSH1021 120
6
CABLE* LENGTH
ITEM NUMBER (FEET)
MPTC10 10
MPTC20 20
4FFQBHF
Smart Series®
CKPTM1 1 2 3
INCLUDED 5
Front Panel Controls and Indicators
|
1. Process Temperature Display:

4IPXTQSPDFTTUFNQFSBUVSF UIFSNPDPVQMFGBVMUTBOEPUIFSPQFSBUJPOBMNPEFT
MOLD POWER AND %JTQMBZTQPXFSXIFOTXJUDI
JTQSFTTFEEPXO
THERMOCOUPLE CONNECTOR* 2. Temperature Deviation Lights:
ITEM NUMBER *OEJDBUFTEFWJBUJPOGSPNTFUQPJOU0VUFSMJHIUTCMJOLBUNPSFUIBO' $

GSPNTFUQPJOU
CKPTIC1
3. Auto / Manual / % Auto Power Switch:
4FFQBHF 4FMFDUT"650PS."/6"-DPOUSPMNPEF4IPXTQPXFSXIFOQSFTTFEJOUP
i"650wQPTJUJPO
4. LED Mode Indicators:
-FGU-&%JMMVNJOBUFTEVSJOHNBOVBMNPEF3JHIU-&%JMMVNJOBUFTXIFOQPXFS
JTTVQQMJFEUPIFBUFS3JHIU-&%CMJOLTEVSJOH4NBSU4UBSU®
5. Setpoint Pushwheel:
5ISFFEJHJUTXJUDIQSPHSBNTTFUQPJOUJO"650NPEF3JHIUUXPEJHJUTQSPHSBN
QPXFSJO."/6"-NPEF
6. Power On/Off Switch:
* ITEMS ORDERED $POUSPMT"$QPXFSUPNPEVMF
SEPARATELY
Rear Panel
3 1. Mold Power and Thermocouple Output Connector:
$,15*$DPOOFDUTUPUIFIFBUFSBOEUIFSNPDPVQMF.BUJOHDPOOFDUPS
$,15.JTTVQQMJFEXJUIDPOUSPMMFS
2. Power Input Cord:

/JOFUFFOGPPUDPSETVQQMJFTQPXFSUPDPOUSPMMFS1MVHTVQQMJFEXJUI
44) 7"$
VOJUT/PQMVHTVQQMJFEXJUI44)
1 2
3. Load Fuse Receptacles:
1SPWJEFTTBGFBOEFBTZSFQMBDFNFOUPGMPBEGVTFT

118 Smart Series®
RoHS/WEEE Compliant
®
Smart Series Single and 2-Zone Mainframes (10 AMP max.)
Single and Two-Zone 10 AMP Mainframes
5IF%.&1PSUBCMF".1.BJOGSBNFTBSFEFTJHOFEGPSVTFXJUIPS".1
4NBSU4FSJFTPS(4FSJFT5FNQFSBUVSF$POUSPM.PEVMFT.BJOGSBNFJTTVQQMJFEXJUI
QPXFSJOQVUBOEQPXFSUIFSNPDPVQMFPVUQVUDPOOFDUPST$JSDVJUCSFBLFSQSPWJEFT
TBGFUZGPSPQFSBUJPO$POUSPMNPEVMFTBOEDBCMFTBSFUPCFPSEFSFETFQBSBUFMZ
NOTE: .BYJNVNTBGFPQFSBUJOHBNQFSBHFJT".14QFS[POFXIFOVTJOH
".1NPEVMFT*GBQQMJDBUJPOXJMMESBXNPSFUIBO".14QFS[POF
VTF".1.BJOGSBNF .''13(

A MFP1G
6TFSNVTUJOTUBMM"#$ ".1
GVTFTJOUIF".1DPOUSPMNPEVMFTUPQSPUFDUUIFNBJOGSBNF
MFP1G1
Single and Two-Zone 10 AMP Mainframes
B
(50-60 Hz, single phase)
A: "$' 1PXFSUP.BJOGSBNF

ITEM WATTS CONNECTORS
"$'TVQQMJFEXJUI.'1( ZONES VOLTS
NUMBERS ** PER ZONE SUPPLIED
B: $,15. $POOFDUPSUPIFBUFS
Smart Series Single and 2-Zone Mainframes
(1) AC1512F (POWER IN)

1 MFP1G1 120 1200
5IJTTJOHMF[POFDPOUSPMMFSJTJEFBMGPS (1) CKPTM1 (POWER-T/C OUT)
VTFXJUI4USBJHIU4IPUBOE(BUF.BUF (1) AC2024F (POWER IN)
IPUTQSVFCVTIJOHT 1 MFP1G 240 2400
(1) CKPTM1 (POWER-T/C OUT)
2 MFPR2G 240 2400
(1) CKPTM1 (POWER-T/C OUT)
*ODMVEFTGSBNFBOEDPOOFDUPSTMJTUFE.PEVMFTBOEDBCMFTPSEFSFETFQBSBUFMZ.
NOTE: 3FQMBDFNFOUQPXFSDPOOFDUPSTJOGSBNFBSFBMTPBWBJMBCMFPOTQFDJBMPSEFS
Recommended Mold Pocket Layout

(For Mold Power-Thermocouple Input Connector CKPTIC1)
MFPR2G
A
|
Smart Series®
A: "$' 1PXFSUP.BJOGSBNF
B: $,15. $POOFDUPSUPIFBUFS
Single zone, horizontal

10 amp controllers
(SSH1022/21) also
available. See page 116
DIMENSIONS
BMMGSBNFT
8Y)Y%
)EJNFOTJPOEPFTOPU
JODMVEFDPOOFDUPSTPSIBOEMF

Smart Series® 119
RoHS/WEEE Compliant: Smart Series® Single and

2-Zone Mainframe Accessories (10 AMP)
For Use With MFP1G, MFP1G1, MFPR2G, SSH1022 and SSH1021
Mold Power-Thermocouple Input Connector
ITEM "4JOHMF;POF1PXFS5IFSNPDPVQMF*OQVU$POOFDUPSJTBWBJMBCMFGPSNPVOUJOHJOPSPO
NUMBER UIFNPMEUPBDDFQUUIFQPXFSUIFSNPDPVQMFDBCMFGSPNUIFNBJOGSBNF8BUFSSFTJTUBOU
CKPTIC1 UIFDPOOFDUPSIBTBOJOUFHSBMSFUBJOJOHMBUDIGPSBTFDVSFDBCMFDPOOFDUJPOBOEOVNCFSFE
TDSFXUZQFUFSNJOBMTGPSQPXFSBOEUIFSNPDPVQMFMFBEXJSFT
$BOCFNPVOUFEPOUPQPGNPMEGPSVTFXJUIIPUTQSVFCVTIJOHT
Armored Mold Power-Thermocouple Cables

ITEM
NUMBER 4JOHMF;POF.PME1PXFS5IFSNPDPVQMF$BCMFTBSFDPOTUSVDUFEPGTQFDJBMMFBEXJSFGPS
MPTC10 VTFJOIJHIUFNQFSBUVSFFOWJSPONFOUT BOEBSFBWBJMBCMFUPDPOOFDUUIFNBJOGSBNFUPUIF
Smart Series®
DPOOFDUPSPOUIFNPME"WBJMBCMFJOMFOHUITPGPSGFFU*OUFHSBMSFUBJOJOHMBUDIFT
MPTC20
POUIFNBJOGSBNFBOENPMEDPOOFDUJPOTQSPWJEFTFDVSFDBCMFDPOOFDUJPOT$POOFDUPS
DPOGJHVSBUJPOTFOTVSFQSPQFSJOTFSUJPOPGDBCMF
Replacement Connector Kits (for Controller & Cables)

MALE POWER – T/C CONNECTORS: FEMALE POWER – T/C CONNECTORS:
|
$,15.JTPO.15$$BCMFT $,15'JTPO.15$$BCMFT
Smart Series Single and 2-Zone Mainframe Accessories

1PXFS*OQVU$POOFDUPST .BUFTXJUI'SBNFPS$,15'-POMZ .BUFTXJUI.PMEPS$,15.-POMZ

'PS.BJOGSBNF $,15.-.BUFT8JUI$,15'POMZ $,15'-.BUFTXJUI$,15.POMZ
MALE
CKPTF1 5 4
AC1512F CKPTM1 1
3 GPS$,15*$
2
+ - BOE$,15.
PS$,15.-
W
PTC210
AC2024F CKPTM1L CKPTF1L B
ITEM ITEM ITEM

VOLTS ITEM FEMALE
NUMBER NUMBER NUMBER
NUMBER 5 1
AC1512F 120 CKPTM1 CKPTF1
PTC210 4
AC2024F 240 CKPTM1L CKPTF1L 2
3 GPS$,150$
- + BOE$,15'
1PXFS5IFSNPDPVQMF0VUQVU Terminal Mounting PS$,15'-
B
$POOFDUPS GPS.BJOGSBNF#VMLIFBE
Boxes – Prewired
(10 AMP) 5 Pin W
ITEM
NUMBER 5FSNJOBM.PVOUJOH#PYFTQSPWJEFUIFFBTJFTUBOENPTU
CKPTOC1 FDPOPNJDBMNFUIPEPGNPVOUJOHQPXFSBOEUIFSNPDPVQMF
DPOOFDUPSTPOUIFNPME$POTUSVDUFEPGQMBUFEIFBWZHBVHF
TUFFM FBDICPYJTQSFDVUBOEESJMMFEGPSRVJDLNPVOUJOHPG
ITEM NUMBER
UIFCPYUPUIFNPME [POF QSFXJSFEUFSNJOBMNPVOUJOH
PTC210TBGTS CPYXJUIUFSNJOBMTUSJQTIPXOXJUIDPWFSQMBUFSFNPWFE


120 Smart Series®
Smart Series® 2-Zone Mainframes (15 AMP) and Accessories
Two-Zone 15 AMP Mainframes

T
MFFPR2G 1
1SPWJEFT".1 XBUUT
QFS[POF'PSVTFXJUI4NBSU4FSJFTPS(4FSJFTNPEVMFT
44VQQMJFEXJUICVJMUJODPPMJOHGBO QPXFSJOQVU QPXFSPVUQVUBOEUIFSNPDPVQMFJOQVU
DDPOOFDUPST$POUSPMNPEVMFTBOEDBCMFTBSFPSEFSFETFQBSBUFMZ
TTWO-ZONE 15 AMP MAINFRAME (240 VAC, 50-60 Hz, SINGLE PHASE)
ITEM NUMBER WATTS PER ZONE CONNECTORS SUPPLIED
MFFPR2G 3500 (1) AC1524M (POWER OUT)
(2) M2MJ (T/C IN)
**ODMVEFTGSBNFBOEDPOOFDUPSTMJTUFE.PEVMFTBOEDBCMFTPSEFSFETFQBSBUFMZ
NOTE: 3FQMBDFNFOUQBSUTJOGSBNFBSFBMTPBWBJMBCMFCZTQFDJBMPSEFS
N
4FFQBHFT
AC1240F
1240F
M2MJ ITEM NUMBERS DESCRIPTION
AC1524M
Smart Series 2-Zone Mainframes and Accessories
Female 240 VAC twist-lock power input connector

AC1240F*
(mates with male frame power input)
Male 240 VAC power output connector
AC1524M*
(mates with female frame power outputs)
Thermocouple mini-plug
M2MJ*
FRAME DIMENSIONS: (mates with frame jack strip connector)
8Y)Y% 2 zone, pre-wired terminal mounting box with terminal strip
PTC2TBGTS
)EJNFOTJPOEPFTOPU (mounts to mold; mates with PTC0110 or PTC0129 cables)
*ODMVEFEXJUI.''13(
Armored Mold Power –

Thermocouple Cables (15 AMP)
4JOHMF;POF.PME1PXFS5IFSNPDPVQMF$BCMFJT
DPOTUSVDUFEPGTQFDJBMMFBEXJSFGPSVTFJOIJHI
UFNQFSBUVSFFOWJSPONFOUT5IJTDBCMFDPOOFDUT
ITEM NUMBER UIFNBJOGSBNFUPUIFDPOOFDUPSPOUIFNPME
|
"WBJMBCMFJOMFOHUITPGPSGFFU3FUBJOJOH
Smart Series®
PTC0110
MBUDIFTPOUIFNPMEDPOOFDUPSQSPWJEFTFDVSF
PTC0120 DBCMFDPOOFDUJPOT
'PSVTFXJUI.''13(POMZ
Terminal Mounting Boxes –

Prewired (15 AMP)
5FSNJOBM.PVOUJOH#PYFTQSPWJEFUIFFBTJFTUBOE
NPTUFDPOPNJDBMNFUIPEPGNPVOUJOHQPXFSBOE
UIFSNPDPVQMFDPOOFDUPSTPOUIFNPME$POTUSVDUFE
PGQMBUFEIFBWZHBVHFTUFFM FBDICPYJTQSFDVUBOE
ESJMMFEGPSRVJDLNPVOUJOHPGUIFCPYUPUIFNPME
ITEM NUMBER [POF QSFXJSFEUFSNJOBMNPVOUJOHCPYXJUI
PTC2TBGTS UFSNJOBMTUSJQTIPXOXJUIDPWFSQMBUFSFNPWFE

'PSVTFXJUI.''13(POMZ NOTE: QJODPOOFDUPSTBOEQJOTBSFBWBJMBCMFBTBTQFDJBMPSEFSPOMZ5IFTFBSFDSJNQ

DPOUBDUT 4FFQBHFTGPSNPVOUJOHEJNFOTJPOT

Smart Series® 121
Smart Series® Single Zone

High Power Mainframes (30 AMP Max.)
MFHP1G 5IF%.&1PSUBCMF4JOHMF;POF)JHI1PXFS.BJOGSBNFJTEFTJHOFEGPSVTFXJUI".1
4NBSU4FSJFTPS(4FSJFTUFNQFSBUVSFDPOUSPMNPEVMFT.BJOGSBNFJTTVQQMJFEXJUICVJMUJO
DPPMJOHGBO QPXFSJOQVU QPXFSPVUQVU BOEUIFSNPDPVQMFJOQVUDPOOFDUPST$JSDVJUCSFBLFS
QSPWJEFTTBGFUZGPSUIFPQFSBUPS$POUSPMNPEVMFTBOEDBCMFBSFPSEFSFETFQBSBUFMZ
Single Zone 30 AMP Mainframes (240 VAC, 50-60 Hz, Single Phase)
Replacement Connectors and Accessories
M2MJ
AC1240F
Smart Series®
AC1240M
FRAME DIMENSIONS:
8Y)Y%
)EJNFOTJPOEPFTOPU
|
Smart Series Single Zone High Power Mainframes

D E
*Included with MFHP1G mainframe
NOTE: Overall dimensions

shown include allowances
for hardware (assembly
screws) but not connectors
TERMINAL MOUNTING BOX

PTCH1TBG
$POOFDUPSTTIPXOBSF
PSEFSFETFQBSBUFMZ
D: TCS1
E: AC1240MI

122 Smart Series®
Smart Series® Mainframes (15 AMP)
WIDTH (W)
Smart Series® Mainframe (15 AMP Max.)
Configurations
5IFDPOGJHVSBUJPOTJMMVTUSBUFECFMPXQSPWJEFBXJEFTFMFDUJPOPG[POFDBQBDJUJFT
Main AC power
UPTVJUNPTUDPOUSPMBQQMJDBUJPOT5IF BOE[POFGSBNFT .'1 BOE(

Cooling Fan
input strain relief VTFJOEJWJEVBMGSBNFTFDUJPOT5IFUISV[POFGSBNFTVTF PSGSBNFTFDUJPOT
SJHJEMZGBTUFOFEUPHFUIFSJOUPPOFQSFXJSFEJOUFHSBMVOJUXIJDISFRVJSFTPOMZPOFNBJO
"$QPXFSJOQVUDPOOFDUJPO5IF$VSSFOU7PMUBHFNPOJUPSPQUJPOXJMMCFGBDUPSZJOTUBMMFE
XIFOPSEFSFEBUTBNFUJNFBT.BJOGSBNF$POUSPMNPEVMFT DBCMFT NPMEDPOOFDUPST
BOEPUIFSBDDFTTPSJFTBSFPSEFSFETFQBSBUFMZ TFFUBCMFPOOFYUQBHF

Thermocouple &BDIGSBNFTFDUJPO
input with
retaining .'1( .'1(
latch
BOE.'1(
IBT
Power output
with retaining
9" JUTPXODPPMJOHGBO
latch
.VMUJTFDUJPOGSBNF
IFJHIUTBSFNVMUJQMFT
12"
PGIFJHIUTIPXO
Smart Series® Mainframes
WORLDWIDE WIRING FH.'1(JT

CAPABILITIES IJHI

6OMFTTPUIFSXJTFTQFDJGJFE BMM .BJO"$JOQVU
4NBSU4FSJFT.BJOGSBNFTXJMMCF
TVQQMJFEUPBDDFQU7"$ QIBTF TIPXOXJMMBMXBZT
XJSF )[JOQVUQPXFS8JSJOH CFJOCPUUPNGSBNF
EJBHSBN JODMVEFEPOUIFBDDFTTDPWFS
TFDUJPO'PSIJHIFS
JMMVTUSBUFTUIFWBSJFUZPGPUIFSWPMUBHF
QPXFSSFRVJSFNFOUT
QIBTFBOEMPBECBMBODJOHBSSBOHFNFOUT
QPTTJCMF TVDIBT 7 QIBTF JOEJWJEVBMQPXFS
XJSF )[
7 TJOHMF JOQVUTBOEDJSDVJU
|
QIBTF XJSF )[

BOE 7 CSFBLFSTDBOCF
Smart Series®
TJOHMFQIBTF XJSF )[

These wiring adjustments can be
GBDUPSZJOTUBMMFEJO
performed in the field to suit the FBDITFDUJPOPGB
requirements of the application. TUBDLGSBNFPOB
If specified at the time of original TQFDJBMPSEFSCBTJT
order, DME will supply the
Mainframe required.
MOLD POWER CABLE (10, 20 OR 30 FOOT)
ITEM NUMBER W*
THERMOCOUPLE CABLE (10, 20 OR 30 FOOT)
.'1(
.'1(
.'1(
%JNFOTJPOEPFTOPUJODMVEF
DPOOFDUPST
NOTE: $PNCJOBUJPOGSBNFTUP
BDDPNNPEBUFCPUIBOE
".1NPEVMFT XJUIPS
XJUIPVUDPNNVOJDBUJPOT

BSFBWBJMBCMFCZTQFDJBMPSEFS

Smart Series® 123
Smart Series® Mainframes (15 AMP)
SMART SERIES MAINFRAMES

CABLES AND MOLD CONNECTORS REQUIRED
Optional Current Voltage Monitor
(Not included with Mainframes and Must be Ordered Separately)
is Factory Installed in CV-Style Frames
Z “MFP” TYPE FOR “MFP” TYPE WITH “MFCP” TYPE FOR “MFCP” TYPE WITH MOLD POWER CABLES THERMOCOUPLE CABLES MOLD POWER INPUT
THERMOCOUPLE
O TEMP. AND CURRENT VOLTAGE TEMP. CONTROL AND CURRENT VOLTAGE C10=10 FT. C20=20 FT. C30=30 FT. C10=10 FT. C20=20 FT. C30=30 FT. CONNECTORS (INCL.
CONNECTORS
N POWER CONTROL MONITOR COMMUNICATIONS MONITOR (SELECT LENGTH DESIRED) (SELECT LENGTH DESIRED) CRIMP CONNECTORS)
E ITEM ITEM NUMBER ITEM ITEM NUMBER ITEM ITEM ITEM ITEM
S QTY. QTY. QTY. QTY.
NUMBER (CV-STYLE) NUMBER (CV-STYLE) NUMBER NUMBER NUMBER NUMBER
5 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
8 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
12 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
16 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(

20 .'1( .'1($7 .'$1( .'$1($7 and and and and
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
24 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(

28 .'1( .'1($7 .'$1( .'$1($7 and and and and
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(

32 .'1( .'1($7 .'$1( .'$1($7 and and and and
Smart Series®
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
36 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(

40 .'1( .'1($7 .'$1( .'$1($7 and and and and
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(

44
|
.'1( .'1($7 .'$1( .'$1($7 and and and and
.1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
Smart Series® Mainframes

48 .'1( .'1($7 .'$1( .'$1($7 .1$$( $(PS$( 5$$( $(PS$( 1*$( .5$(
NOTE:'PSEFUBJMTPODBCMFTBOEDPOOFDUPST TFFQBHFT
Terminal Mounting Boxes

ORDER ITEMS A and B or C ORDER ITEMS A and B or C
Z Z
O (A) (B) (C) O (A) (B) (C)
N FOR POWER INPUT FOR THERMOCOUPLE CABLES COMBINATION N FOR POWER INPUT FOR THERMOCOUPLE CABLES COMBINATION
E CONNECTORS CONNECTORS POWER & TC E CONNECTORS CONNECTORS POWER & TC
S ITEM ITEM ITEM S ITEM ITEM ITEM
QTY. QTY. QTY. QTY. QTY. QTY.
NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER
5 1*$5#( .5$5#( 15$5#( .5$5#( 15$5#(
8 1*$5#( .5$5#( 15$5#( 32 1*$5#( and and
.5$5#( 15$5#(
12 1*$5#( .5$5#( 15$5#(
36 1*$5#( .5$5#( 15$5#(
16 1*$5#( .5$5#( 15$5#(
.5$5#( 15$5#(
.5$5#( 15$5#( 40 1*$5#( and and
20 1*$5#( and and .5$5#( 15$5#(
.5$5#( 15$5#(
.5$5#( 15$5#(
24 1*$5#( .5$5#( 15$5#(
44 1*$5#( and and
.5$5#( 15$5#( .5$5#( 15$5#(
28 1*$5#( and and
.5$5#( 15$5#( 48 1*$5#( .5$5#( 15$5#(
NOTES: $PNCJOBUJPOUFSNJOBMNPVOUJOHCPYFTBSFBWBJMBCMFXJUIDPOOFDUPSTQSFXJSFEUPUFSNJOBMTUSJQT4FFQBHFGPSEFUBJMT
4FFQBHFGPSEJNFOTJPOBMEFUBJMT'PSCFMPXGMVTINPVOUJOHPGDPOOFDUPST TFFNPMEQPDLFUMBZPVUTPOQBHFT
4FFQBHFGPSDVSSFOUWPMUBHFNPOJUPS

124 Smart Series®
Smart Series® High Power Mainframes (30 AMP)
50 AMP 3-PHASE
CIRCUIT BREAKER HIGH POWER MOLD POWER CABLE (10, 20 OR 30 FOOT)
THERMOCOUPLE CABLE (10, 20 OR 30 FOOT)

9" (USE 5-ZONE CABLE) HIGH POWER
MOLD POWER
THERMOCOUPLE CONNECTOR INPUT CONNECTOR
TERMINAL MOUNTING BOX (OPTIONAL)
(14 3/16" WIDE)
INSULATED
CRIMP
50 AMP 3-PHASE CONNECTORS
CIRCUIT BREAKER (INCLUDED WITH
MOLD POWER
MAINFRAME WITH CIRCUIT BREAKER
INPUT
DISCONNECT IS STANDARD; CURRENT
9" CONNECTOR)
VOLTAGE MONITOR IS OPTIONAL
5IFDPOGJHVSBUJPOTJMMVTUSBUFEBUMFGUQSPWJEF PS[POFTPG".1DPOUSPMGPS
IJHIFSXBUUBHFIFBUFSBQQMJDBUJPOT5IF$VSSFOU7PMUBHFNPOJUPSPQUJPOXJMMCFGBDUPSZ
(20 3/16" WIDE)
JOTUBMMFEXIFOPSEFSFEBUUIFTBNFUJNFBT.BJOGSBNF$POUSPMNPEVMFT DBCMFT NPME
DPOOFDUPSTBOEPUIFSBDDFTTPSJFTBSFPSEFSFETFQBSBUFMZ
Smart Series® High Power Mainframes
70 AMP 3-PHASE
CIRCUIT BREAKER SMART SERIES HIGH POWER MAINFRAMES
Optional Current Voltage Monitor is Factory Installed in CV-Style Frames
Z “MFHP” TYPE FOR “MFHP” TYPE WITH “MFCHP” TYPE FOR TEMP. “MFCHP” TYPE WITH CURRENT
9" O TEMP. CONTROL CURRENT VOLTAGE MONITOR CONTROL AND COMMUNICATIONS VOLTAGE MONITOR
N
E ITEM ITEM NUMBER ITEM ITEM NUMBER
S NUMBER (CV-STYLE) NUMBER (CV-STYLE)
(28 3/16" WIDE) 2 .')1( .')1($7 .'$)1( .'$)1($7

3 .')1( .')1($7 .'$)1( .'$)1($7
DIMENSIONS ABOVE DO 5 .')1( .')1($7 .'$)1( .'$)1($7
NOT INCLUDE CONNECTORS
BMMGSBNFTBSFEFFQ CABLES AND MOLD CONNECTORS REQUIRED
(Not included with Mainframes and Must be Ordered Separately)
NOTE: #MBOLQBOFMTDPWFS Z MOLD POWER CABLES THERMOCOUPLE CABLES MOLD POWER INPUT
THERMOCOUPLE
O C10=10 FT. C20=20 FT. C30=30 FT. C10=10 FT. C20=20 FT. C30=30 FT. CONNECTORS
VOVTFE[POFTJOGSBNFT CONNECTORS
N (SELECT LENGTH DESIRED) (SELECT LENGTH DESIRED) (INCL. CRIMP CONNECTORS)
|
TIBEFEQBOFMTBCPWF
'PS E ITEM ITEM ITEM ITEM
Smart Series®
DPNNVOJDBUJPOT .'$)1
S QTY. NUMBER
QTY.
NUMBER
QTY.
NUMBER
QTY.
NUMBER
UZQFGSBNFT UIFTF 2 .1$)$( $(PS$( 5$$( $(PS$( 1*$)( .5$(
[POFTNBZCFVTFEGPS 3 .1$)$( $(PS$( 5$$( $(PS$( 1*$)( .5$(
DPNNVOJDBUJPONPEVMFT 5 .1$)$( $(PS$( 5$$( $(PS$( 1*$)( .5$(
NOTE: 'PSEFUBJMTPODBCMFTBOEDPOOFDUPST TFFQBHFT

Z
ORDER ITEMS A and B or C
O (A) (B) (C)
N FOR POWER INPUT CONNECTORS FOR THERMOCOUPLE CABLES CONNECTORS COMBINATION POWER & TC
E
S QTY. ITEM ITEM ITEM
QTY. QTY.
NUMBER NUMBER NUMBER
NOTE: $PNCJOBUJPOGSBNFT
2 1*$)5#( .5$5#( 15$)5#(
UP BDDPNNPEBUF
3 1*$)5#( .5$5#( 15$)5#(
CPUIBOE".1
NPEVMFT XJUIPSXJUIPVU 4 1*$)5#( .5$5#( 15$)5#(
DPNNVOJDBUJPOT
BSF
NOTE: 4FFQBHFGPSEJNFOTJPOBMEFUBJMT'PSCFMPXGMVTINPVOUJOHPGDPOOFDUPST TFF
BWBJMBCMFCZTQFDJBMPSEFS
NPMEQPDLFUMBZPVUTPOQBHFT

Smart Series® 125
Smart Series® Digital Current/Voltage Monitor
Streamlined Design For Improved Performance

5IFOFX$VSSFOU7PMUBHF.POJUPSJTTJNQMFUPPQFSBUFBOEGFBUVSFTBMBSHF 3
FBTZUPSFBEEJHJUBMEJTQMBZ&BTFPGPQFSBUJPOIBTCFFOFOIBODFECZTUSFBNMJOJOH
4
UIFVOJUBOEFMJNJOBUJOHVOOFDFTTBSZTXJUDIFTBOEDPOUSPMT8IFOTFUUJOHUIF
TFMFDUPSTXJUDIUPUIFEFTJSFE[POFOVNCFS UIFA".14GVODUJPOJTTFMFDUFE
5IFNFUFSXJMMUIFOEJTQMBZUIFBNPVOUPGDVSSFOUCFJOHEFMJWFSFECZUIFTFMFDUFE
NPEVMF*OQVUWPMUBHFUPUIFTZTUFNDBOCFNFBTVSFECZSPUBUJOHUIFTFMFDUPS 5
TXJUDIUPPOFPGUIFUISFFAMJOFWPMUBHFQPTJUJPOT5IJTXJMMTFUUIFNFUFSJOUIF
AWPMUBHFGVODUJPOBOEEJTQMBZUIFWPMUBHFPGUIFTFMFDUFEQIBTF
Current Supply To Each Zone

5PNPOJUPSUIFDVSSFOUTVQQMZUPFBDI[POF TJNQMZTFUUIFSPUBSZTFMFDUPSTXJUDI 2
UPUIFEFTJSFENPEVMF[POFOVNCFS5IFi".14wGVODUJPOJTUIFOBVUPNBUJDBMMZ
TFMFDUFEBOEJTJOEJDBUFECZUIFMFUUFS"KVTUUPUIFSJHIUPGUIFOVNCFSTJOUIF 1
Smart Series®
EJTQMBZXJOEPX5IFNFUFSEJTQMBZTUIFDVSSFOUCFJOHEFMJWFSFEUPUIFIFBUFSMPBE
JOBNQFSFT
Input Voltage From Each Phase

4FUUIFSPUBSZTFMFDUPSUPUIFEFTJSFEQIBTFWPMUBHFQPTJUJPO5IJTBVUPNBUJDBMMZ
TFMFDUTUIFAWPMUTGVODUJPOXIJDIJTJOEJDBUFEXIFOUIFMFUUFSA7BQQFBSTUPUIF
|
Smart Series® Digital Current/Voltage Monitor
SJHIUPGUIFOVNCFSTJOUIFEJTQMBZXJOEPX5IFNFUFSXJMMEJTQMBZUIFMJOFWPMUBHF
PGUIFTFMFDUFEQIBTF
1. CIRCUIT BREAKER/DISCONNECT – "QQMJFTPSSFNPWFTQPXFSUPBMMNPEVMFT
JOUIFGSBNF
2. POWER ON LIGHT (amber) – *MMVNJOBUFTXIFO$*3$6*5#3&",&3JTJOUIF
0/QPTJUJPO
3. AMPS/VOLTS METER – %JHJUBMNVMUJTDBMFNFUFSQSPWJEFTBDDVSBUFSFBEJOHT
PG[POFDVSSFOU ".14
PSJOQVUWPMUBHF 70-54

4. AMPS/VOLTS INDICATOR – "QQFBSTBVUPNBUJDBMMZXIFOFJUIFS".14PS
70-54JTTFMFDUFE
5. SELECTOR SWITCH – .VMUJQPTJUJPOTXJUDIBVUPNBUJDBMMZTFMFDUT[POF
DVSSFOUPSQIBTFMJOFWPMUBHFUPCFNPOJUPSFE'PSTZTUFNTXJUINPSFUIBO
[POFT BEEJUJPOBMNFUFSBOETFMFDUPSTXJUDIQBOFMTBSFTVQQMJFE
Specifications
Voltmeter Range UP7"$ GPSWPMUTZTUFNT
UP7"$ GPSWPMUTZTUFNT
NOTE: 5IF%JHJUBM$VSSFOU7PMUBHF.POJUPS
JTBGBDUPSZJOTUBMMFEPQUJPOXIJDI
Voltmeter Accuracy PGSFBEJOH UP)[ SFQMBDFTUIFTUBOEBSEDJSDVJU
CSFBLFSEJTDPOOFDU BOEJTTVQQMJFE
Maximum Voltmeter Input 7"$
XIFOi$7TUZMFwNBJOGSBNFT
Input Voltage 7"$ UP)[ BSFPSEFSFE
Ammeter Range UPUPUPANQFSFT
Ammeter Accuracy !UP%VUZ$ZDMF )[ See pages 123 and 124 for
appropriate mainframe
Maximum Ammeter Input "NQFSFT item numbers.

126 Smart Series®
Smart Series® Accessories
Universal Floor Stand

3 SECTIONS 'MPPSTUBOE
5IF6OJWFSTBM'MPPS4UBOEXJMMBDDPNNPEBUFBMMPSBNQ XJEUIBEKVTUT
1 SECTIONS .BJOGSBNFTGSPNPOFUPGPVSTFDUJPOTIJHI4UBOEJTNBEFGSPN GPSBOE
IFBWZHBVHFTUFFMBOEJODMVEFTMPDLJOHDBTUFST MCSBUJOH
[POF
2 SECTIONS "MMBTTFNCMZBOE.BJOGSBNFNPVOUJOHIBSEXBSFJTJODMVEFE NBJOGSBNFT
)FBWZEVUZGMPPSTUBOEBWBJMBCMFGPSMBSHFSTZTUFNT MCSBUJOH

4 SECTIONS
46"
ITEM NUMBER RATING
.'4( -#4
.'4()% -#4
)%TUBOEOPUTIPXO 28 1/4
'MPPSTUBOEDPNFTXJUIQMBUFTGPS[POFGSBNFNPVOUJOH
25 3/4" PO[POFiYwQBUUFSO
Step-Down Transformer Kits (from 480 VAC to 240 VAC)

5SBOTGPSNFS,JUTBSFQSFXJSFEBOEJODMVEFFODMPTFEUSBOTGPSNFS 7"$JOQVU 7"$PVUQVU

XJUIBEKVTUBCMFUSBOTGPSNFSWPMUBHFUBQT POFGPPUDBCMFGPS"$QPXFSJO OPDPOOFDUPS
POF
GPPUDBCMFGPSNBJOGSBNF "$JOQVU
POFTBGFUZTXJUDI UXPFYUSBGVTFT GMPPSTUBOE .'4(

BOEBMMNPVOUJOHCSBDLFUTBOEIBSEXBSFSFRVJSFE4IJQQFEXJUIJOTUSVDUJPOTGPSFBTZBTTFNCMZ
Smart Series® Accessories
4JOHMFTFDUJPOGSBNFTNPVOUUPGSPOUPSSFBSPGTUBOE Also Available:

ITEM NUMBER RATING 5SBOTGPSNFSPOMZ
5,"( ,7"
5SBOTGPSNFSBOEDBCMFTPOMZ
5,"( ,7"
5SBOTGPSNFSTXJUIPUIFSWPMUBHF
5,"( ,7"
PSDVSSFOUDBQBDJUJFT
5,"( ,7"
*TPMBUJPO5SBOTGPSNFST
.BJOGSBNFOPUJODMVEFE $POUBDU%.&GPSEFUBJMTBOEQSJDFT
"EBQUFSQMBUFTGPSOBSSPXFSGSBNFTBWBJMBCMFCZTQFDJBMPSEFS
$PNFTXJUIQMBUFTGPSNPVOUJOH[POFPO[POFiYwQBUUFSO
|
4VQQMJFEXJUI.'4()%GPSUIJTUSBOTGPSNFSTJ[FPSMBSHFBOEUSBOTGPSNFSTNPVOUFEGMBU
Smart Series®
NOTE: 1PXFSDBQBDJUZOFFEFEEFQFOETPOUPUBMMPBEPGTZTUFN
JFOVNCFSPG[POFTBOEIFBUFSMPBEQFS[POF

Mainframe Module Replacement Fuses Insulated Crimp Connectors

Blank Panels (sold in packages of 5) 'PSDPOOFDUJPOPGNPMEQPXFSJOQVUDPOOFDUPSMFBET
6TFEUPDPWFSVOVTFE UPIFBUFSMFBET '$NBYJNVNUFNQFSBUVSF
[POFTJONBJOGSBNFT
1VTIQVMMGBTUFOFST
JODMVEFEJOQBOFM
MFBP10G DPWFST ITEM NUMBER AMPS
POFAMP[POF "#$
MFBP30G DPWFST ITEM NUMBER AMPS RATING
"#$
POFAMP[POF PS )8$$ #BHPG
3&%
"#$
UXPAMP[POFT
)8$$ #BHPG
#-6&
9
ITEM NUMBER 9 )8$$ #BHPG
:&--08
.'#1( 31. NOTE: *OJUJBMTVQQMZJTQSPWJEFEXJUINPMEQPXFS
.'#1( 31. JOQVUDPOOFDUPST

Smart Series® 127
Smart Series® Mainframe Connector Wiring
Standard Mainframe Connector Wiring
SIDE OF
MAINFRAME
|Smart Series®
Smart Series® Mainframe Connector Wiring
High Power Mainframe Connector Wiring
SIDE OF
MAINFRAME

Smart Series® | Wiring Diagram with Smart Series® Mold Connectors
128
U.S. 800-626-6653

BLACK (+)
WHITE (+)
Canada 800-387-6600

Smart Series®
CHECK CONNECTIONS OF BLACK BLK BLK BLK
BETWEEN BLK & WHITE LEADS.

with Smart Series® Mold Connectors
dme@milacron.com

Wiring Diagram for DME Hot Runner Molding System
NOTES: "MMHSPVOETNVTUCFDPOOFDUFEUPNPMEUPFOTVSFPQFSBUPSTBGFUZ
www.milacron.com
"MMDSJNQDPOOFDUJPOTDBOCFFMJNJOBUFECZVTJOHUFSNJOBMNPVOUJOHCPYXJUIUFSNJOBMTUSJQ4FFQBHF
U.S. 800-626-6653
BLACK (+)

WHITE (+)
BLACK WHITE
Canada 800-387-6600

Smart Series®
dme@milacron.com

CHECK CONNECTIONS OF BLACK AND WHITE LEADS TO ENSURE
with High Power Smart Series® Mold Connectors
Wiring Diagram for DME Hot Runner Molding System
USE OHM METER TO MEASURE BETWEENF BLACK AND WHITE LEADS .
NOTES: "MMHSPVOETNVTUCFDPOOFDUFEUPNPMEUPFOTVSFPQFSBUPSTBGFUZ
www.milacron.com
"MMDSJNQDPOOFDUJPOTNBZCFFMJNJOBUFE4JNQMZSFNPWFMFBETGPSN1*$DPOOFDUPSTBOEXJSFEJSFDUMZ
Wiring Diagram with High Power Smart Series® Mold Connectors | Smart Series®
129
130 Smart Series®
Mold Power and Thermocouple Cables
.PME1PXFS$BCMFTBSFVTFEUPDPOOFDUUIF.BJOGSBNFUPUIF1PXFS*OQVU$POOFDUPSPOUIF
NPME"WBJMBCMFJOMFOHUITPG PSGFFU*OUFHSBMSFUBJOJOHMBUDIFTPOCPUIUIFGSBNFBOE
NPMEDPOOFDUPSTQSPWJEFTFDVSFDBCMFDPOOFDUJPOT$POOFDUPSDPOGJHVSBUJPOTFOTVSFQSPQFS
JOTFSUJPOPGDBCMF$BCMFTBSFXJSFEGPS PS[POFT ".1
BOEPS[POFT ".1

MPC12C10G GPSVTFXJUIUIFBQQSPQSJBUF4NBSU4FSJFT.BJOGSBNFTBOE.PME1PXFS*OQVU$POOFDUPST
Universal Mold Power Cable (15 AMP)

5IF.1$$( (PS(.PME1PXFS$BCMFBMTPTFSWFTBTBVOJWFSTBMDBCMFGPSDPOOFDUJOH
BOZ".14NBSU4FSJFT.BJOGSBNFUPBOZ".1.PME1PXFS*OQVU$POOFDUPS5IFNBYJNVN
OVNCFSPG[POFTXJMMCFEFUFSNJOFECZUIFDPOOFDUPSJOUIFNPME

10 FOOT LONG 20 FOOT LONG 30 FOOT LONG NUMBER FOR CONNECTIONS
OF ZONES
ITEM ITEM ITEM FROM 15 AMP TO POWER INPUT
(MAX.)
NUMBER NUMBER NUMBER FRAME (S) CONNECTOR
Mold Power and Thermocouple Cables
.1$$( .1$$( .1$$( ;0/& 1*$(

.1$$( .1$$( .1$$( ;0/& 1*$(
.1$$( .1$$( .1$$( ;0/& 1*$(

SPECIAL CABLES 10 FOOT LONG 20 FOOT LONG FOR CONNECTIONS
NUMBER OF ZONES
7JSUVBMMZBOZUZQFPG ITEM ITEM FROM 30 AMP TO POWER INPUT
(MAX.)
$POWFSTJPOPS4QFDJBM$BCMF NUMBER NUMBER FRAME (S) CONNECTOR
DPOGJHVSBUJPODBOCFQSPWJEFE .1$)$( .1$)$( ;0/& 1*$)(
CZTQFDJBMPSEFS .1$)$( .1$)$( ;0/& 1*$)(
5IFSNPDPVQMF$BCMFTBSFVTFEUPDPOOFDUUIF.BJOGSBNFUPUIF5IFSNPDPVQMF$POOFDUPSPO
UIFNPME BOEBSFBWBJMBCMFJOMFOHUITPG PGGFFU*OUFHSBMSFUBJOJOHMBUDIFTPOCPUI
UIFGSBNFBOENPMEDPOOFDUPSTQSPWJEFTFDVSFDBCMFDPOOFDUJPOT$POOFDUPSDPOGJHVSBUJPOT
|
FOTVSFQSPQFSJOTFSUJPOPGDBCMF$BCMFTBWBJMBCMFBSFXJSFEGPS PS[POFTGPSVTFXJUI
Smart Series®
TC12C10G UIFBQQSPQSJBUF4NBSU4FSJFT.BJOGSBNFTBOE5IFSNPDPVQMF$POOFDUPST
Thermocouple Cables (for use with 15 or 30 AMP Mainframes)

5IFTF5IFSNPDPVQMF$BCMFTTFSWFBTDBCMFTGPSDPOOFDUJOHEJTTJNJMBS.BJOGSBNFTBOE
5IFSNPDPVQMF$POOFDUPST'PSFYBNQMFUIF5$$(DPVMECFVTFEUPDPOOFDUB[POF
GSBNFUPBO[POF.5$(DPOOFDUPS5IFNBYJNVNOVNCFSPG[POFTXJMMCFEFUFSNJOFECZ
UIFDPOOFDUPSJOUIFNPME
Thermocouple Cables
10 FOOT LONG 20 FOOT LONG 30 FOOT LONG NUMBER FOR CONNECTIONS
OF ZONES
ITEM ITEM ITEM FROM 15 AMP TO THERMOCOUPLE
(MAX.)
NUMBER NUMBER NUMBER FRAME (S) CONNECTOR
5$$( 5$$( 5$$( ;0/& .5$(
5$$( 5$$( 5$$( ;0/& .5$(
5$$( 5$$( 5$$( ;0/& .5$(
6TFEXJUIBMM".1.BJOGSBNFT

Smart Series®
131
RoHS/WEEE Compliant: Mold Power Input Connectors
For 15 AMP .PME1PXFS*OQVU$POOFDUPSTBSFNPVOUFEPOUIFNPMEUPBDDFQUQPXFSDBCMF T

GSPN
Applications UIF.BJOGSBNF5IFZBSFTVQQMJFEXJUITJYJODIFTPGOVNCFSFEMFBETBOEBHSPVOEXJSF
"MMUISFF".1DPOOFDUPSTBSFUIFTBNFQIZTJDBMTJ[FBOEVTFHBVHFXJSF0OMZUIF
OVNCFSPGBDUJWFQJOTDIBOHF5IF".1DPOOFDUPSTBSFTVQQMJFEXJUIHBVHFMFBET
BOEBSFBUUBDIFEUPTDSFXUFSNJOBMT&BDIJTFRVJQQFEXJUIBOJOUFHSBMSFUBJOJOHMBUDIUP
QSPWJEFBTFDVSFDBCMFDPOOFDUJPO$POOFDUPSDPOGJHVSBUJPOFOTVSFTQSPQFSJOTFSUJPOPG
PIC5G
DBCMF4QMJDJOHPGMFBETUPIFBUFSQPXFSMFBETJTFBTJMZBDDPNQMJTIFEXJUIUIF*OTVMBUFE
$SJNQ$POOFDUPSTTVQQMJFE
NOTE: (SPVOEXJSFNVTUCF
DPOOFDUFEUPNPMEUP
FOTVSFPQFSBUPSTBGFUZ
PIC8G Mold Power Input Connectors
Smart Series®
PIC12G
|
Mold Power Input Connectors
For 30 AMP NOTE: 3FQMBDFNFOUQBSUTBOE
FYUSBDUJPOUPPMTDBOCF
Applications GPVOEPOQBHF
NOTE: %JNFOTJPOTTIPXONBZWBSZTMJHIUMZ
PICH23G Insulated Crimp Connectors
PICH5G
NOTES: NOTE: *OJUJBMTVQQMZJTQSPWJEFEXJUI
$POOFDUPS1*$)(JT NPMEQPXFSJOQVUDPOOFDUPST
EJNFOTJPOBMMZJEFOUJDBMUP "MTP TFFQBHF
UIFSNPDPVQMFDPOOFDUPS
.5$(4FFOFYUQBHF
'PS1*$)(BOE1*$)(
EJSFDUXJSJOHXJUIPVUDSJNQ
DPOOFDUPSTJTQPTTJCMFCZ
SFNPWJOHMFBET.

132 Smart Series®
RoHS/WEEE Compliant: Mold Thermocouple Connectors
5IFSNPDPVQMF$POOFDUPSTBSFNPVOUFEPOUIFNPMEUPVTFXJUIUIFSNPDPVQMF
DBCMF T
GSPNUIF.BJOGSBNF4DSFXUZQFUFSNJOBMTGPSVTFXJUIJSPO
BOE
DPOTUBOUBO
UIFSNPDPVQMFMFBETBSFOVNCFSFEBOEDPEFEPOUIFTJEFBOECPUUPN
PGFBDIDPOOFDUPS"MMUISFFDPOOFDUPSTBSFFRVJQQFEXJUIJOUFHSBMSFUBJOJOHMBUDIFT
MTC5G UPQSPWJEFBTFDVSFDBCMFDPOOFDUJPO$POOFDUPSDPOGJHVSBUJPOFOTVSFTQSPQFS
JOTFSUJPOPGDBCMF1JOTBSFNBEFPGDPQQFSBMMPZBOEBSFTJMWFSQMBUFE&YQFSJFODF
IBTQSPWFOUIBUJSPOBOEDPOTUBOUBOBSFOPUSFRVJSFE
MTC8G
Mold Thermocouple Connectors
NOTE: .0-%108&3*/165$0//&$5031*$)(*4%*.&/4*0/"--:*%&/5*$"-50.5$(
MTC12G MOLD THERMOCOUPLE CONNECTOR MOLD POWER AND THERMOCOUPLE

MTC5G CONNECTOR TPC0001
MTC8G
MTC12G
|
Smart Series®
TPC0001
6TFXJUI BOE[POF ".1

NBJOGSBNFT

Smart Series® 133
Mold Connector Pocket Layouts
NOTE: %SBXJOHEFQJDUT 8IFSFTQBDFPSNPMEIBOEMJOHBOETUPSBHFSFRVJSFNFOUTEPOPUQFSNJUUIFVTFPG

CFMPXGMVTINPVOUJOH 5FSNJOBM.PVOUJOH#PYFT UIFDPOOFDUPSTDBOCFCFMPXGMVTIPSTVSGBDFNPVOUFE
%JTSFHBSEEJNFOTJPOT
NBSLFEXJUIGPS
4FFESBXJOHTCFMPXBOEOFYUQBHFGPSEJNFOTJPOT
TVSGBDFNPVOUJOH
|Smart Series®
NOTE: %JTSFHBSEEJNFOTJPOT
NBSLFEXJUIGPS
TVSGBDFNPVOUJOH
NOTE: .PMEQPXFSJOQVUDPOOFDUPS1*$)(JT
EJNFOTJPOBMMZJEFOUJDBMUP.5$(

134 Smart Series®

NOTE: %SBXJOHEFQJDUTCFMPXTVSGBDFNPVOUJOH%JTSFHBSEEJNFOTJPOTNBSLFEXJUIGPSTVSGBDFmounting.

|
Smart Series®
6TFQPDLFUEJNFOTJPOTTIPXOPOQBHFTBTEFUBJMFEGPSUIFSNPDPVQMFDPOOFDUPS.5$(

Smart Series® 135
RoHS/WEEE Compliant: Terminal Mounting Boxes
Pre-wired Combination Terminal Mounting Boxes

*ODMVEFTUFSNJOBMTUSJQGPSFBTFPGXJSJOH BMMOFDFTTBSZDPOOFDUPSTJOTUBMMFE BOEQPXFS
DPOOFDUPSQSFXJSFEUPBUFSNJOBMTUSJQ"MMVOJUTTIPXOXJUIPVUDPWFST
PTC5TBGTS PTC8TBGTS PTC12TBGTS
PTC5TBTS PTC8TBTS PTC12TBTS
|Smart Series®
15$5#(54JTOPUUPCFVTFEXJUI44)

44) .'1( .'1( .'1(
.'13(DPOUSPMTNBJOGSBNFT
PTC210TBGTS
Combination Terminal Mounting Boxes – with Terminal Strip

ITEM NUMBER X Y H M1 M2 ACCEPTS
15$5#(54 .15$.15$
15$5#(54 15$15$
15$5#(54 .1$$ PS
(5$$ PS
(
15$5#(54 .1$$ PS
(5$$ PS
(
15$5#(54 .1$$ PS
(5$$ PS
(
15$5#(54 ø
.1$$ PS
(
5$$ PS
(
15$5#(54
.1$$ PS
(
5$$ PS
(
15$5#54 .1$$ PS
(5$$ PS
(
15$5#54 .1$$ PS
(5$$ PS
(
15$5#54 .1$$ PS
(5$$ PS
(
$PNFTXJUIBMMOFDFTTBSZDPOOFDUPSTJOTUBMMFEBOEQPXFSDPOOFDUPSQSFXJSFEUPBUFSNJOBMTUSJQ
1PXFSBOEUIFSNPDPVQMFDPOOFDUPSTBSFQSFXJSFE

136 Smart Series®
PTC8TBG
†
PTC5TBG
PTC0012 †
Overall dimensions shown include allowances for hardware (assembly screws) but not connectors
(example: For Item Number PTC0012 the “X” dimension is 4.29 not including screw heads)
* Used with 2-zone, 15 AMP mainframe MFFPR2G ** Used with 1-zone, 30 AMP mainframe MFHP1G

|
PIC512TBG
Smart Series®
PTC210 NOTE: Overall dimensions

shown include allowances
5FSNJOBM.PVOUJOH#PYFTQSPWJEF for hardware (assembly
UIFFBTJFTUBOENPTUFDPOPNJDBM screws) but not connectors
NFUIPEPGNPVOUJOHQPXFSBOE
UIFSNPDPVQMFDPOOFDUPSTPOUIF
NPME$POTUSVDUFEPGQMBUFEIFBWZ
HBVHFTUFFM FBDICPYJTQSFDVU
BOEESJMMFEGPSRVJDLNPVOUJOHPG
UIFDPOOFDUPSUPUIFCPY BOECPY
UPUIFNPME$POOFDUPSNPVOUJOH
IBSEXBSFJTTVQQMJFE$POOFDUPST
BSFPSEFSFETFQBSBUFMZ
Smart Series® 137
RoHS/WEEE Compliant: Microprocessor-Based Temperature Control

Modules with Digital Display and Setpoint Pushwheel
COMPATIBLE WITH TAS0512 SSM1512/11 (15 AMP) & SSM3012 (30 AMP)
ALARM AND SYSTEM CONTROL 5IF44.JTUIFTFDPOEHFOFSBUJPOPGUIFQPQVMBS44.(5IJTWFSTJPONBJOUBJOTTJNQMJDJUZPGPQFSBUJPO
XJUITJNVMUBOFPVTEJTQMBZPGTFUQPJOUBOEUFNQFSBUVSF0UIFSOFX JNQSPWFE BOEVOJRVFGFBUVSFTJODMVEF
FUNCTIONS. SEE PAGES 143-144.
Key Features
t-BSHF%JHJUBM%JTQMBZ
'PSFBTJFSSFBEBCJMJUZPGUFNQFSBUVSF QPXFSBOEGBVMUT
tSetpoint Pushwheel
'PSTFUUJOHEFTJSFETFUQPJOUUFNQFSBUVSF
"MMPXTBEKVTUNFOUPGTFUQPJOUCFGPSFUVSOJOHQPXFSPO
t"VUP1PXFS%JTQMBZ
4IPXTQPXFSPVUQVUXIJMFJO"650NPEF
*OEJDBUFTBWFSBHFQPXFSSFRVJSFNFOUPOUIFSNPDPVQMFGBJMVSF
4FSWFTBTBEJBHOPTUJDUPPMGPSTPMWJOHIPUSVOOFSTZTUFNQSPCMFNT
Operational Refinements
tImproved SmartStart®
"NPSFHSBEVBMUFNQFSBUVSFSJTFMFBETUPBNPSFFGGFDUJWFIFBUFSESZPVUQFSJPE
UIFSFCZFYUFOEJOHIFBUFSMJGF
Smart Series®
4NBSU4UBSU®OPXBWBJMBCMFJO."/6"-NPEF PQUJPOBM
tSelectiveCycle®
"WFSZIJHITQFFEQPXFSPVUQVUBQQSPBDI
&OBCMFTBDDVSBUFUFNQFSBUVSFDPOUSPMBOEMPOHFSIFBUFSMJGF
tBumpless Transfer
8IFOBUIFSNPDPVQMFGBJMVSFPDDVST PQFSBUJPOJTBVUPNBUJDBMMZDPOUJOVFEXJUIBMFBSOFEQPXFS
6OJRVFTPGUXBSFBDDVSBUFMZBTTJHOTQFSDFOUQPXFSTFUUJOH
|
tThird Fuse
Control Modules with Digital Display

"MMPXTGPSBMBSNPVUQVUXIFOUIFMPBEGVTFTBSFCMPXO
1SPUFDUTNPEVMFGSPNBQQMJDBUJPOPGFYDFTTJWFWPMUBHF
tAnti-Arcing Feature
1SPUFDUTDJSDVJUCPBSEGSPNEBNBHFXIFONPEVMFJTFJUIFSJOTFSUFEPSSFNPWFEVOEFSQPXFS
Switchable Options
tBoost, Idle and Power Off Features
1SPWJEFTTZTUFNXJEFBEKVTUNFOUPGUFNQFSBUVSFT
&OBCMFTBMBSNBVEJPWJTVBMPVUQVUBOESFNPUFBMBSNT
3FRVJSFT5"4NPEVMFBOEDPNNVOJDBUJPOTNBJOGSBNF
4FFQBHFTGPSNPSFJOGPSNBUJPOPOUIFTFDBQBCJMJUJFT
tUnique AutoBoost Option

*OTUBOUBOFPVTMZPQFOTGSP[FOHBUFTPOTUBSUVQ
5"4NPEVMFPSNBJOGSBNFDPNNVOJDBUJPOTBSFOPUSFRVJSFE
tLights Out Feature
"GUFSTUBCJMJ[JOHBUTFUQPJOU EJTQMBZUVSOTPGGXIFOBGBVMUPDDVST EJTQMBZJTUVSOFEPOBOEGMBTIFT
'PSFBTJFSEFUFDUJPOPGGBVMUT
tShorted Thermocouple Sensitivity Adjustment
0QFSBUJPODBOCFUBJMPSFEUPGBTUPSTMPXSFBDUJPOUJNFT
4FOTJUJWJUZDBOCFBEKVTUFEXJUIJOUFSOBMTXJUDIFT
7FSZVTFGVMGPSNBOJGPME[POFTXJUIMPOHTUBSUVQUJNFT
tSwitchable °C/°F Operation
4DBMFJOEJDBUFEBUTUBSUVQ
NOTE: 44.JTUXJDFBT t K Type Thermocouple Support
XJEFBTBCPWFBOEIBT t Cut Feature
DJSDVJUCSFBLFSJOTUFBE (BJODVUGFBUVSFGPSTNBMMOP[[MFTBOEIFBUFSTXJUIVOHSPVOEFEJOUFSOBMUIFSNPDPVQMFT
PGQPXFSPOPGGTXJUDI

138 Smart Series®
RoHS/WEEE Compliant: Microprocessor-Based Temperature Control
Modules with Digital Display and Setpoint Pushwheel
SSM1512/11 (15 AMP) & SSM3012 (30 AMP)

Warranty: MODULE VOLTAGE
5XPZFBST ITEM NUMBER AMPS WATTS
(VAC)
FYDMVEJOHUSJBDBOEGVTFT
SSM1512 240 15 3600

Fuse Requirements SSM1511 120 15 1800
(15 AMP only)

"#$GVTFT #VTTNBOPOMZ
SSM3012 240 30 7200

TQBSFGVTFTJODMVEFE
XJUINPEVMF NOTE: 4UBOEBSE 7"$
NPEVMFTBSFDPNQBUJCMFXJUINBJOGSBNFTXJSFEGPSFJUIFS
7"$UISFFQIBTF TUBOEBSE
PS7"$TJOHMFQIBTF

1. Process Temperature Display
*OEJDBUFTQSPDFTTUFNQFSBUVSF UIFSNPDPVQMFGBVMUTBOEPUIFSPQFSBUJPOBMNPEFT
%JTQMBZTQPXFSXIFOTXJUDI
JTJOi"VUPwQPTJUJPO
Control Modules with Digital Display
4
2. Temperature Deviation Lights
1 *OEJDBUFTEFWJBUJPOGSPNTFUQPJOU0VUFSMJHIUTCMJOLXIFOUFNQFSBUVSFJTNPSF
UIBO' $
GSPNTFUQPJOU
2
3. Auto/Manual/Auto % Power Switch
4FMFDUT"650PS."/6"-DPOUSPMNPEF4IPXTQPXFSXIFOQSFTTFEJOUP
i"650wQPTJUJPO
5 4. LED Mode Indicators

-FGU-&%JMMVNJOBUFTEVSJOH."/6"-NPEF
3JHIU-&%JMMVNJOBUFTXIFOQPXFSJTTVQQMJFEUPIFBUFS
3JHIU-&%CMJOLTPOBOEPGGEVSJOH4NBSU4UBSU®
3
|
Smart Series®
5. Setpoint Pushwheel
5ISFFEJHJUTXJUDIQSPHSBNTTFUQPJOUJO"650NPEF3JHIUUXPEJHJUTQSPHSBN
QPXFSJO."/6"-NPEF
6. Power On/Off Switch

$POUSPMT"$QPXFSUPNPEVMF
6
Front Panel Digital LED Indicators

Smart Series® 139
RoHS/WEEE Compliant: Microprocessor-Based Temperature

Control Modules with Dual Digital Display
COMPATIBLE WITH TAS MODULE
DSS1512/11 (15 AMP) & DSS3012 (30 AMP)
ALARM AND STANDBY HEAT 5IF%444NBSU4FSJFT.PEVMFIBTEVBMEJHJUBMEJTQMBZTQSPWJEJOHSFBEPVUTPGCPUIQSPDFTTBOE
TFUQPJOUUFNQFSBUVSFTBUBHMBODF$MPTFEMPPQ GV[[ZMPHJD1*%DPOUSPM BOEBVUPUVOJOHPG1*%
FUNCTIONS. SEE PAGES 143-144.
QBSBNFUFSTQSPWJEFQSFDJTFDPOUSPMFWFOVOEFSUIFNPTUBEWFSTFQSPDFTTJOHDPOEJUJPOT
*OUIFFWFOUPGBUIFSNPDPVQMFGBJMVSF UIF%44DBOBVUPNBUJDBMMZJOWPLFCVNQMFTTUSBOTGFSUPB
QFSDFOUQPXFSNPEFCBTFEPOUIFMBTUWBMJEQFSDFOUBHFMFBSOFECFGPSFUIFUIFSNPDPVQMFGBJMVSF
*GEFTJSFE NBOVBMCVNQMFTTUSBOTGFSNBZCFTFMFDUFE JOXIJDIDBTFBUIFSNPDPVQMFGBVMUXJMMUVSO
PGGQPXFSUPUIFIFBUFSVOUJMUIFNBOVBMQFSDFOUQPXFSNPEFJTBDUJWBUFECZUIFPQFSBUPS
"VOJRVFGFBUVSFPGUIF%44JTBQPXFSPQUJPO'PSBTXJUDITFMFDUBCMF JOUFSWBMPGPS
1 TFDPOET GVMMQPXFSDBOCFJNNFEJBUFMZEFMJWFSFEUPUIFIFBUFSUPSBQJEMZCSFBLUISPVHIGSP[FO
HBUFTUPBDIJFWFRVJDLFSTUBSUVQT5IFQPXFSNPEFDBOCFEJTFOHBHFEBUBOZUJNFCZ
TJNQMZQSFTTJOHBOZGSPOUQBOFMCVUUPO
2 *OEJDBUPSMJHIUTQSPWJEFRVJDLSFGFSFODFGPSNPEVMFDPOUSPMNPEFT UFNQFSBUVSFEFWJBUJPOBOE
3 CMPXOGVTFT5IFQSPDFTTUFNQFSBUVSFEJTQMBZBMTPQSPWJEFTRVJDLEJBHOPTUJDTPGUIFSNPDPVQMF
GBVMUT VTJOHUIFGPMMPXJOHBCCSFWJBUFEDPEFT
4IJ4IPSUFE5IFSNPDPVQMF
P1J0QFO5IFSNPDPVQMF
Smart Series®
CDJ3FWFSTFE5IFSNPDPVQMF
5IF%44NPEVMFBMTPJODMVEFTB4NBSU4UBSU®NPEFUPTBGFMZCBLFPVUEBNBHJOHJOUFSOBMIFBUFS
4 NPJTUVSFBUTZTUFNTUBSUVQBOEUPQSPMPOHIFBUFSMJGF'BTUPSTMPXMPBENPEFTNBZBMTPCF
TFMFDUFE
5
UPQSPUFDUTNBMMFSIFBUFSTPSDPNQFOTBUFGPSiTMPXwMPBETTVDIBTFYUFSOBMMZIFBUFENBOJGPMET
6 "OBDDVSBUF EVSBCMFBOEGVMMGFBUVSFENPEVMF UIF%44JTGVMMZDPNQBUJCMFXJUIBMM4NBSU4FSJFT
10
7 PS(4FSJFT®AMPNBJOGSBNFT
|

8
11 1. Smart Start Light
9
*OEJDBUFT4NBSU4UBSUJTPO
12
2. Process Temperature Display
*OEJDBUFTQSPDFTTUFNQFSBUVSFBOEUIFSNPDPVQMFGBVMUTBTEFTDSJCFEBCPWF
3. Temperature Deviation Lights
*OEJDBUFTEFWJBUJPOGSPNTFUQPJOU0VUFSMJHIUTCMJOLBUNPSFUIBO¡'GSPNTFUQPJOU
13 4. Setpoint Display
*OEJDBUFTTFUQPJOUUFNQFSBUVSFPSQFSDFOUQPXFS EFQFOEJOHPODPOUSPMMFSNPEF
5. Auto/Manual Switch
4FMFDUTBVUPPSNBOVBMDPOUSPMNPEF
6. Auto Light
*OEJDBUFTBVUPNPEF
7. Manual Light
*OEJDBUFTNBOVBMNPEF
8. 100% Power Switch
*OEJDBUFTQPXFSPVUQVUGPSTFMFDUBCMFJOUFSWBMPGPSTFDPOET
NOTE: %44JTUXJDFBT 9. 100% Power Light
XJEFBTBCPWFIBT *OEJDBUFTQPXFSNPEF
DJSDVJUCSFBLFSJOTUFBE 10. Up Arrow Front Panel Digital LED Indicators
PG''MJHIUTBOEQPXFS
*ODSFBTFTEFTJSFETFUQPJOUWBMVF
POPGGTXJUDI
11. Down Arrow
%FDSFBTFTEFTJSFETFUQPJOUWBMVF
12. F1/F2 Lights
*MMVNJOBUFXIFOGVTFJTCMPXO
13. Power On/Off Switch
140 Smart Series®
Microprocessor-Based Temperature
DSS1512/11 (15 AMP) & DSS3012 (30 AMP)
Performance Specifications
Auto and Manual Control Modes: 5JNFQSPQPSUJPOJOH4FMFDUJWF$ZDMF®
Temperature Range: Ambient to 999°F (537°C)
Control Accuracy: ¡' ¡$
EFQFOEFOUPOUIFUPUBMUIFSNBMTZTUFN
Temperature Stability: PGGVMMTDBMFPWFSUIFBNCJFOUSBOHFPGUP¡' UP¡$
Calibration Accuracy: #FUUFSUIBOPGGVMMTDBMF

Power Response Time: TFDPOET
Manual Control: "EKVTUBCMFGSPN NBJOUBJOTPVUQVUQPXFSUPXJUIJOPGTFUQPJOU
Smart Start®: -JOFBSWPMUBHFSBNQJOH
Maximum Smart Start Duration: NJOVUFT
Smart Start Override Temperature: ¡' ¡$)
100% Power: "QQMJFTQPXFSUPUIFPVUQVU4PGUXBSFTFMFDUBCMFJOIJCJUPS4 -TFDPOET
Operational Mode Priority: r4NBSU4UBSU®QSFDFEFTBVUPNPEF
r5IFSNPDPVQMF 5$
CSFBL SFWFSTFEPSTIPSUFOFE5$PWFSSJEFT4NBSU4UBSUBOEBVUPNPEFT
r.BOVBMDPOUSPMPWFSSJEFTBVUPNPEF 5$CSFBLT SFWFSTFEPSTIPSUFOFEUIFSNPDPVQMFT
r0VUQVUJTJOIJCJUFEEVSJOHBMMGBVMUDPOEJUJPOT
Input Specifications
Thermocouple Sensor: 5ZQF+ HSPVOEFEPSVOHSPVOEFE
External T/C Residence: -FTTUIBO¡' .
T/C Isolation: *TPMBUFECZDPOUSPMDJSDVJUQPXFSTVQQMZ
Cold Junction Compensation: "VUPNBUJD CFUUFSUIBO¡'' ¡$¡$

T/C Break, Reversed & Shorted Protection: "VUPNBUJDBMMZJOIJCJUTQPXFSUPIFBUFSVOMFTT CVNQMFTTUSBOTGFSJTJOWPLFE
Input Impedance: .FHPINT
Input Amplifier Stability: (SFBUFSUIBO¡'¡' ¡$¡$

.
Common Mode Rejection Ratio: (SFBUFSUIBOE#
Power Supply Rejection: (SFBUFSUIBOE#
Output Specifications
Voltage Power Capability: ".1OPNJOBM TJOHMFQIBTF 7"$BWBJMBCMF BNQFSFT XBUUT!7"$ XBUUT!7"$

".1BNQFSFT XBUUT!7"$
Output Drive: *OUFSOBMTPMJETUBUFUSJBD USJHHFSFECZ[FSP"$DSPTTJOHQVMTFT
Overload Protection: ".1'VTFTBSFQSPWJEFEPOCPUITJEFTPG"$MJOF
".1'BTUBDUJOHDJSDVJUCSFBLFS
Transient Protection: EWEUBOEUSBOTJFOUQVMTFTVQQSFTTJPOJODMVEFE
Power Line Isolation: 0QUJDBMMZBOEUSBOTGPSNFSJTPMBUFEGSPN"$MJOFT*TPMBUJPOWPMUBHFJTHSFBUFSUIBOWPMUT
Controls and Indicators

Auto/Manual Selection: 1VTICVUUPOTXJUDIXJUI-&%JOEJDBUPSTBEKBDFOUUPTXJUDI
Setpoint Adjustment: 1VTICVUUPOVQEPXOBSSPXLFZT
100% Power Selection: 1VTICVUUPOTXJUDIXJUI-&%JOEJDBUPSBEKBDFOU
Power On/Off: AMPSPDLFSTXJUDI AMP
PSAMPDJSDVJUCSFBLFS BNQ
#PUIBSF6- $4" 7%&approved.
Setpoint Display: 5ISFF TFWFOTFHNFOUEJHJUEJTQMBZ
Process Display: 5ISFF TFWFOTFHNFOUEJHJUEJTQMBZ"MTPEJTQMBZTBMBSNDPEFTBOEGMBTIJOHiwGPSQPXFSPQFSBUJPO
100% Power Indication: 3FE-&%BEKBDFOUUPQPXFSLFZGMBTIFT1SPDFTTEJTQMBZGMBTIFTiw
Auto Indication: *MMVNJOBUFTHSFFO-&%BEKBDFOUUP"VUP.BOLFZ
Manual Indication: *MMVNJOBUFTZFMMPX-&%BEKBDFOUUP"VUP.BOLFZ
|
Smart Start Indication: *MMVNJOBUFTHSFFO-&%BCPWFUIFQSPDFTTEJTQMBZ

Smart Series®
Shorted T/C Indication: 'MBTIFTi4IJwJOQSPDFTTEJTQMBZ

Opened T/C Indication: 'MBTIFTiP1JwJOQSPDFTTEJTQMBZ
Reversed T/C Indication: 'MBTIFTiCDJwJOQSPDFTTEJTQMBZ
Temperature Deviation Indicators: 'JWFTFQBSBUF-&%T ¡'¡$3FE
¡'¡$:FMMPX
¡(SFFO
Blown Fuse Indicators: OFPOJOEJDBUPST AMPPOMZ
Electrical Power Specifications

Input Voltage: 7"$
Frequency: )[
DC Power Supplies: *OUFSOBMMZHFOFSBUFE SFHVMBUFEBOEDPNQFOTBUFE
Module Power Usage: -FTTUIBOXBUUT FYDMVEJOHMPBE
Dimensions: ".18Y)Y% YYDN
".18Y)Y% YYDN
NOTE: 4UBOEBSE 7"$

NPEVMFTBSF
DPNQBUJCMFXJUINBJOGSBNFTXJSFE Smart Series Microprocessor-Based Temperature Control Modules
GPSFJUIFS7"$UISFFQIBTF
TUBOEBSE
PS7"$TJOHMFQIBTF (240 VAC, standard) (120 VAC, optional)
FOR °C OPERATION: 4XJUDIUP¡$POGSPOUQBOFM ITEM NUMBER AMPS WATTS ITEM NUMBER AMPS WATTS
FUSE REQUIREMENTS (15 AMP ONLY):

"#$'VTFT #VTTNBOPOMZ
DSS1512 15 3600 DSS1511 15 1800
NOTE:
TQBSFGVTFTJODMVEFEXJUINPEVMF DSS3012 30 7200
WARRANTY: 5XPZFBST FYDMVEJOHUSJBDBOEGVTFT

Smart Series® 141
Control Modules with Color Touch Screen Display
TSM-15-12
5IF54.4NBSU4FSJFT.PEVMFIBTBDPMPSUPVDITDSFFOEJHJUBMEJTQMBZQSPWJEJOHSFBEPVUT
GPS "DUVBM5FNQFSBUVSF $VSSFOU.PEF 1FSDFOUBHF1PXFSBOE$VSSFOU3FBEJOH$MPTFEMPPQ
GV[[ZMPHJD1*%DPOUSPM BOEBVUPUVOJOHPG1*%QBSBNFUFSTQSPWJEFQSFDJTFDPOUSPMFWFO
VOEFSUIFNPTUBEWFSTFQSPDFTTJOHDPOEJUJPOT
*OUIFFWFOUPGBUIFSNPDPVQMFGBJMVSF UIF54.DBOBVUPNBUJDBMMZJOWPLFCVNQMFTT
USBOTGFSUPBQFSDFOUQPXFSNPEFCBTFEPOUIFMBTUWBMJEQFSDFOUBHFMFBSOFECFGPSFUIF
UIFSNPDPVQMFGBJMVSF*GEFTJSFE NBOVBMCVNQMFTTUSBOTGFSNBZCFTFMFDUFE JOXIJDIDBTF
BUIFSNPDPVQMFGBVMUXJMMUVSOPGGQPXFSUPUIFIFBUFSVOUJMUIFNBOVBMQFSDFOUQPXFSNPEF
JTBDUJWBUFECZUIFPQFSBUPS
5IF54.CPPTUMFWFMPQUJPOMJNJUTCPPTUJOHPGUIFUFNQFSBUVSFCZ¡$PS¡'UPMJNJUUIF
EFHSBEBUJPOPGNBUFSJBM
Smart Series®
5IF54.NPEVMFBMTPJODMVEFTB4NBSU4UBSU®NPEFUPTBGFMZCBLFPVUEBNBHJOHJOUFSOBM
IFBUFSNPJTUVSFBUTZTUFNTUBSUVQBOEUPQSPMPOHIFBUFSMJGF'BTUPSTMPXMPBENPEFT
NBZBMTPCFTFMFDUFEUPQSPUFDUTNBMMFSIFBUFSTPSDPNQFOTBUFGPSiTMPXwMPBETTVDIBT
FYUFSOBMMZIFBUFENBOJGPMET"OBDDVSBUF EVSBCMFBOEGVMMGFBUVSFENPEVMF UIF54.JT
GVMMZDPNQBUJCMFXJUIBMM4NBSU4FSJFTPS(4FSJFT®".1NBJOGSBNFT
|
-FBL%FUFDUJPODBQBCJMJUJFT SFGFSFODF54.6TFS.BOVBM
TSM15 SmartSeries® Controller with Default Settings (Factory Settings)
Zone temperature 260ºC or 500ºF

Standby level 100ºC or 180ºF
Boost level 75ºC or 135ºF
Over temperature range
10ºC or 18ºF
Under temperature range
Ramp On
Auto-Manual On
Extended alarms for Manual, Standby and
Off
Boost
When reconfiguring your controller for a new tool or environment, this chapter of the manual shows
how to alter controller default settings to your preferred values and afterward to save them.
4IPVMEBOZUIJOHTFFNXSPOHXJUIZPVSOFXTFUUJOHTUIFOJUJTQPTTJCMFUPSFTUPSFUIFEFGBVMUTFUUJOHT
BUBOZUJNF
1 Actual temperature (and scale)

Front Panel Controls
2 Current mode shows set-point and Indicators
3 Percentage power applied
4 Current reading
U.S. 800-626-6653 Canada 800-387-6600 sales@dme.net www.dme.net

142 Smart Series®
Individual Card Diagnostics

5IFDPOUSPMTZTUFNIBTTFWFSBMGFBUVSFTXIJDIQSPWJEFBEJBHOPTJTPGGBVMUTJOUIFDPOUSPMTZTUFN UIFUPPMIFBUFSTBOEUIFSNP
DPVQMFTFOTPST
*GB[POFUFNQFSBUVSFJTTFFOUPEFWJBUFGSPNUIFBDUVBMTFUUJOHCFZPOEUIFBMBSNMJNJUTUIFOUIFEJTQMBZXJMMDIBOHFUP8IJUF
UFYUJO3FECPYBOEHFOFSBUFBSFNPUFBMBSN
The following is a list of alarm conditions that may be detected and which will also activate
the output contacts.
ERROR MESSAGE CAUSE ACTION

-JUUMFPSOPUFNQFSBUVSFSJTFIBTCFFOEFUFDUFEJOUIBU
[POF8IFOUIFDPOTPMFTUBSUTUPBQQMZQPXFSJUFYQFDUT
UPTFFBOFRVJWBMFOUIFBUSJTFBUUIFUIFSNPDPVQMF*GUIF
UIFSNPDPVQMFIBTCFFOUSBQQFEBOEQJODIFEFMTFXIFSF
$IFDLUIFSNPDPVQMFXJSJOHJUNBZCFSFWFSTFE)FBUFS
ERR! JOUIFUPPMPSDBCMFUIFOJUDBOOPUTFOTFUIFGVMMIFBUSJTFUIBU
XJSJOHNBZCFGBVMUZPSFMFNFOUNBZCFPQFODJSDVJU
PDDVSTBUUIFUJQ*GMFGUVODPSSFDUFE UIFSFJTBEBOHFSUIBUUIF
[POFDPVMEPWFSIFBUBOEEBNBHFUIFUJQ*OTUFBEUIFDJSDVJU
NBJOUBJOTUIFPVUQVUBUXIBUFWFSMFWFMJUSFBDIFEXIFOUIF
NPOJUPSDJSDVJUEFUFDUFEUIFGBVMU
5IFPVUQVUGVTFGPSUIBU[POFIBTGBJMFE1MFBTFOPUF
"GVTFDBOPOMZGBJMEVFUPBGBVMUFYUFSOBMUPUIFDPOUSPMMFS
*EFOUJGZBOESFDUJGZUIFGBVMUCFGPSFSFQMBDJOHUIFGVTF
/PUF5IFGVTFEFUFDUJPODJSDVJUSFRVJSFTBDPOUJOVPVTMPXMFWFM
3FQMBDFUIFGVTFXJUIPOFPGUIFTBNFSBUJOHBOEUZQF
DVSSFOUUISPVHIBIJHIJNQFEBODFCMFFESFTJTUPSUPNBJOUBJOUIF
JF)JHI3VQUVSF$VSSFOUMPBEGVTF5IFCMPXOGVTFJT
FUSE BMBSNDPOEJUJPO"TBSFTVMUUIFMPBEDJSDVJUJTTUJMMDPOOFDUFEUP
MPDBUFE
UIFNBJOTWPMUBHFTVQQMZBOEJUJTOPUTBGFUPBUUFNQUUPSFQBJS
POUIFDPOUSPMDBSE
PSSFQMBDFUIFGVTFXJUIPVUåSTUJTPMBUJOHUIFDJSDVJU*GUIFGVTF
JORVFTUJPOJTNPVOUFEPOBDPOUSPMDBSEUIFOJUJTTBGFUPVOQMVH
UIFCPBSEJOPSEFSUPJTPMBUFUIFDJSDVJUBOESFQMBDFUIFGVTFPO
UIFDBSE
$IFDLZPVSIFBUFSXJSJOHGPSBMPXJNQFEBODFQBUIUP
GND 5IFTZTUFNIBTEFUFDUFEBOHSPVOEGBVMU
UIFHSPVOE
|
Smart Series®
5IFSFJTBQIBTFEFUFDUJPODJSDVJUPOFBDI5.44FSJFT
/PNBJOTTVQQMZTZODISPOJ[BUJPOQVMTFTCFJOHSFDFJWFE5IF DBSEBOEBDPNNPOQIBTFEFUFDUJPODJSDVJUPOBMMPUIFS
QIBTFTVQQMZJTVTFEJOBDSPTTPWFSEFUFDUJPODJSDVJUUPHFOFS DPOUSPMMFSUZQFT"MUIPVHIBGBVMUJOTVDIDJSDVJUTNBZ
BUFUJNJOHQVMTFTGPSBDDVSBUFQIBTFDPOUSPMBOEåSJOHUIFUSJBD DBVTFUIF-*/&FSSPSNFTTBHF TVDIGBVMUJTWFSZSBSFMZ
LINE *GUIFQIBTFEFUFDUJPOGBJMTPOPOFPSUXPQIBTFTUIFOUIFSFJT TFFO5IFNPTUDPNNPOFSSPSJTFJUIFSUIFBCTFODFPG
OPQVMTFUPVTFUPNFBTVSFQIBTFBOHMFBOEUIF-*/&FSSPSNFT POFQIBTFPS JGBQMVHIBTCFFOSFXJSFEJODPSSFDUMZ B
TBHFJTHFOFSBUFE.FBOXIJMF BMMDJSDVJUTPOUIFIFBMUIZQIBTFT TXBQQFEQIBTFBOEOFVUSBM*GB-*/&FSSPSNFTTBHFPD
XJMMDPOUJOVFUPXPSLOPSNBMMZ DVSTUIFOTXJUDIPGGBOEJTPMBUFUIFDPOUSPMMFSUIFODIFDL
TVQQMZXJSJOHGPSQSFTFODFPGBMMUISFFQIBTFT
5IFDBSEIBTEFUFDUFEBOBCOPSNBMJOQVUBUUIF5$UFSNJOBUJPO *GUIF3&7BMBSNQFSTJTUT TXJUDIPGGUIFDPOUSPMMFSBOE

REV
UIBUJOEJDBUFTBTIPSUFEPSSFWFSTFEUIFSNPDPVQMF JOWFTUJHBUFUIFPGGFOEJOH[POF
'PSJNNFEJBUFSFDPWFSZ DIBOHFUPPQFOMPPQDPOUSPM
.BLFBOPUFPGUIFBCPWFBDUJPOTPUIBUXIFOUIF
"OPQFODJSDVJUUIFSNPDPVQMFIBTCFFOEFUFDUFEBOEOPBVUP
DPOUSPMMFSJTGSFFZPVDBODIFDLUPTFFXIFUIFSUIFJOQVU
T/C SFTQPOTFIBTCFFOTFMFDUFEJOUIF5$0QFO&SSPSDPMVNOPGUIF
GVTFPOUIFDPOUSPMDBSEIBTSVQUVSFE*GUIFGVTFJTHPPE
4FUVQQBHF
UIFOZPVNBZOFFEUPDIFDLUIFXJSJOHGPSGBVMUTPSFWFO
SFQMBDFUIFUIFSNPDPVQMF
U.S. 800-626-6653 Canada 800-387-6600 sales@dme.net www.dme.net

Smart Series® 143
Temperature Alarm/System Control Modules
TAS0512/11 Temperature Alarm Function

t1SPWJEFTBMBSNGPSPWFSPSVOEFSUFNQFSBUVSF PSEJBHOPTUJDFSSPS
t1SPWJEFTWJTVBMBOEBVEJCMFJOEJDBUJPOTPGBOBMBSN
1 t5IFBVEJCMFBMBSN
DBOCFUVSOFEPOPSPGGXJUITXJUDI

t3FMBZDPOUBDUT
BSFQSPWJEFEUPBMMPXIPPLVQPGSFNPUFFRVJQNFOUTVDIBTBMJHIU
BDPOWFZPSPSBNBDIJOFGVODUJPO
t3FMBZDPOUBDUTBSFVOBGGFDUFECZUIFQPTJUJPOTXJUDI
2
t"OJOGJOJUFOVNCFSPG[POFTPGDPOUSPMDBOCFNPOJUPSFEBTMPOHBTUIFZBSFDPOUBJOFEXJUIJO
UIFTBNFDPNNVOJDBUJPOTTUZMFNBJOGSBNFBTUIF5"4NPEVMF
3 System Control Functions

6QUP[POFTDBOCFDPOUSPMMFESFNPUFMZBUPOFUJNF5IFTF[POFTNVTUCFDPOUBJOFEXJUIJO
4 UIFTBNFDPNNVOJDBUJPOTTUZMFNBJOGSBNFBTUIF5"4NPEVMF
5
Smart Series®
NORMAL / IDLE
t3PUBSZTXJUDI
QSPWJEFTSFNPUFDPOUSPMPG%44 %44 $44
44. BOE44.
t$POUSPMNPEVMFTDBOBMMCFDPNNBOEFEUPSFTQPOEGSPN/03."-UP*%-& 4UBOECZ)FBU
6
t*O*%-& UIFNPEVMFTXJMMBEKVTUUPBTFUUJOHPG$ ¡'
|
&YDFQUJPOT44.BOE44.BEKVTUUPBTFUUJOHPG$ ¡'

t.PWJOHUIFSPUBSZTXJUDICBDLUP/03."-SFTUPSFTBMMNPEVMFTUPUIFJSFTUBCMJTIFETFUQPJOUT
t5IFVTFSDBOTFMFDU*%-&GPSUFNQPSBSZMPXFSJOHPGBMM[POFTUPQSFWFOUNBUFSJBMEFHSBEBUJPO
t5IJTGFBUVSFDBOCFVTFEUPLFFQIFBUFSTXBSNFOPVHIUPQSFWFOUBCTPSQUJPOPGNPJTUVSF
7
BOOST / OFF
t5IF44.BOE44.DBOCFQMBDFEJOUP#0045BOE0''
t#0045XJMMSBJTFUIFTFUQPJOUPGUIFNPEVMFCZ PS
t0''TIVUTPGGQPXFSUPUIFIFBUFSCVUBMMPXTUIFVTFSUPNPOJUPSDPPMEPXOPGUIF
IPUSVOOFSTZTUFN
t&BDI44.BOE44.DBOCFJOEJWJEVBMMZQSPHSBNNFEUPSFTQPOEUP0''
*%-&BOE#0045DPNNBOET
t5IFVTFSDBORVJDLMZESJWFBMMOP[[MF[POFTJOUP#0045UPPQFOGSP[FOHBUFT

1. Power On Indicator: -&%JMMVNJOBUFTXIFOQPXFSJTBQQMJFEUPUIFNPEVMF
2. Audible Alarm: &NJUTBMPVEBVEJCMFBMBSNXIFOUIFBMBSNTXJUDI
JTQMBDFEJOUIF
iwQPTJUJPO 0/
BOEBOBMBSNDPOEJUJPOJTTFOUCZBDPNQBUJCMFDPOUSPMNPEVMF
3. Alarm Indicator: -&%JMMVNJOBUFTXIFOBOBMBSNDPOEJUJPOJTTFOUCZBDPNQBUJCMFNPEVMF
4. Audio Alarm On/Off Switch: 5VSOTUIFBVEJPBMBSN
POPSPGG
5. Alarm Relay Connector 1SPWJEFTSFMBZDPOUBDUTGPSVTFXJUISFNPUFFRVJQNFOU
.BUJOHDPOOFDUPSJTTVQQMJFE
6. System Control Switch: "DUJWBUFTUIF0'' *%-&BOE#0045NPEFJOBMM
DPNQBUJCMFNPEVMFT
7. Power On/Off Switch: CPOUSPMT"$QPXFSUPUIFNPEVMF

144 Smart Series®
ITEM NOTE: 4UBOEBSE 7"$

NPEVMFTBSFDPNQBUJCMFXJUINBJOGSBNFTXJSFEGPSFJUIFS7"$
VOLTS UISFFQIBTF TUBOEBSE
PS7"$TJOHMFQIBTF6TF5"4GPS7"$PQFSBUJPO
NUMBER
TAS0512 240 VAC FUSE REQUIREMENTS:
"#$GVTFT/05&
TQBSFGVTFTJODMVEFEXJUINPEVMF
TAS0511 120 VAC WARRANTY: 5XPZFBST FYDMVEJOHGVTFT

NOTE:
TAS Module Compatibility 5"4NPEVMFJTOPUDPNQBUJCMFXJUIPMEFS$44((PS%44((NPEVMFT
MODULE FUNCTIONS MODULE FUNCTIONS
ALARM IDLE BOOST OFF ALARM IDLE BOOST OFF
SSM1502/01/12/11 CSS1502/01
SSM3002/12 CSS3002
DSS1502/01/12/11 SSM15G
DSS3002/12 SSM15G1
TSM1512 SSM30G
BOOST
5IFi#0045wTFUUJOHJTUIF/03."-TFUQPJOUQMVT PSGPSFYBNQMF
BOOST iGTFUQPJOU'BOE#0045JT UIFO#0045UFNQFSBUVSF'
NORMAL i/03."-wPQFSBUJPOJTBTUIPVHI Remote

NORMAL
UIF5"4NPEVMFJTOPUQSFTFOU Control
Functions
IDLE i*%-&w 4UBOECZIFBU

SFEVDFTIFBUUP'PS'
IDLE
93˚C (200˚F)
or
100˚C (212˚F)
OFF i0''wDVUTQPXFSUPUIFIFBUFS
AMBIENT 5IFVTFSDBONPOJUPSDPPMEPXO
|
TIME
Smart Series®
Upgrade Kits For Converting to Communications Mainframes
ITEM NUMBER MAIN FRAME ITEM NUMBER MAIN FRAME
CIK4 4-ZONE CIK28 28-ZONE

CIK16 16-ZONE CIK2HP 2-ZONE HIGH POWER

Smart Series® 145
Replacement Parts and Service Items for DME

|Smart Series®
Replacement Parts for Smart Series® Temperature Control Systems
NOTE: 'PSVQQFSJOTJEFDPNNVOJDBUJPOTDPOOFDUPST TFFQSFWJPVTQBHF
Connectors / Connector Kits (5-48 zone, 15 Amp; 2-5 zone, 30 Amp)

REFERENCE
DESCRIPTION ITEM NUMBER
LETTER
A .PME5IFSNPDPVQMF0VUQVU$POOFDUPS TFFQBHF
# .PME1PXFS*OQVU$POOFDUPS TFFQBHF
.PME&OE,JUGPS;POF5IFSNPDPVQMF$BCMF PS".1
$,5'(
C .PME&OE,JUGPS;POF5IFSNPDPVQMF$BCMF PS".1
$,5'(
.PME&OE,JUGPS;POF5IFSNPDPVQMF$BCMF PS".1
$,5'(
.PME&OE,JUGPSBMMPS".11PXFS$BCMFT $,1'#(
D .PME&OE,JUGPSBMMPS;POF".11PXFS$BCMFT $,1'$(
.PME&OE,JUGPSBMM;POF".11PXFS$BCMFT $,1'$(
E 'SBNF&OE,JUGPSBMM5IFSNPDPVQMF$BCMFT PS".1
$,5'"(
'SBNF&OE,JUGPSBMMPS".11PXFS$BCMFT $,1.#(
F 'SBNF&OE,JUGPSPS;POF".11PXFS$BCMFT $,1.$(
'SBNF&OE,JUGPSBMM;POF".11PXFS$BCMFT $,1.$(
( 5IFSNPDPVQMF*OQVU,JUGPSBMM.BJOGSBNFT PS".1
$,5."(
1PXFS0VUQVU,JUGPSBMMPS".11PXFS$BCMFT $,1'#(
) 1PXFS0VUQVUGPSBMMPS;POF".11PXFS$BCMFT $,1'$(
1PXFS0VUQVU,JUGPSBMM;POF".11PXFS$BCMFT $,1'$(
I &EHF$BSE$POOFDUPS,JUGPSBMM.BJOGSBNF1$#PBSET PS".1
$,'(

146 Smart Series®
Mainframe, Cable Components, and Service Tools*

CBD10M 10 AMP 2 POLE, CIRCUIT BREAKER USED IN MFP1G AND MFP1G1
CBD20M 20 AMP 2 POLE, CIRCUIT BREAKER USED IN MFR2G
CBD30M 30 AMP 2 POLE, CIRCUIT BREAKER USED IN MFFPR2G AND MFHP1G
CBD50 50 AMP 3 POLE, CIRCUIT BREAKER USED IN 5 THROUGH 12 ZONE MAINFRAMES
CBD70 70 AMP 3 POLE, CIRCUIT BREAKER USED IN 16 THROUGH 48 ZONE & HIGH POWER MAINFRAMES
PIN0114 14 GAUGE MALE PIN FOR “B”& “F” POWER CONNECTORS (PACKAGE OF 30) SEE PREVIOUS PAGE
PIN0214 14 GAUGE FEMALE SOCKET FOR “D”& “H” POWER CONNECTORS (PACKAGE OF 30) SEE PREVIOUS PAGE
PIN0120 20 GAUGE MALE PIN FOR “G” THERMOCOUPLE CONNECTOR (PACKAGE OF 30) SEE PREVIOUS PAGE
PIN0220 20 GAUGE FEMALE PIN FOR “E” THERMOCOUPLE CONNECTOR (PACKAGE OF 30) SEE PREVIOUS PAGE
WHT1919 CRIMP TOOL FOR ALL PIN-XXXX LISTED ABOVE
RPM0048 EXTRACTION TOOL FOR ALL PIN-TYPE CONNECTOR PINS
RPM0038 NEON INDICATORS USED ON 240 VAC MAINFRAME CIRCUIT BREAKER PANELS
RPM0044 CARD GUIDES FOR ALL MAINFRAMES
RPM0046 PINS FOR WHITE EDGE CARD CONNECTORS “I” (PACKAGE OF 20)
RPM0059 PANEL MOUNT BASE & LATCH FOR 5-ZONE THERMOCOUPLE MOLD CONNECTION “A” SEE PREVIOUS PAGE
RPM0062 MALE INSERT FOR 5 ZONE THERMOCOUPLE MOLD CONNECTION “A” SEE PREVIOUS PAGE
RPM0063 MALE INSERT FOR 8-ZONE THERMOCOUPLE MOLD CONNECTION “A” SEE PREVIOUS PAGE
RPM0064 MALE INSERT FOR 12-ZONE THERMOCOUPLE MOLD CONNECTION “A” SEE PREVIOUS PAGE
RPM0065 FEMALE INSERT FOR 5-ZONE THERMOCOUPLE CABLE CONNECTOR “C” SEE PREVIOUS PAGE
RPM0068 HOOD FOR 5 ZONE THERMOCOUPLE CABLE CONNECTOR “C” SEE PREVIOUS PAGE
RPM0071 HOOD FOR 5, 8 & 12 POWER & THERMOCOUPLE CABLE CONNECTIONS “D”,“E” & “F” SEE PREVIOUS PAGE
RPM0072 MALE INSERT FOR “B”, “F” & “G” (15 AMP CONNECTOR RATING IS EXCLUSIVE TO DME) SEE PREVIOUS PAGE
RPM0073 FEMALE INSERT FOR “D”, “E” & “H” (15 AMP CONNECTOR RATING IS EXCLUSIVE TO DME) SEE PREVIOUS PAGE
*(Reference page 134-147 for Letter Designations)
All Smart Series Modules

ABC1 1 AMP 250 VAC FUSE
ABC3 3 AMP 250 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES
|
ABC5 5 AMP 250 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES
Smart Series®
ABC10 10 AMP 250 VAC FUSE - NOTE: REQUIRED FOR 15 AMP MODULES USED IN 10 AMP FRAMES
ABC15 15 AMP 250 VAC FUSE
RPM0123 15 AMP 250 VAC FUSE - ULTRAFAST
RPM0124 .062 AMP TC FUSE FOR TSM MODULES ONLY
NYL0001 “NYLATCH” MODULE RETENTION PLUNGER AND GROMMET (10/PKG) - NOTE: AT THE BOTTOM OF EACH MODULE
RPM0008 POWER ROCKER SWITCH FOR ALL MODULES EXCEPT DSS AND CSS1524
RPM0009 TRANSFORMER TYPE DST416 FOR ALL MODULES EXCEPT DSS & TAS
RPM0027 ALUMINUM HANDLE FOR 15 AMP MODULES
RPM0039 30 AMP 2 POLE, CIRCUIT BREAKER FOR MODULES
RPM0023 TRIAC - TYPE Q6040P 40 AMP 600 VOLT FOR USE ON ALL MODULES
RPM0054 TRIAC - TYPE BTA40800B 40 AMP 800 VOLT FOR USE ON ALL MODULES EXCEPT CSS
RPM0050 2200 OHM FLAME PROOF FUSIBLE LINK RESISTOR USED IN THERMOCOUPLE CIRCUIT (10/PK) USED ON ALL MODULES
RPM0088 A/D CONVERTER FOR SSM15G, SSM15G1, SSM30G, SSH1001, SSH-1002 AND ALL CSS MODULES
Smart Series® 147

|Smart Series®

148 Smart Series®
Input Power Wiring Diagrams (Option A)
The diagrams on pages 148 through 150 are printed on the back panels of the mainframes.
For your convenience, they are depicted here along with additional information.
For information on input wiring for 30 AMP mainframes, contact DME.
4UBOEBSEJOQVUXJSJOHGPSNBJOGSBNFT VOMFTTTQFDJGJFEPUIFSXJTFBUUJNFPGPSEFS JT7"$

UISFFQIBTF XJSF )[ 015*0/"
*GJUCFDPNFTOFDFTTBSZUPDIBOHFUPBOPUIFS
DPOGJHVSBUJPO SFGFSUPUIFBQQSPQSJBUFEJBHSBNBOEJOGPSNBUJPOPOUIFGPMMPXJOHQBHFT
1BHF (OPTION A)7"$ QIBTF XJSF
1BHF (OPTION B) 7"$ QIBTF XJSF
1BHF(OPTION C) 7"$ QIBTF XJSF
(OPTION D) 7"$ TJOHMFQIBTF XJSF7"$ QIBTF XJSF
NOTE: 'PSNPMEQPXFSBOEUIFSNPDPVQMFDPOOFDUPSXJSJOHJOGPSNBUJPO TFFQBHFT

Input Power Wiring Diagrams (Option A)
OPTION A 208 – 240 VAC, Three-Phase, 4-Wire Delta

(Standard) or “Y” Power Distribution System
|
Smart Series®
"TTIPXOBCPWF FBDINPEVMFJTQPXFSFEGSPNPOFPGUIFUISFFQIBTFT;POF
GPS
FYBNQMF JTQPXFSFEGSPN1IBTF XIJDIJTTVQQMJFECZ3-BOE4-;POF
JT
QPXFSFECZ1IBTF XIJDIJTTVQQMJFECZ4-BOE5-;POF
JTQPXFSFECZ1IBTF
XIJDIJTTVQQMJFECZ3-BOE5-
NOTE: "UUIJTQPJOU UIFTFRVFODFSFQFBUTJUTFMG'PSFYBNQMF ;POF

JTDPOOFDUFE
UIFTBNFBT;POF
UP3-BOE4-BOE;POF
JTDPOOFDUFEUIFTBNFBT;POF
UP
4-BOE5-BOE;POF
JTDPOOFDUFEUIFTBNFBT;POF
UP3-BOE5-;POF

JTUIFODPOOFDUFEUPUIFTBNFQIBTFBT;POF
BOE
FUD5IJTNFUIPEPGDPOOFDUJPO
BTTVSFTUIFHSFBUFTUMJLFMJIPPEPGMJOFCBMBODF

Smart Series® 149
Input Power Wiring Diagrams (Option B)
OPTION B 380 – 415 VAC, Three-Phase, 5-Wire

“Y” Power Distribution System
Smart Series®
CAUTION NOTE:5IFWPMUBHFTGSPNMJOFUPMJOFJOUIJTTZTUFNBSFUPWPMUT4FWFSFEBNBHFUPNPEVMFBOE
|
Input Power Wiring Diagrams (Option B)
NBJOGSBNFDPVMESFTVMUJGUIJTUZQFPG"$JOQVUTZTUFNJTDPOOFDUFEUPBNBJOGSBNFXJSFEBT015*0/"5IJTUZQFPGQPXFS
EJTUSJCVUJPOJTOPUGPVOEPSJTWFSZVODPNNPOJOUIF6OJUFE4UBUFTCVUJTUIFNPTUDPNNPOTZTUFNGPVOEJONBOZPUIFS
DPVOUSJFTXPSMEXJEF
WARNING: *GFYQPSUPGUIJTTZTUFNJTJOUFOEFE NBLFTVSFUIBUXJSJOHJTSFDPOGJHVSFEGPSUIFDPVOUSZXIFSFJUJTUPCFVTFE
1MFBTFOPUFUIBUUIF7PMU1PXFS%JTUSJCVUJPO4ZTUFNJTUIFTBNFBTUIFi:wDPOOFDUJPOTIPXOJO015*0/"FYDFQU
GPSUIFWPMUBHFMFWFMTBOEUIFVTFPGUIF.1/UPEFWFMPQUIFWPMUGSPNUIFWPMUTZTUFN/PUJDFUIBUBMMNPEVMFT
IBWFPOFMJOFDPOOFDUFEUP.1/BOEUIFPUIFSTJEFDPOOFDUFEUPPOFPGUIFUISFFQIBTFMJOFT
Example: ;POF
JTDPOOFDUFEUP1IBTF XIJDIJTTVQQMJFECZ3-BOE.1/
;POF
;POF
;POF
TUBSUTUIFTFRVFODFPWFSBHBJO*UJTDPOOFDUFEUP1IBTF3-
BOE.1/ FUD

150 Smart Series®
Input Power Wiring Diagrams (Options C and D)
Example: ;POF
JTDPOOFDUFEUP.1/BOE3-;POF
JTDPOOFDUFEUP.1/BOE4- FUD
;POF
TUBSUTUIFTFRVFODFPWFSBHBJO*UJTDPOOFDUFEUP.1/BOE3- TBNFBT[POF

OPTION C 240 VAC, Two-Phase, 4-Wire

Input Power Wiring Diagrams (Options C and D)
5IFWPMUTJOHMFQIBTFDPOOFDUJPOPOMZVTFTUXPQPXFSMJOFTQMVTHSPVOE
CAUTION: 0OMZQPXFSDPOEVDUPSTTIPVMECFDPOOFDUFEUISPVHIUIFDJSDVJUCSFBLFS/FWFSNBLFHSPVOE
DPOOFDUJPOTUISPVHIBDJSDVJUCSFBLFS/PUJDFUIBUUIFPVUQVUPGUIFDJSDVJUCSFBLFSJTDPOOFDUFEUPUFSNJOBMTUSJQT
3-BOE4-"MTPOPUJDFUIBUHSPVOEJTDPNNPOXJUI.1/JOUIJTTZTUFN"MM[POFTJOUIJTTZTUFNIBWFUPCF
DPOOFDUFEUP.1/BOEFJUIFS3-PS4--JOFCBMBODFJTBDIJFWFECZBMUFSOBUJOHCFUXFFO3-and S/L2.
OPTION D 208 – 240 VAC, Single-Phase, 3-Wire or 120 VAC,

Two-Phase, 4-Wire
|
Smart Series®
"CPWFEJBHSBNEFQJDUTUXPEJGGFSFOUXJSJOHDPOGJHVSBUJPOT0OFJTWPMU TJOHMFQIBTF XJSF/PUFUIBU

MJOFT3-BOE4-BSFDPOOFDUFEUISPVHIUIFDJSDVJUCSFBLFSUPUIFBQQSPQSJBUFUFSNJOBMTUSJQT"MM[POFTXJMMCF
DPOOFDUFECFUXFFO3-BOE4-.1/JTDPNNPOXJUIHSPVOEBOEJTOPUDPOOFDUFEUISPVHIUIFDJSDVJUCSFBLFS
*OUIFWPMUDPOOFDUJPO [POFDPOOFDUJPOTTIPXOXJUIJOUIFEBTIFEMJOFBSFB
UIFWPMUTJTEFWFMPQFECFUXFFO
3-BOE.1/BOE4-BOE.1/"HBJO HSPVOEBOE.1/BSFOPUDPOOFDUFEUISPVHIUIFDJSDVJUCSFBLFS&BDI
[POFJOUIJTTZTUFNXJMMCFDPOOFDUFEUP.1/BOEFJUIFS3-PS4--JOFCBMBODFJTBDIJFWFECZBMUFSOBUJOH
CFUXFFO3-BOE4-
Smart Series® Alternate Connectors 151
Alternate Cable Configuration

Mold-Masters to DME Smart Series Conversion Cables
Smart Series® Alternate Connectors

Combination Mold Power and Thermocouple Conversion Cables allow
ease of conversion between Mold-Masters and DME systems
t Mold Power and Thermocouple combined in a single cable

t Conversion for 12 zones
t Cables available in standard lengths of 10’ and 20’ (custom lengths are
available)
|
Mold Power Thermocouple Cable Mainframe Mold
Mold-Masters to DME Smart Series

Item Number Zones Zones Length Connector Connector Splits
PITC1210YFE 10’ HBE48

DME “G” (Mold 5
Series Master (Frame End)
PITC1220YFE 20’ MPlug.12)
12 12
PITC1210YME 10’ HBE48
(Mold DME “G” 5
Master Series (Mold End)
PITC1220YME 20’ MPlug.12)
Works with the following connectors:
PIC12G MTC12G MPlug.12

Smart Series® Alternate Connectors | Mold-Masters to DME Smart Series
152
5-ZONES OF CONTROL
B PTCO5TB 5-ZONE TERMINAL MOUNTING BOX
U.S. 800-626-6653

C MPCO5C10 OR 20G 5-ZONE MOLD POWER CABLE; 10' OR 20' O.A.L.
D PICO5 5-ZONE MOLD POWER INPUT CONNECTOR
E TCO5C10 OR 20G 5-ZONE THERMOCOUPLE CABLE; 10' OR 20'
O.A.L.
F MTCO5 5-ZONE MOLD THERMOCOUPLE CONNECTOR
A
8-ZONES OF CONTROL
F E
Canada 800-387-6600

THERMOCOUPLE D PICO8 8-ZONE MOLD POWER INPUT CONNECTOR
E TCO8C10 OR 20G 8-ZONE THERMOCOUPLE CABLE; 10' OR 20'
O.A.L.
B
12-ZONES OF CONTROL
MOLD POWER
dme@milacron.com

D PICO12 12-ZONE MOLD POWER INPUT CONNECTOR
HUSKY COMPATIBLE CONTROL SYSTEM COMPONENTS
D C E TCO12C10 OR 20G 12-ZONE THERMOCOUPLE CABLE; 10' OR 20'

O.A.L.
Husky is a trademark of
Husky Injection Molding Systems
www.milacron.com
HEATER POWER LEADS
DISTRIBUTOR TUBE OR MANIFOLD HEATER (ZONE 1)
MOLD POWER
INPUT CONNECTORS MOLD THERMOCOUPLE CONNECTORS REAR
REAR
2 3 4 5 6 7 8 9 10 11 12 THERMOCOUPLE LEADS 13 14 15 16 17 18 19 20 21 22 23 24 VIEW
VIEW
WHITE (-)
U.S. 800-626-6653
BLACK (+)

PICO12
MTCO12
13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
PICO8
9 10 11 12 13 14 15 16 TYPE “J”
T/C ONLY
MTCO8
1 2 3 4 5 PROBE OR 1 2 3 4 5 6 7 8
NOZZLE 6 7 8 9 10
HEATER
PICO5
6 7 8 9 10
MTC05
Z 1 2 3 4 5
Canada 800-387-6600
ZONE BEFORE POWER BEFORE POWER IS

1 13 1 9 1 6 ZONE 1 IS CONNECTED: O CONNECTED: ZONE BLK WHT BLK WHT BLK WHT
2 14 2 10 2 7 ZONE 2 t 64&0)..&5&350
CHECK EACH HEATER
ZONE 1 1 6 1 9 1 13
3 15 3 11 3 8 ZONE 3 POWER LEAD. RESISTANCE
N ZONE 2 2 7 2 10 2 14
4 16 4 12 4 9 ZONE 4 TO GROUND SHOULD BE ZONE 3 3 8 3 11 3 15
5 17 5 13 5 10 ZONE 5 GREATER THAN 20,000 E
OHMS. ZONE 4 4 9 4 12 4 16
6 18 6 14 ZONE 6 t $)&$,3&4*45"/$& ZONE 5 5 10 5 13 5 17
7 19 7 15 ZONE 7 BETWEEN HEATER POWER
6 14 6 18
LEADS. (SEE CALCULATION

ZONE 6
8 20 8 16 ZONE 8 ZONE 7 7 15 7 19
BELOW) 1
9 21 ZONE 9 ZONE 8 8 16 8 20
10 22 ZONE 10 ZONE 9 9 21
dme@milacron.com
11 23 ZONE 11
2

ZONE 10 10 22
12 24 ZONE 12 ZONE 11 11 23
HEATER HEATER HEATER ZONE 12 12 24
MEASURED
TYPICAL MOLD CONNECTOR WIRING DIAGRAM (REVISION “A”)
VOLTS VOLTS WATTS RESISTANCE

MARKED ON × MARKED ON ÷ MARKED ON # OHMS
HEATER HEATER HEATER
EXAMPLE: (240 VOLTS) × (240 VOLTS) ÷ 820 WATTS # 70 OHMS
NOTE: ALL GROUNDS MUST BE CONNECTED TO MOLD TO INSURE OPERATOR SAFETY.
www.milacron.com
Alternate Cable Configuration | Smart Series® Alternate Connectors
153
154 Smart Series® Alternate Connectors
Terminal Box Detail & Mold Connectors
EUROPEAN CONFIGURATION
2
E
5
1
4
Terminal Box Detail & Mold Connectors
B
A D
C
3
Callout Number 1 is special B

order with a short lead time;
D
all other items are in stock
A
C
|
ITEM NUMBER ITEM NUMBER DIMENSIONS

CALLOUT CALLOUT
TERMINAL MOLD
NUMBER NUMBER
BOX CONNECTOR A B C D E
1 PTO5TB 2 PICO5 1.50" 38mm 4.25" 108mm 2.44" 62mm 4.88" 124mm 4.10" 104mm
1 PTO5TB 2 MTCO5 1.50" 38mm 4.25" 108mm 2.44" 62mm 4.88" 124mm 4.10" 104mm
3 PTCO5TB 4 PICO5 1.50" 38mm 8.84" 225mm 2.44" 62mm 9.47" 241mm 4.10" 104mm
5 MTCO5 1.50" 38mm 8.84" 225mm 2.44" 62mm 9.47" 241mm 4.10" 104mm
5 MTCO8 1.50" 38mm 9.91" 252mm 2.44" 62mm 10.53" 267mm 4.10" 104mm
5 MTCO12 1.50" 38mm 12.17" 309mm 2.44" 62mm 12.79" 325mm 4.10" 104mm
NOTE: ALLOW AN ADDITIONAL 0.25" (10mm) IN HEIGHT AND WIDTH FOR SCREW HEAD CLEARANCE

Smart Series® 155
DME Mainframe Stand Accessory – Cable Storage Basket
FSCB0001 CABLE BASKET

*ODMVEFT
BOE
MPOH[JQUJFT
t Compatible with DME Smart Series

t Durable molded plastic construction
t Keep all your cables and connectors safely off the floor
|Smart Series®
Mainframe Stand Accessory – Cable Storage Basket
Note: Product color may differ from
what is shown.
Smart Series 8-zone stand Smart Series 12-zone stand
INSTALLATION GUIDE
Step 1
1PTJUJPO#BTLFUPOCPUUPNPGUIF%.&.BJOGSBNF'MPPS4UBOE
%FDJEFJGZPVXJMMBUUBDIUIFCBTLFUUPUIFSJHIUPSMFGU.BJOGSBNF6QSJHIU1PTU.
Step 2
4FDVSF#BTLFUUP.BJOGSBNF'MPPS4UBOEXJUI4VQQMJFE$BCMF5JFT
Attach Longer Cable Tie to Side Post Attach Shorter Cable Ties to Corners

Valve Gate C ontrols
ENERGY EFFICIENT, RELIABLE

AND COMPACT HYDRAULIC AND
PNEUMATIC CONTROLS
Valve Gate Controls 157
DME Pneumatic Sequential Valve Gate Controller
The SVG controller provides the user with full control over valve gate flow sequence, critical when
molding complex or large parts. All SVG controllers feature the NEW APS (Adaptive Process System)
technology providing faster processing and response speed.
BENEFITS
t The sequential valve gate technology is integrated in a precise hot runner control unit
with all available features or stand alone unit
t SVGP systems are air cooled & energy efficient
t Designed to easily connect to any valve gate system
t Precise filling control with performance graphs displaying time and position,
with up to 4 steps per cycle
t (2) digital and analog triggers for 2-shot applications
Valve Gate Controls

CONFIGURATION
t Pin position feedback for gate open /close confirmation
t Automatic and manual mode for individual gate control
t Absolute and incremental timer selections
t Single or dual acting solenoid valves for gate activation, valve banks re-locatable SVGP
|
t Calibrate analog signals for position, pressure and volumetric settings
DME Valve Gate Controller Products and Solutions

t Reconfigure pin position feedback inputs for 12 additional sequences
t 500 or 1000 Watt 24VDC power supply - Standard 220V single phase (185-245V range)
or Optional 480V three phase
ITEM
DESCRIPTION INCLUDES
NUMBER
SVGP2 2 ZONE PNEUMATIC SVG12 HMI, 1-2 SOLENOID VALVE BANK

SVGP12 12 ZONE PNEUMATIC SVG12 HMI, 2-6 SOLENOID VALVE BANKS
SVGPC2 2 ZONE COMPACT PNEUMATIC SVG12C HMI, 1-2 SOLENOID VALVE BANK
SVGPC
SVGPC12 12 ZONE COMPACT PNEUMATIC SVG12C HMI, 2-6 SOLENOID VALVE BANKS
If you do not see the number of controlled zones required in the table above please contact us.
Optional Accessories
ITEM Pneumatic Power pack
DESCRIPTION
NUMBER
ITSPTROLLEY STAND Stand

PNEUPP PNEUMATIC POWER PACK 500 PSI

Valve Gate
textControls
158
158 text
DME Pneumatic Sequential Valve Gate Controller
page content
KEY TECHNICAL FEATURES AT A GLANCE

t Digital outputs – fused at 2 amps
t Digital inputs - pin position back/forward
t Integrated 24 VDC power supply to drive valve gate solenoids
t 7” color touch screen on standalone controller
t Controls single or dual coil solenoid valves
t Real time valve status graph
t Configurable Easy View status page
t NEW SVG Power pack combines hot runner control, SVG,
hydraulic power pack and solenoid valve bank all in one package
|
Valve Gate Controls
PROGRAMMABLE TRIGGERS & ALARMS

t Digital input – sequence start trigger
t Digital input triggers – programmable sequence triggers
t (2) Analog inputs 0-10 volts
t Analog input 4-20ma
t Remote enable signal – from IMM
t Fault relay output (dry contact) – to IMM
t Dry contact or 24VDC input triggering
Controller includes 15ft (4.8m) cables
DME Hydraulic Sequential Valve Gate Controller
The SVG controller provides the user with full control over valve gate flow sequence, critical when
molding complex or large parts. All SVG controllers feature the NEW APS (Adaptive Process System)
technology providing faster processing and response speed.
BENEFITS
t The sequential valve gate technology is integrated in a precise hot runner control unit
with all available features or stand alone unit
t SVGH6 systems - air cooled & energy efficient
SVGH1200 & 1600 systems - built-in water cooling circuit for the hydraulic power pack
t Designed to easily connect to any valve gate system
t Precise filling control with performance graphs displaying time and position,
with up to 4 steps per cycle
t (2) digital and analog triggers for 2-shot applications
Valve Gate Controls

CONFIGURATION
t Pin position feedback for gate open /close confirmation
t Automatic and manual mode for individual gate control
t Absolute and incremental timer selections
t Single or dual acting solenoid valves for gate activation, valve banks relocatable
t Calibrate analog signals for position, pressure and volumetric settings
|
t Configure up to 4 cards to control as many as 48 single acting valve gates

t Reconfigure pin position feedback inputs for 12 additional sequences
t 500 or 1000 Watt 24VDC power supply - Standard 220V single phase (185-245V range) 3L-1200 PSI / 3L-1600 PSI
or Optional 480V three phase Power pack
t Available as standalone controller or semi-integrated into the TSP or TSP Plus
temperature controller
ITEM POWER PACK

DESCRIPTION CONSISTS OF
NUMBER PSI
SVGH62 2 ZONE HYDRAULIC SVG12 HMI, POWER PACK, 1-2 SOLENOID VALVE BANK, STAND
SVGH66 6 ZONE HYDRAULIC 3L-600 PSI SVG12 HMI, POWER PACK, 1-6 SOLENOID VALVE BANK, STAND
SVGH68 8 ZONE HYDRAULIC SVG12 HMI, POWER PACK,1-8 SOLENOID VALVE BANK, STAND
SVGH612 12 ZONE HYDRAULIC SVG12 HMI, POWER PACK, 2-6 SOLENOID VALVE BANKS, STAND
SVGH126 6 ZONE HYDRAULIC SVG12 HMI, POWER PACK, 1-6 SOLENOID VALVE BANK, STAND 3L-600 PSI Power pack
SVGH128 8 ZONE HYDRAULIC 3L-1200 PSI SVG12 HMI, POWER PACK,1-8 SOLENOID VALVE BANK, STAND
SVGH168 8 ZONE HYDRAULIC 3L-1600 PSI SVG12 HMI, POWER PACK,1-8 SOLENOID VALVE BANK, STAND
If you do not see the number of controlled zones required in the table above please contact us.
160
text
160 Valve Gate
textControls
pageValve
DME Sequential content
Gate Controller
KEY TECHNICAL FEATURES AT A GLANCE

t Digital outputs – fused at 2 amps
t Digital inputs - pin position back/forward
t Integrated 24 VDC power supply to drive valve gate solenoids
t 7” color touch screen on standalone controller
t Controls single or dual coil solenoid valves
t Real time valve status graph
t Configurable Easy View status page
t NEW SVG Power pack combines hot runner control, SVG,
hydraulic power pack and solenoid valve bank all in one package
|
Valve Gate Controls
PROGRAMMABLE TRIGGERS & ALARMS

t Digital input – sequence start trigger
t Digital input triggers – programmable sequence triggers
t (2) Analog inputs 0-10 volts
t Analog input 4-20ma
t Remote enable signal – from IMM
t Fault relay output (dry contact) – to IMM
t Dry contact or 24VDC input triggering
Controller includes 15ft (4.8m) cables
VCAP Air Valve Assemblies and 4-Zone Timer
VCAP multi-station air valve assemblies

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UPFOTVSFUIBUVOVTFEWBMWFTEPOPUMFBLBJS

VCAP0400 4-STATION AIR VALVE ASSEMBLY
Valve Gate Controls

Note: Each valve assembly includes a valve cable.
|
VCAP Air Valve Assemblies and 4-Zone Timer
Compact 4-zone pneumatic or hydraulic control unit
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VCTB4000 4-ZONE PNEUMATIC Highly accurate DME
HYDRAULIC CONTROLLER
VCPT0100 100-FT. LENGTH OF solid state timers
PNEUMATIC TUBING
Note: Trigger signal cable included with controller.

feature resolution to
1/100 of a second, far
exceeding the industry
standard of 1/10 of
a second.

162 Valve Gate Controls
DME Single Zone Timer
DME Single Zone Timer: TCM03024D
Versatile for virtually any type of operation that requires a timer, including single-zone valve gate systems, core
pulls, and air sweeps.
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DME Single Zone Timer
DME Single Zone Timers (TCM03024D)

|
are highly accurate, solid state timers

Valve Gate Controls
that feature resolution to 1/100 of second,

far exceeding the industry standard of
1/10 of a second.
Shown next to a SSM1512 Temperature Controller in a Standard 2-Zone

Smart Series Mainframe.

Control Systems 163
Technical Support
Customer Power Requirement Worksheet – Option A Delta 3-Phase Power 240 VAC
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%.&)PU3VOOFS$POUSPM4ZTUFN.BJO$JSDVJU#SFBLFS&WFOUIPVHIFBDITMPUNBZCFSBUFEBUBNQT BMMTMPUT$"//05
OFDFTTBSJMZEFMJWFSGVMMQPXFSGSPNBMM[POFTTJNVMUBOFPVTMZ
PHASE A POWER PHASE B POWER PHASE C POWER
ZONE # WATTAGE ZONE # WATTAGE ZONE # WATTAGE
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
16 17 18
19 20 21
22 23 24
25 26 27
28 29 30
31 32 33
34 35 36
37 38 39
Control Systems
40 41 42
43 44 45
46 47 48
49 50 51
52 53 54
55 56 57
58 59 60
|
TOTAL PHASE A WATTS TOTAL PHASE B WATTS TOTAL PHASE C WATTS
Technical Support
Record Product Breaker Record Product Breaker Record Product
Size Phase Wattage Not Size Phase Wattage Not Breaker Size Phase
To Exceed To Exceed Wattage Not To Exceed
Breaker Wattage Size Table – For Delta 240 VAC 3-Phase Power
MAXIMUM PHASE WATTS MAXIMUM PHASE AMPS
BREAKER RATING AMPS EACH PHASE A,B,C EACH PHASE A,B,C
CANNOT EXCEED THIS VALUE CANNOT EXCEED THIS VALUE
10 AMP 1,386 WATTS 5.77 AMPS
100 AMP 13,856 WATTS 57.74 AMPS
'PS1IBTF%FMUB1PXFS505"-8"5544RVBSF3PPU
Y7PMUT"$Y".14
."9*.6.1)"4&8"554505"-8"554

164 Control Systems
Technical Support
TECHNICAL SUPPORT: RETURNING ITEMS TO DME

Return for Repair
U.S. Customers:
TSP, TSP Plus, TSP-SVG Systems and TSM modules needing repair or calibration:
Please call 800-626-6653 for a Repair SR#. Please make sure
the SR# is on the outside of the box to expedite the repair.
%
.&$PNQBOZ
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.BEJTPO)FJHIUT .*
"UUFOUJPO3FQBJST
All other temperature controls needing repairs send to:
%.&3FQBJST
4UBUF3PVUF4PVUI
"VTUJOCVSH 0)
Canadian Customers:
%.&$PNQBOZ
/PSUIXFTU%S
.JTTJTTBVHB 0/5-7+
| blankSupport
"UUFOUJPO3FQBJST

$BMMJGZPVOFFEBEEJUJPOBMIFMQ
| Technical
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5IJTQSPDFEVSFJODMVEFTJUFNTTUJMMVOEFSXBSSBOUZ IPXFWFSGVTFTBOEUSJBDTBSFOPUDPWFSFE
Systems
Systems
Return for Credit

Control
$BMM%.&64"BUPS%.&$BOBEBBUUPMMGSFF
Control

DME Mold Technology Catalogs
DME: Your Complete Mold Technologies Provider
Check Out All of the DME Mold Technology Catalogs

And You’ll See Why We’re an Essential Resource to Thousands of Customers Worldwide!
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☎ 800-626-6653 (toll-free)
☎ 800-387-6600 (toll-free) ☎ 52 442 713 5666
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DME

Mold Power & Thermocouple Cables..........................134

> High-Performance ....................................................69-70 SSM Modules............................................................141-142

> S-Series ...........................71 DSS Modules.............................................................143-144

Hot Runner Services

U.S. 800-626-6653  Canada 800-387-6600  dme@milacron.com  www.milacron.com

Hot Runner Systems

U.S. 800-626-6653  Canada 800-387-6600  dme@milacron.comwww.milacron.com

technical service coverage and response. The DME

DME’s molding systems.

qualification before any metal is cut

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

Terms and Conditions of Sale

U.S. 800-626-6653  Canada 800-387-6600  dme@milacron.comwww.milacron.com

Sales and Ordering Information

Estimating locations are:

 70 East Hillis Street, Youngwood, Pa 15697, FAX: 724-925-2424

 1117 Fairplains Street, Greenville, MI 48838, Tel. 616-754-4601, FAX: 616-225-3924

Hot Runner Warranty

U.S. 800-626-6653  Canada 800-387-6600  dme@milacron.comwww.milacron.com

DME Hot Runner…

Your essentiaal resource for

Whether your application requires best-in-class components or a turnkey

DME: An Essential Resource for System Solutions

Hot Runner Productivity DME offers a comprehensive family of hot runner

the industry’s broadest range of hot runner products

A wide range of DME nozzles allows Stellar Micromolding Nozzles

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

…from components and manifolds to turnkey hot halves

U.S. 800-626-6653 Canada 800-387-6600  dme@milacron.comwww.milacron.com

Standard Global Manifold

Key Features of the DME Global Manifold Include:

From Machine Nozzle to

HOT SPRUE BUSHING TIP STYLE

PLASTIC MATERIAL PROCESS CONDITIONS

Polyethylene PE 200 392 25 77 225 437 0.74 0.0267 0.96 0.0347

SPRUE GATE TIP

RING GATE TIP

Hot Runner Quote Request Form

EMAIL TO DMEUS_AE_QUOTE@MILACRON.COM OR FAX

DME / Milacron Applications Engineering

Hot One Hot Runner Technology

AE001 Rev 2.5.2016 Page 1 of 1

U.S. 800-626-6653  Canada 800-387-6600  dme@milacron.comwww.milacron.com

Hot Runner Technology............................................15-17

Stellar Micromolding Hot Runner Systems..........19-23

Hot One Hot Runner Technology............................25-42

user-friendliness and affordability

Cartridge Heaters & Thermocouples....................36-42

Custom-configured manifolds, manifold and

component systems, and complete hot half

Meteor® Hot Runner Systems.................................44-50

Online Price Guide Go to www.dme.net/prices for the latest pricing guide.

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

Features and Benefits

Our ongoing customer-driven philosophy has

Tubular Heated Systems

Using exclusive, distributed wattage Tubular

Heaters, the DME Hot Runner Systems can

process many engineering grade resins.

heat required, providing the added benefit of

DME’s Hot Runner Technology has become

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.com www.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

70 East Hillis Street, Youngwood, Pa 15697, FAX: 724-925-2424

1117 Fairplains Street, Greenville, MI 48838, Tel. 616-754-4601, FAX: 616-225-3924

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

Two interchangeable tip styles – Point Gate and Sprue Gate

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com

U.S. 800-626-6653 Canada 800-387-6600 dme@milacron.comwww.milacron.com