Hot Runner Control Systems

DME
HOT RUNNER
&
CONTROL SYSTEMS
Hot Runner Systems
Table of Contents
Hot Runner Systems
Temperature Control Systems

SS TSP & TSP Plus
Customer Commitment........................................................4
Terms and Conditions of Sale ............................................5
Sales and Ordering Information ........................................6
Hot Runner Warranty ..........................................................7
Hot Runner Systems Overview ...................................... 8-9
Custom Applications Engineered Hot Runner Systems
Standard Global Manifold and Components .................10
Hot Runner Quote Request Form .....................................11
Hot Runner Selection Guide .............................................12
Plastic Materials,Specifications/ Bushing Selection ..13
TSP (Touch Screen Panel)......................................110-112

TSP Plus (Touch Screen Panel..............................113-114
Smart Series
Typical System Configurations......................................119
Single Zone Controllers...........................................120-121
2-zone Controllers............................................................122
Single & 2-zone Accessories.................................123-124
Single Zone High Power Controller & Accessories...125
Smart Series 15 AMP Mainframe
Configurations...........................................................126-127
Configurations..................................................................128
Digital Current/Voltage Monitor.....................................129
Floor Stand........................................................................130
Step-Down Transformer Kits..........................................130
Blank Panels, Fuses & Crimp Connectors...................130
Mainframe Connector Wiring.................................131-133
Mold Power & Thermocouple Cables..........................134
Mold Power Input Connectors.......................................135
Mold Thermocouple Connectors...................................136
Mold Connector Pocket Layouts............................137-138
Pre-wired Combination Terminal Mounting Boxes....139
Terminal Mounting Boxes...............................................140
SSM Modules............................................................141-142
DSS Modules.............................................................143-144
TSM Modules............................................................145-146
TAS Temperature Alarm/System Modules...........148-148
Replacement Parts...................................................149-151
Input Wiring Diagram..............................................152-154
Alternate Cable Configurations..............................155-158
Stand Accessories..........................................................159
Thermal Gate Hot Runner Systems

DME Hot Runner Technology......................................16-17
Stellar Micromolding....................................................18-23
Hot Runner Systems
Table of Contents
Standard Pre-Engineered
Hot Runner Systems
The Hot One Technology.............................................24-42
Meteor Hot Runner......................................................43-50
Hot Sprue Bushings

D-MAX............................................................................53-59
Gate-Mate .....................................................................60-67
Straight-Shot ................................................................68-78
> High-Performance ....................................................69-70
> S-Series ...........................71
> E-Series ....................72-73
> ER-Series .................74-75
> T-Series ...........................76
> TR-Series .........................77
> Replacement Parts ........78
Integrally Heated Sprue Bushings ...........................79-84
Hot Runner Services
Valve Gate Controller Products &

Solutions
Moldflow........................................................................86-87
Moldflow Quote Request Form........................................88
Hot Runner Service Center.........................................89-90
SVG Pneumatic Control Systems...........................161-161

SVG Hydraulic Control Systems.............................163-164
VCAP Air Valve Assemblies...........................................165
Compact 4-zone Pneumatic/Hydraulic controller......165
Single Zone Timer............................................................166
Obsolete System Replacement Parts

Gate-Mate......................................................................92-93
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
Index
Alternate Cable Configuration........................................151-152

Alternate Cable Wiring Diagram .......................................... 153
Index
Blank Panels, Fuses & Crimp Connectors............................. 128

Bushing Selection....................................................................12
Cable Storage Baskets...........................................................157
Cartridge Heaters............................................................... 36-38
Control Systems..............................................................103-164
D-MAX High Performance Hot Sprue Bushings ................ 53-59
Digital Current/Voltage Monitor ........................................... 125
DSS Modules ................................................................. 139-140
Flexible Tubular Heaters .................................................... 31-32
Floor Stand (Temp Control) ................................................... 126
Gate-Mate Hot Sprue Bushings.........................................60-67
Global Manifolds .................................................................... 10
U.S. 800-626-6653
Canada 800-387-6600
Sales and Ordering Information ............................................... 6

Selection Guide, Hot Runner Technology ............................... 11
Single & 2-Zone Controller Accessories ....................... 118-121
Single Zone Controllers ................................................. 116-117
Single Zone High Power Controller & Accessories.............. 121
Single Zone Timer ................................................................. 161
Configurations ................................................................ 122-123
Configurations ....................................................................... 124
SSM Modules ................................................................ 137-138
Stellar Micromolding Hot Runner Systems ....................... 18-23
Step-Down Transformer Kit .................................................. 126
Straight Shot Hot Sprue Bushings ................................. 69-77
TAS Temperature Alarm/System Modules .................... 143-144
Technical Support Data (Temp Control) ......................... 163-164
Terminal Mounting Boxes ...................................... 135-136, 154
Terms and Conditions of Sale ................................................... 5
Thermocouple Cables ........................................................... 130
Thermocouple Input Connectors ........................................... 132
TSM Modules ................................................................ 141-142
TSP Temperature Controllers ......................................... 106-108
TSP Plus Temperature Controllers ................................. 109-110
Tubular Heaters, Flexible ................................................... 31-32
Two Zone (2-Zone) Temperature Controllers ........................ 118
Typical System Configuration (Temp Control) ...................... 115
VCAP Air Valve Accessories ................................................. 161
Valve Gate Controls ....................................................... 157-161
Valve Gate Single Zone Tiimer...............................................162
Warranty Information................................................................ 7
dme@milacron.comwww.milacron.com
Index
Mainframe Connector Wiring ........................................ 127-128

Meteor Hot Runner Systems ............................................. 43-50
Moldflow Services.......................................................... 86-88
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
Replacement Parts (Temp Control) ................................ 145-147
Input Power Wiring Diagrams........................................148-149

ntegrally Heated Hot Sprue Bushings ............................... 79-84
Obsolete Hot Runner Replacement Parts........................92-101

Cool One & Micro Cool One.......................................94-101
Gate-Mate Nozzles............................................................92
Gate Shell Insulators.........................................................93
Hot Runner Systems
Hot One Components & Accessories ................................ 24-42

Hot One Hot Runner Technology Overview .................... 15-17
Hot Runner Modular Components ........................................ 102
Hot Runner Quote Request Form ........................................ 13
Hot Runner Services .......................................................... 85-90
Hot Runner Selection Guide ................................................... 11
Hot Runner Warranty ................................................................ 7
Hot Sprue Bushings, D-MAX High Performance ............... 53-59
Hot Sprue Bushings, E-Series Straight Shot ..................... 72-73
Hot Sprue Bushings, ER-Series Straight Shot ................... 74-75
Hot Sprue Bushings, High-Performance ............................ 69-70
Hot Sprue Bushings, Integrally Heated ............................. 79-84
Hot Sprue Bushings, Straight Shot Replacement ................ 181
Hot Sprue Bushings, S-Series Straight Shot .......................... 71
Hot Sprue Bushings, Straight Shot ................................ 72-78
Hot Sprue Bushings, T-Series Straight Shot ..................... 76-77
Pre-Wired Combination Terminal Mounting Boxes .............. 135

Plastic Materials and Specifications......................................12
Hot Runner Systems
Customer Commitment
Applications Engineering
Is there a hot runner application on your wish list that
you dont see here? DME can help. Our design and
applications engineering group consists of professional
engineers and experienced designers. Once you provide
the information necessary for proper application design
and analysis, the DME applications engineering team
will go to work diligently analyzing, designing and
manufacturing a hot runner system that will best suit
your needs and requirements.
Hot Runner Systems
Customer Commitment
Technical Service
DME is proud to say that it is an industry model for
technical service coverage and response. The DME
technical service department covers the entire United
States and Canada, with additional service representatives
in Europe, Asia and throughout the world. Because
DME knows you need assistance starting, operating,
and maintaining hot runner systems it has made a
great effort to strategically staff a Technical Service
Department that is responsible for the success of
DMEs molding systems.
To take advantage of any or all of these services, or if

you have any questions, problems, or ideas please call
DME at:
800-626-6653 (U.S.)
800-387-6600 (Canada)
Part prints or system design prints may be sent in the

following ways:
dme_appl_eng@milacron.com
248-544-5707 (U.S.) fax
905-677-5280 (Canada) fax
DME offers you a wide range of services from

component selection to on-site system installation.
Our ever-growing list of services include the ability to:
Analyze the best system to fit your needs
Assist in system design
Perform computerized system analysis and resin

qualification before any metal is cut
Marry your system to the mold base, plates and

components required
Provide quotations for and perform all of the special

machining required
Assemble and wire the system
Check mechanical fit of all components and perform

electrical load testing
Assist with system start-up and maintenance
Field Sales and Customer Service

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

cavities and cores!
U.S. 800-626-6653Canada 800-387-6600dme@milacron.comwww.milacron.com
Hot Runner Systems
Terms and Conditions of Sale

1. FOB POINT / PRICES: Products are sold FCA Madison Heights.
Any taxes are in addition to the prices and may be invoiced later.
2. SHIPPING SCHEDULE: The shipping schedule is our current estimate
of delivery dates and we agree to use reasonable efforts to comply
with the schedule.
3. WARRANTY:
(a) Any DME trademarked or tradenamed product or part thereof
manufactured by or for us which, under normal operating conditions
in the plant of the Buyer thereof, proves defective in material or
workmanship, as determined by our inspection, within 12 months
from the date of shipment will be replaced or repaired free of charge
to Buyer.
This warranty is contingent upon the following conditions: that we
promptly receive notice of the defect; that Buyer establish that the
product has been properly installed, maintained, and operated within
the limits of related and normal usage as specified by us; and that,
upon our request, Buyer will return to us at our expense the
defective product or part thereof.
5.
6.
7.
8.
U.S. 800-626-6653
Canada 800-387-6600
(b) The claim of infringement is not based, directly or indirectly,

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

prepaid transportation and an issued RMA number. All items are
subject to our inspection before credit will be allowed.
NO GOODS ARE RETURNABLE LATER THAN THIRTY DAYS AFTER
RECEIPT OF MERCHANDISE.
9. PATENT INDEMNITY: We shall defend any suit or proceeding
brought against Buyer and pay all costs and damages awarded
against Buyer provided that:
(a) The suit or proceeding is based upon a claim that the product or
part thereof is an infringement of any claim of a presently existing
U.S. patent;
Hot Runner Systems
Sales and Ordering Information
U.S.A.
TERMS AND CONDITIONS OF SALE: See previous page.
PHONE ORDERS TOLL FREE: 800-626-6653. DMEs 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:
Hot Runner
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and Ordering
Information
Custom
Hot Runner
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DME Customer Service

248-544-5113 or 888-808-4363
CHECKS OR MONEY ORDERS: When paying invoices by check or money order, please make payable to DME Company.
include remittance copy of invoice and mail to:
DME Company, Department Lock Box 774867, 4867 Solutions Center, Chicago, IL 60677-4008
WALK-IN ORDERS, PICK-UPS AND RETURNS: If desired, ordered products in stock at your nearest DME Service Center
can be picked up rather than shipped. Walk-in orders at Service Center locations can also be processed while you wait.
Products being returned for repair or exchange should be processed through Customer Service prior to being returned.
SPECIAL MACHINING SERVICES: Prints for quotation on special machining work can be sent by EDI to dme_cad@dme.net
or mailed to the Estimating Department of the DME manufacturing location nearest you. Call our toll-free number if desired to
clarify location which serves your area.
Estimating locations are:
70 East Hillis Street, Youngwood, Pa 15697, FAX: 724-925-2424
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 Systems
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 Companys 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
Plastic leakage, due to manufacturing defect, within hot
runner plates covered for Two (2) years; excluding Gate
Detail.
Stellar Hot Runner Hot Halves

(plates designed, machined & assembled by DME, excluding Electrical Parts)
Plastic leakage, due to manufacturing defect, within hot

runner plates covered for Two (2) years; excluding Gate
Detail.
DME Hot One and Stellar Manifold and Components

(neither plates nor assembly supplied by DME, excluding Electrical Parts)
One (1) year
DME Electrical Parts

(all heaters and thermocouples)
One (1) year
DME Mold Controls

(Temperature, Valve Gate & Cavity Pressure Controls, excluding Fuses & Triacs)
Two (2) years
Replacement or repair will be made at the election of DME; implemented at a DME facility and/or by shipment of replacement parts to the customer for
installation and/or return of defective parts to DME for repair.
Transferability:
This warranty may be transferred by the original DME Customer to a subsequent owner of the product if all of the following conditions exist: (i) the original
DME Customer purchased the product for purposes of re-sale or other immediate transfer and DME was made aware of these purposes at the time of
purchase in writing, (ii) within thirty (30) days from the date of invoice, DME is notified in writing of the transfer and provided with the name of the new
owner (hereafter Transferee), the contact person of the Transferee and the Transferees address.
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
caused by improper assembly, operation, disassembly and maintenance
t Wear or damage resulting from corrosion or processing of abrasive/aggressive resins
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 products 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
U.S. 800-626-6653
Canada 800-387-6600
Hot Runner
Systems
Custom
Hot Runner
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Products
| Hot Runner
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DME Hot One Hot Halves

(plates designed, machined & assembled by DME, excluding Electrical Parts)
Hot Runner Systems
DME Hot Runner
Hot
Runner
Custom
Hot Systems
Runner Systems
| HRS Overview
| Index
Your essentiaal resource for

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

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

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

versatility in system selection
System Solutions
DME offers a comprehensive family of hot runner
systems built on our modular architecture making custom configuration easy and quick.
Systems include:
Stellar Micromolding Systems

engineered for tight pitch molding
The Hot One 250, 375 and 625 series
Stellar Micromolding Nozzles

provide application flexibility
9
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Hot Runner
from components and manifolds to turnkey hot halves

page content
Specialized Systems
As one of the worlds leading hot runner
manufacturers, we recognize that
some application challenges demand
specialized solutions. Offerings include:
Stellar Manifold and Components
Stellar Hot Halves
Hot One Manifold and Components
Hot One Hot Halves
Stellar & Hot One Systems are custom

configured for your application
U.S. 800-626-6653
Knowledge That Gives

You an Advantage
Service and Support to

Keep You Productive
Our team of trained, experienced experts

can help you with needs analysis, design,
configuration, operation, and all the other
services that enable you to focus on your
core business.
DME provides essential support to

keep your hot runner systems in-service.
Our dedicated hot runner service center
is staffed by trained, experienced
technicians who support DME systems,
as well as other brands, to provide help
when and where you need it, every step
of the way.
Applications engineering
Moldflow analysis
Moldflow predictive analysis optimizes

part design and lowers costs
Canada 800-387-6600
DME Hot Runner Service Center provides

total support for your hot runner system
Hot Runner
Systems
Overview
Custom
Hot Runner
Systems
Products
| HRS
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Our goal is simple: to be an essential resource for your molding challenges.

Every step of the way.
10
Hot Runner Systems
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 youre 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.
Hot Runner Systems
Standard Global Manifold and Components
Key Features of the DME Global Manifold Include:
Flexible tubular heaters
Locating rings that fit virtually any injection press platen hole diameters
Heated Manifold Extension Nozzles available
High-tolerance, press-fit heaters
Upper and center Manifold supports constructed of high-strength, low-heat conductive titanium that minimizes
heat loss and maintains an even heat profile
J-type thermocouples are black-and-white, coinciding with the IEC 584-3 International Standard
Flow channel sizes range from 6mm to 16mm
DME customers are assured that DME Manifold Systems are designed and built with a global standard that ensures efficient
molding anywhere in the world. And, since replacement parts are identical worldwide, they are readily available wherever
your mold is operating, not just where it was built. All DME nozzles, including, Stellar and the Hot One, perform flawlessly
with the DME Global Manifold Standard.
Heated MEN
From Machine Nozzle to
Manifold
Available in all balanced design layout patterns up to 24 nozzle drops*, including inline, X, Y, H, Double H
& Multiple Level Systems.
*Contact DME for Higher Cavitation
MANIFOLD DESIGN, SPECIFICATION & TOLERANCE STANDARDS

HARMONIZED FOR GLOBAL PRODUCT OFFERING
AMERICAS EUROPE ASIA AUSTRALIA / NEW ZEALAND INDIA AFRICA
DME Hot Runner Technology Selection Guide

Good
Contact DME Applications
Engineering or Technical Service
for resin application guidance
NOZZLE
Stellar
High Performance
Heater
Hot One 250 Series
Coil Heater
Hot One 250 Series
Cast-In Heater
H = High
TIP
Sprue Tip
Recommended
Gate Diameter Range
Flow Capacity
(Grams)
Viscosity
Min
(mm)
Max
(mm)
Min
(inch)
Max
(inch)
Low
MFI >16
Medium MFI
7-16
High
MFI .02-7
2.0
2.0
0.080
0.080
20
15
10
Standard Point Gate Tip
0.7
1.9
0.028
0.075
10
10
10
Wear Resistane Point Gate Tip
1.3
1.9
0.050
0.075
10
10
10
Sprue Tip
2.0
3.1
0.080
0.125
625
475
315
0.7
2.5
0.028
0.100
200
150
100
Sprue Tip
2.0
3.1
0.080
0.125
625
475
315
Wear Resistant Point Tip
0.7
2.5
0.060
0.100
200
150
100
Sprue Tip
3.2
4.7
0.125
0.187
1000
750
450
Hot One 375 Series

Coil Heater
0.125
310
Hot One 375 Series

Cast-In Heater
Sprue Tip
3.2
4.7
0.125
0.187
1000
750
450
Wear Resistant Point Tip
0.7
3.1
0.060
0.125
310
200
150
Hot One 625 Series

Coil Heater
Hot One 625 Series
Cast-In Heater
Radius
Hot Sprue Bushings
Sprue Tip
D-MAX
375 Series
High Performance
D-MAX
625 Series
High Performance
4.7
3.1
7.9
0.028
0.187
0.312
1500
200
1100
150
750
3.2
4.4
0.125
0.175
800
550
400
Sprue Tip
4.7
7.9
0.187
0.187
1500
1100
750
550
400
S-Series & T-Series
4.1
4.1
0.160
0.160
700
500
300
E-Series
Wear Resistant Point Gate Tip
1.5
1.5
0.060
0.060
300
150
50
ER-Series & TR-Series
3.2
3.2
0.125
0.125
500
300
200
High Performance Series

D-MAX
250 Series
High Performance
0.7
3.2
1.6
4.4
1.6
0.125
0.062
0.175
0.062
800
300
150
50
3.2
3.2
0.125
0.125
500
300
200
Sprue Tip
2.0
3.1
0.080
0.125
700
500
350
1.25
2.5
0.050
0.100
250
175
125
Wear Resistane Point Gate Tip
1.5
2.5
0.060
0.100
250
175
125
Sprue Tip
3.2
4.7
0.125
0.187
1100
800
500
1.25
3.1
0.050
0.125
350
250
200
1.5
3.1
0.060
0.125
350
250
200
Sprue Tip
4.7
7.9
0.187
0.312
1600
1200
850
3.0
4.4
0.125
0.175
900
650
500
3.0
4.4
0.125
0.175
900
650
500
TPE
M = Medium
PE
NOTE: If flame retardant is present in

the desired resin grade, please contact
DME for product suitability or application guidance.
PE
Not recommended for

resin application
L = Low
NOTE: THE CHART BELOW SHOWS COMMODITY RESINS IN BLUE TYPE; ALL OTHERS ARE ENGINEERING RESINS.
Part dimension, wall thickness, length of fill

within part, mold conditions and molding
parameters must also be considered.
Polymer Viscosity Key
www.dme.net
GENERIC POLYMER NAME (TRADE NAME) [A = AMORPHOUS or C = CRYSTALLINE]
(Ela
stom
e
(Po
lyeth r) [A]
ylen
GF
e)
(Po
lyeth [C]
PS
(Po
lysty ylene)
PS
[C]
ren
GF
e
) [A
(P
]
SAN olysty
ren
[A]
e) [A
TPO
]
[C]
PP
(Po
lypr
opy
PP
GF
len
(Po
e) [C
ly
PP
]
TF (P propy
len
e) [C
ABS olypro
]
p
[A]
ylen
e) [C
ABS
]
/PC
[A]
PM
MA
POM (Acryli
c) [A
(Ac
]
eta
PA
l) [C
(Ny
]
lon
) [C
PA
]
GF
(Ny
lon
PA
) [C
MF
]
GF
(Min
PPE
lon
[A]
) [C
PPO
]
(No
ryl)
PPO
[A]
GF
PBT (Noryl)
Poly
[A]
este
PBT
r [C
GF
]
PET Polyes
ter
[C]
[C]
PC
(Po
lyca
PC
rbo
GF
nate
(Po
) [A
lyca
PPS
]
rbo
[C]
nate
PSU
) [A
]
[A]
PSU
GF
[A]
LCP
[C]
PEI
(Ult
em)
PEI
[A]
GF
(Ult
e
PEE
K [C m) [A]
]
PUR
(Ure
tha
PVC
ne)
[A]
(Fle
xV
inyl)
[A]
*
Resin Application Key
3/21/16
NOZZLE FLOW CAPACITY RECOMMENDATIONS
The values expressed in grams are for reference

only and are determined by using a nominal
wall thickness of 1.8mm (.070") and unfilled polypropylene.
H M H M
M H
M M H
H M
H M H
Plastic Materials and Specifications
Bushing Selection
HOT SPRUE BUSHING TIP STYLE
PLASTIC MATERIAL PROCESS CONDITIONS
240
464
0.93
0.0366
1.11
0.0401
255
491
0.99
0.0358
1.08
0.0390
PS
210
410
45
113
230
446
0.95
0.0343
1.05
0.0379
Polystyrene
Polycarbonate
PC
300
572
80
176
330
626
1.08
0.0390
1.20
0.0434
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
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
Polyphenylene Oxide-Styrene
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
TPE
240
464
35
95
265
509
0.78
0.0282
0.90
0.0325
POM
180
356
100
212
200
392
1.16
0.0419
1.42
0.0513
PMMA
235
455
70
158
250
482
1.09
0.0394
1.18
0.0426
ABS
225
437
70
158
250
482
0.95
0.0343
1.08
0.0390
Thermal Plastic Elastomers

Polyoxymethylene (Polyacetal)
Polymethyl Methacrylate
Acrylonitrile Butadiene Styrene
Ideal for low vestige commodity and engineering grade resin applications. The Ring Gate features
a sealed tip for efficient shut-off at the part surface. Available with standard or wear resistant
needles. Extended style provides additional stock for machining profiles or part contours.
RING GATE TIP

STANDARD / EXTENDED
Suitable for high viscosity resins, engineering plastics and applications requiring optimum gate
cosmetics with minimal gate vestige. Available with standard or wear resistant needles.
POINT GATE TIP
BUSHING TIP AND PLASTIC MATERIAL COMPATIBILITY

THERMOPLASTIC RESIN TYPE
AMORPHOUS
SEMI-CRYSTALINE
NOZZLE
SPRUE GATE TIP

STANDARD / EXTENDED
RING GATE TIP

STANDARD / EXTENDED
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.
POINT GATE TIP
Green Works well with this resin

Yellow Contact DME Engineering for guidance
Red Not recommended
LCP
113
176
PSU
45
80
PPE/PS *
428
446
ABS/PC *
220
230
TPO *
PUR
SAN
ABS
Polyurethane
Styrene-acrylonitrile
SPRUE GATE TIP

STANDARD / EXTENDED
PMMA *
0.0369
POM *
[Ibs/inch3]
1.02
TPE *
[g/cm3]
0.0366
PA *
[Ibs/inch3]
0.93
PBT *
[g/cm3]
446
PET *
[F]
230
PPS *
[C]
158
PEEK
[F]
70
PP
[C]
410
PE
[F]
210
PPO *
[C]
For use where gate vestige is allowed. Provides low resistance to flow with excellent flow rates.
Extended style provides additional stock for machining profiles or part contours.
SOLID
DENSITY
PC *
DENSITY
MELTING
PS
HOT RUNNER
TEMPERATURE
SAN *
MOLD
TEMPERATURE
PEI *
SB
PROCESS
TEMPERATURE
PUR *
Styrene Butadiene
STANDARD RESIN
SYMBOL
SB
MATERIAL
13
Hot One Hot Runner Technology
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
29111 Stephenson Highway
Madison Heights, MI. 48071-2383
Applications Engineering
QUOTE REQUEST FORM

Email to: DME_AE_Quote@milacron.com
Tech Service Approval, Final Drawings and In-House Due Date Required for Firm Quote - QUOTE TYPE
Preliminary
Yes
No
Hot One Hot Runner Technology
Customers 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)
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
Firm
Recessed Connectors
Flush Mounted Connectors
Manifold Extension Nozzle None
Mold Flow Analysis (Piece Part)
SYSTEM TYPE (REQUIRED)
QUOTE STYLE (REQUIRED)
STELLAR
(Z-Dim) Max 135mm [5.314 in.] / Min 27mm [1.063 in.]
HOT ONE Nozzle Series (Standard)
250
375
625
Nozzle Series (High Performance)
250
375
625
Nozzle Heaters
Front-load (default)
Rear-load
Special Terminal Box

Describe:
Special Connectors
Describe:
Hot Half - Plate Material

Manifold & Components
Hot Half Plate Material
Manifold & Components
#2
#2
#7 (Stainless Steel)
Manifold Material
Other
#7 (Stainless Steel)
Other
Mainfold Only
Manifold Material
NOTES:
Selected components verified to fit application by:

Completed By:
Tech Service Approval
AE001 Rev 2.5.2016
U.S. 800-626-6653
Tech Rep
Applications Engineer
Page 1 of 1
Canada 800-387-6600
Sales
Date
Date
Hot Runner Quote Request Form
Options Required
Leader Pins in Nozzle Plate
Mounting Bolts from Parting Line
Mounting Bolts from Back Side
Cavity Mounting Screws
14
14
text
Table
Contents
pageofcontent
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

Custom
Hot Runner
Hot Runner
Systems
Systems
| Index
| Index
A long-standing industry standard in

user-friendliness and affordability
Cartridge Heaters & Thermocouples....................36-42

Custom-configured manifolds, manifold and
component systems, and complete hot half
assemblies for quick delivery
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
Hot Runner
Technology
Features and
Benefits
Custom
Hot Runner| Systems
| Index
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. DMEs Hot
Runner Technology has become an industry
standard in technology, user-friendliness, and
affordability. Available in two styles Manifold
& Components and as a complete Hot Half
System.
Tubular Heated Systems

Using exclusive, distributed wattage Tubular
Heaters, the DME Hot Runner Systems can
process many engineering grade resins.
Tubular Heaters reduce the number of zones of
heat required, providing the added benefit of
lowering your temperature control costs.
DMEs Hot Runner Technology has become

an industry standard in technology, userfriendliness, 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
CIA/EHA Nozzles
For example, the EHA series of nozzles can be used

for many applications using commodity resins with low
crystallinity. The CIA series, with High Performance
heaters developed exclusively for DME, can be used for all
applications, especially engineering grade resins with a high
degree of crystallinity.
EHA/CIA Nozzle Tips
Sprue Gate/Extended
Sprue Gate Used primarily
in applications where gate
vestige is not a concern. Offers
minimal flow resistance and
handles most resins very
effectively. Extended style
provides additional stock for
machining of runner profiles or
part contours.
Point Gate Used for

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

for low vestige, commodity
grade resin applications. The
Ring Gate features a sealed
tip for efficient shut-off at the
parting line.
Ordering Options: Use this information and our design and machining guidelines to build your system, or take advantage
of DME Applications Engineering services to help you select the system best suited to your requirements. Then, either order the
steel and components to construct your system or let DME do all of the machining, assembly and wiring for you.
U.S. 800-626-6653
Canada 800-387-6600
Custom
HotHot
OneRunner
Hot
HotRunner
Runner
Systems
Systems
Technology
Products
Products
| New
| New
| Nozzles
The DME Hot One is accompanied by a nozzle offering

that allows versatility in system selection to best suit
the material and molded part configuration. DME offers
different styles of nozzles: The EHA series, using square
coil heaters and The CIA series, using High Performance
heaters. Each nozzle series has its own characteristics
and advantages.
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
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.
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.
|
Stellar is perfect for todays 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
For a Wide Range

of Applications
20
Excellent
Results with
Engineering Thermoplastics
CUSTOMER DESIGN
CRITERIA FORMS
CDC
To provide your Stellar
application specications,
visit www.dme.net/cdc
The complexity of todays very small part

molding applications demands the added properties of high
performance engineered materials.
Stellar was designed for outstanding processing of these
materials. Challenging amorphous materials such as PET or
crystalline materials including PBT and PA are easily processed
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
21

High Process Temperature Capability
with Precision Heat Profiling
Todays 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.
|
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 industryleading 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 injection 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.
U.S. 800-626-6653
Canada 800-387-6600
Increase Productivity and Reduce Molding Costs With Stellar-Infused Quick-Change Systems
text
Stellar Systems
22
22
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
SUB-ASSEMBLY
ITEM NUMBER
DESCRIPTION
TIP
ITEM
NUMBER
TIP
CTE
(10-6/degC)
RETAINER
ITEM
NUMBER
GATING
STYLE
APPLICABLE
STELLAR
SYSTEM
SXG5110
Standard
Point Gate Tip
Sub-Assembly
SXT4010
17.5
SXF5100
Point Gate
Standard
SXG5020
High Performance
Point Gate Tip SubAssembly
SXT5010
4.5
SXF5000
Point Gate
High
Performance
SXT7040
12.8
N/A
Sprue Gate
All
SXT7140
12.8
N/A
Sprue Gate
All
N/A
N/A
Sprue Gate Tip
Sprue Gate Tip
NOTE: All units are in mm.
text
Stellar Systems
23
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)
2mm/0.08in x 45
5mm/.20in MIN
DISTANCE
BETWEEN
WATERLINE
AND DROP
Z DIMENSION
CLEARANCE
DIAMETER
19.0mm/
0.75in
R 0.25mm/
0.010in MIN
R 3.00mm/
0.118in MAX
+0.005
+0.13
R0.25mm/.010in MIN
R0.38mm/.015in MAX
5mm/
.20in MIN
+0.00
R3.18mm/.125in*
R12.70mm/.500in MIN*
MIN GATE DIAMETER

0.71mm/.028in for unfilled resins
1.27mm/.050in for filled resins
U.S. 800-626-6653
2 0.08
45
30
+ 0.005
0.000
+ 0.0002
0.0000
19.050
+ 0.012
0.000
+ 0.0005
0.0000
0.7500
SXT7140
Canada 800-387-6600
Position gate detail within

0.013mm/.0005in from nominal.
The gate diameter can be

opened by the customer
to suit the application.
(The land must be re-machined
N
IO
ST to the maximum dimension
E
after increasing the
QU
gate diameter.)
IN
10.000
0.3937
SXT7040
2.
3.
Z-DIMENSION
x 45
19.0 0.75
SXT7040
5.30 0.209
19.5 0.77
SXT7140
NOTES for Figure 6 & 7:

1. If gate detail does not properly
fit the application, contact
DME for assistance about
gate detail options.
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.
6.
For faster color changes,

remove (decone) the
resin from the front of
each point gate tip prior
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.
Gate Details for use with Hardened Steel (50HRC min.)
Gate Details for Sprue Gate Tips, SXT7040 & SXT7140
3.30 0.130
MAX RUNNER
HEIGHT
0.89mm/.035in
MAX*
Stellar Systems
0.13mm/.005in
MAX LAND
0.62mm/.024in
To Bottom of Radius
5 0.20
MIN
+.000
2.54mm 0.13 /.100in .005
R4.76mm/.187in
5 0.20
MIN
+.005
2.03mm 0.00 /.080in .000
30
90
Fig. 7
+.0002
9.800mm 0.000 /.3858in .0000
24
Hot One Noz zles
ENABLING VERSATILITY
Custom
Hot Runner
Hot Runner
Systems
Systems
| Index
| Index
IN SYSTEM SELECTION
Hot One Nozzles
25
250 Series Nozzles

(.250 Diameter Flow Channel)
SQUARE COIL HEATER
REAR LOAD
(SCHXXXX)
250 Series Nozzle Sub-Assembly

1
1.500
(Add .750 to A dimension for extended sprue gate and extended full body point gate tips.)
A
SUB-ASSEMBLY
ITEM NUMBER
1.000
2.000
2
A
1/2-24 UN
2.500
0.250
3.000
3.500
4.000
HIGH PERFORMANCE HEATER
REAR LOAD
(CIHXXXX-S)
5.000
6.000
2
EHA1001
3
SEAL RING
SCH0081
CIB1359
SCH1081
CIA0001S
1.250
CIA1001S
CIH1081S
EHA0002
SCH0082
1.250
EHA1002
CIA0002S
1.250
CIA1002S
CIH1082S
SCH0083
CIB1360
CIH0081S
SCH1082
CIH0082S
EHA0003
1.250
EHA1003
CIA0003S
1.250
CIA1003S
CIH1083S
SCH0084
CIB1361
SCH1083
CIH0083S
EHA0004
1.250
EHA1004
CIA0004S
1.250
CIA1004S
CIH1084S
EHA0005
SCH0085
1.250
EHA1005
CIB1362
CIB1363
SCH1084
CIH0084S
SCH1085
CIA0005S
1.250
CIA1005S
CIH1085S
EHA0006
SCH0086
1.250
EHA1006
CIA0006S
1.250
CIA1006S
CIH1086S
EHA0007
SCH0087
1.250
EHA1007
CIA0007S
1.250
CIA1007S
CIB1364
CIB1365
EHR7154
CIH0085S
SCH1086
CIH0086S
SCH1087
CIH0087S
CIH1087S
WIRING INFORMATION:
Power leads are tan
Ground leads are green
Thermocouple leads are black and white

FRONT LOAD
(CIH1XXX-S)
EHA0001
2
HEATER
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 rings must be installed each time manifold is assembled.
U.S. 800-626-6653
Canada 800-387-6600
EHR7154
.561 DIA.
Hot One Nozzles

Custom| Hot
250Runner
Series Systems
Nozzles (.250
Diameter
Products
Flow Channel)
| New
SQUARE COIL HEATER

FRONT LOAD
(SCH1XXX or SCH2XXX)
1.250
1
NOZZLE BODY
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.)
1
2.000
A
1.000
2.000
2
A
Hot One Nozzles
375Custom
Series High
Hot Runner
Performance
Systems
Nozzles
| Index
5/8-20 UN
2.500
0.375
SQUARE COIL HEATER
FRONT LOAD
(SCH1XXX or SCH2XXX)
3.000
3.500
4.000
REAR LOAD
(CIHXXXX-S)
5.000
6.000
2
7.000

FRONT LOAD
(CIH1XXX-S)
SUB-ASSEMBLY
ITEM NUMBER
1
NOZZLE BODY
2
HEATER
3
SEAL RING
EHA0008
1.250
EHA1008
SCH0088
CIA0008S
1.250
CIA1008S
CIH1088S
EHA0009
SCH0089
1.250
EHA1009
CIB1366
CIB1367
SCH1088
CIH0088S
SCH1089
CIA0009S
1.250
CIA1009S
CIH1089S
EHA0010
SCH0090
1.250
EHA1010
CIA0010S
1.250
CIA1010S
CIH1090S
SCH0091
CIB1368
CIH0089S
SCH1090
CIH0090S
EHA0011
1.250
EHA1011
CIA0011S
1.250
CIA1011S
CIH1091S
EHA0012
SCH0092
CIB1369
SCH1091
CIH0091S
1.250
EHA1012
CIA0012S
1.250
CIA1012S
CIH1092S
EHA0013
SCH0093
1.250
EHA1013
CIB1370
CIB1371
SCH1092
CIH0092S
SCH1093
CIA0013S
1.250
CIA1013S
CIH1093S
EHA0014
SCH0094
1.250
EHA1014
CIA0014S
1.250
CIA1014S
CIH1094S
EHA0015
SCH0095
1.250
EHA1015
CIA0015S
1.250
CIA1015S
CIB1372
CIB1373
EHR7155
CIH0093S
SCH1094
CIH0094S
SCH1095
CIH0095S
CIH1095S
WIRING INFORMATION:
Power leads are tan

Used between manifold and nozzle to prevent leakage. New seal
rings must be installed each time manifold is assembled.
.062
ITEM NUMBER
EHR7155
.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
2.000
RearLOAD
Load
REAR
(SCHXXXX)
(SCHXXXX)
3.000
1.000
3.000
1.500
4.000
0.625
0.375
SQUARE COIL HEATER

Square Coil
Heater
FRONT
LOAD
Front Loador SCH2XXX)
(SCH1XXX
(SCHXXXX)
5.000
1
6.000
7.000
High
Heater
HIGHPerformance
PERFORMANCE
HEATER
Rear
LoadLOAD
REAR
(CIHXXXX-S)
(CIHXXXX-S)
8.000
9.0003
10.000
High
Performance
Heater
HIGH
PERFORMANCE
HEATER
FRONT
Front
LoadLOAD
(CIH1XXX-S)
(CIHXXXX-S)
2
CIA0023S
1.750
CIA1023S
EHA0016
1.750
EHA1012
CIA0016S
1.750
CIA1016S
EHA0017
1.750
EHA1017
CIA0017S
1.750
CIA1017S
EHA0018
1.750
EHA1018
CIA0018S
1.750
CIA1018S
EHA0019
1.750
EHA1019
CIA0019S
1.750
CIA1019S
EHA0020
1.750
EHA1020
CIA0020S
1.750
CIA1020S
EHA0021
1.750
EHA1015
CIA0021S
1.750
CIA1021S
EHA0022
1.750
EHA1015
CIA0022S
1.750
CIA1022S
1
NOZZLE BODY
2
HEATER
3
SEAL RING
CIH0104S
CIB1381
CIH1104S
SCH0096
EHB0074
SCH1092
CIH0096S
CIB1374
CIH1096S
SCH0097
EHB0075
SCH1093
CIH0097S
CIB1375
CIH1097S
SCH0098
EHB0076
SCH1094
CIH0098S
CIB1376
CIH1098S
SCH0099
EHB0077
SCH1095
EHR7156
CIH0099S
CIB1377
CIH1099S
SCH0100
EHB0078
SCH1095
CIH0101S
CIB1378
CIH1101S
SCH0101
EHB0079
SCH1095
CIH0102S
CIB1379
CIH1102S
SCH0102
EHB0080
SCH1095
CIH0103S
CIB1380
CIH1103S
WIRING INFORMATION:
Power leads are tan
.062
Item Number
Used between manifold and nozzle to prevent leakage. New

seal rings must be installed each time manifold is assembled.
U.S. 800-626-6653
Canada 800-387-6600
EHR7156
dme@milacron.com
1.063 DIA.
www.milacron.com
625 Series
Hot High
Runner
Performance
Systems Nozzles
Products
Diameter Flow Channel)
| Custom
| New(.625
SUB-ASSEMBLY
ITEM NUMBER
Hot One Nozzles
5/8-20 UN
1"-16 UN
28
Hot One Nozzles
Gate Tip Detail

Sprue Gate/Extended Sprue Gate
SERIES
GATE TIP
2.03
SPRUE GATE
250
EXTENDED SPRUE GATE
SPRUE GATE
375
EXTENDED SPRUE GATE
5 PER SIDE
SPRUE GATE
EXTENDED SPRUE GATE
625
ITEM NUMBER
EHT0010
EHT0011
EHT0012
EHT0013
EHT0014
EHT0015
EHT0016
EHT0017
EHT0018
EHT0019
EHT0020
EHT0021
EHT0022
EHT0023
B DIA.
.080
.125
.187
T DIA.
.500
.750
1.000
.500
.750
1.000
.500
.750
1.000
.500
.750
1.000
1.000
.250
.375
.100
1.000
1.125
.850
.250
.375
1.000
1.125
.250
1.000
.500
1.250
(Add .750 to A dimension for extended sprue gate tips.)
Point Gate (Bodiless)

SERIES
GATE TIP
ITEM NUMBER
STANDARD
NEEDLE
A
250
WEAR RESISTANT
STANDARD
RETAINER TIP
375
WEAR RESISTANT
STANDARD
625
WEAR RESISTANT
EHT0005
EHT1314
EHT1308
EHT1313
EHT0039
EHT1312
EHT1303
EHT1309
EHT1306
EHT1311
EHT1307
EHT1310
INCLUDES
T DIA.
NEEDLE
EHN0015
.375
EHN0401
EHN0016
.500
EHN0400
EHN0019
.625
EHN0402
RETAINER TIP
EHT0024
EHT0324
EHT0324
EHT1324
EHT0025
EHT0325
EHT0325
EHT1325
EHT1354
EHT0326
EHT0326
EHT1354
Custom
Hot One
Hot
Nozzles
Runner |Systems
Gate Tip Detail
| Index
Point Gate (Full Body)

SERIES
TYPE
STANDARD
NEEDLE
250
WEAR RESISTANT
RETAINER TIP
STANDARD
375
WEAR RESISTANT
O
625
STANDARD
WEAR RESISTANT
ITEM NUMBER
EHT2001
EHT2002
EHT2003
EHT2004
EHT2005
EHT2006
EHT2007
EHT2008
EHT2009
EHT2010
EHT2011
EHT2012
EHT2013
EHT2014
EHT2015
EHT2016
EHT2017
EHT2018
EHT2019
EHT2020
EHT2021
EHT2022
T DIA.
.375
.500
.375
.500
.500
.750
1.000
.500
.750
1.000
O DIA.
.060
.080
.060
.080
.060
.080
.060
.080
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.187
.230
1.000
.125
.250
T DIA.
O DIA.
INCLUDES
NEEDLE
RETAINER TIP
EHT0026
EHT0027
EHN0015
EHT0028
EHT0029
EHT1326
EHT1327
EHN0401
EHT1328
EHT1329
EHT0030
EHT0031
EHT0032
EHN0016
EHT0033
EHT0034
EHT0035
EHT1330
EHT1331
EHT1332
EHN0400
EHT1333
EHT1334
EHT1335
EHN0019
EHT0036
EHN0402
EHT1336
Point Gate (Full Body Extended)

SERIES
TYPE
STANDARD
NEEDLE
250
WEAR RESISTANT
RETAINER TIP
STANDARD
375
WEAR RESISTANT
0.750
5 PER SIDE
O
T
625
STANDARD
WEAR RESISTANT
SERIES
250
375
625
THREAD TYPE
1/2-24 UN
5/8-20 UN
1"-16 UN
ITEM NUMBER
EHT2301
EHT2302
EHT2303
EHT2304
EHT2305
EHT2306
EHT2307
EHT2308
EHT2309
EHT2310
EHT2311
EHT2312
EHT2313
EHT2314
EHT2315
EHT2316
EHT2317
EHT2318
EHT2319
EHT2320
EHT2321
EHT2322
.375
.500
.375
.500
.500
.750
1.000
.500
.750
1.000
1.000
.060
.080
.060
.080
.060
.080
.060
.080
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.125
.938
.980
1.000
INCLUDES
NEEDLE
RETAINER TIP
EHT2326
EHT2327
EHN0015
EHT2328
EHT2329
EHT2326
EHT2327
EHN0401
EHT2328
EHT2329
EHT2330
EHT2331
EHT2332
EHN0016
EHT2333
EHT2334
EHT2335
EHT2330
EHT2331
EHT2332
EHN0400
EHT2333
EHT2334
EHT2335
EHN0019
EHT2336
EHN0402
Hot One Nozzles
29
Housing, Nozzle Plate and

Gate Machining Dimensions Detail
Manifold Housing, Nozzle Plate, A Plate and
Gate Machining Dimensions
LOCATING RING
.261 DIA. HOLE THRU
5/1618 TAP
F DIA.
WATER LINES ARE
RECOMMENDED IN
HOUSING
G DIA.
H DIA.
.34 DEEP
2-PLC'S. TYP.
J DIA.
.219
RISER PAD
HEIGHT
.25 MIN.
1.000
(1.500 FOR
625 SERIES)
G DIA.
H DIA.
J DIA.
EHL0252
4.000
3.312
3.000
2.500
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
N DIA.
NOZZLES
.625 WIRE
CHANNEL
.250 MIN.
+.001
.250 MIN. .000
SPACER RING
AND SUPPORT
PAD HEIGHT
.250
RECOMMENDED
(.125 MIN.)
A + BE
.31 MIN.
SERIES
K DIA.
250
375
625
1.56
2.06
3.06
1.875 NOZZLE PLATE

RECOMMENDED
WATER LINES ARE

RECOMMENDED IN
"A" PLATE AND
NOZZLE PLATE
+.001
.000
M DIA.
1.501
2.001
3.001
N DIA. MIN for

SQ. COIL
1.062
1.250
1.875
N DIA. MIN for

HIGH
PERFORMANCE
1.187
1.437
2.125
.125 RAD. MAX.
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.
Formula for determining this expansion factor is as follows:

BE = A dimension x .00000633 x nozzle setpoint temp 68(assuming the mold is at 68F during
operation). If mold temperature is different, substitute 68F with actual mold temperature.
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.
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.
250 & 375 SERIES

POINT GATE (BODILESS)
MACHINING DIMENSIONS
SPRUE AND POINT GATE (FULL BODY)

625 SERIES
POINT GATE (BODILESS)
2.125 MIN
80
80
R RAD.
300'
.010 .015 RAD.
300'
30
NOTE: Extended sprue length
+.0005
.0000
Q DIA.
AT TANGENT
0.6250
will add .750 to land.
250
AND
375
625
T DIA.
S DIA.
*.375
.500
.750
1.000
1.000
*.3755
.5005
.7505
1.0005
1.0005
SERIES
NOZZLE
250
375
625
0.47
O DIA.
UNFILLED
RESIN
FILLED
RESIN
Q DIA.
R RAD.
.028 MIN.
.028 MIN.
.080 MIN.
.060 MIN.
.060 MIN.
.100 MIN.
.3750
.5000
.6250
.125
.187
.312
NOTE: The O diameter can be opened by the

customer to suit the application. Also the
land must be remachined to .005 max. after
increasing the gate diameter.
*250 Point Gate (Full Body) only.
U.S. 800-626-6653
+0.0005
0.0000
0.235
R0.312
.020
0.125
R0.010-0.015
.180
.100
0.020 AT TANG.
.005
LAND
MAX.
0 DIA.
.080 LAND
0.005 LAND MAX
S DIA.
SERIES
R0.125
+.0005
.0000
Canada 800-387-6600
Hot One NozzlesCustom

Hot Runner
Nozzle Plate
Systems
and Gate
Machining
ProductsDimensions Detail
| Housing,
| New
HOUSING MUST BE EQUAL

TO RISER PADS, SPACER
RING AND MANIFOLD AT
ROOM TEMPERATURE
M DIA.
MANIFOLD
HEIGHT
F DIA.
Manifold housing and insulator sheet are to be same width and

length as mold base. Height of manifold housing to vary with
stackup of manifold, riser pads and spacer rings.
.250 MIN.
K DIA.
ITEM
NUMBER
30
Hot One Nozzles
Replacement Nozzle Heater Detail

Replacement Square Coil
Nozzle Heater
250, 375 AND 625 NOZZLE HEATER

240 VAC, T/C TYPE J, 36" LONG
WIRING INFORMATION:
Power leads are black
Ground lead is green
White is negative () and constantan
(non-magnetic)
Replacement High Performance

Nozzle Heater
D
DIA
L
LENGTH
D DIA.
Hot OneCustom
NozzlesHot| Runner
Replacement
Nozzle
Systems
Index Detail
| Heater
SERIES
250
375
625
ITEM
NUMBER
SCH0081
SHC1081
SCH0082
SCH1082
SCH0083
SCH1083
SCH0084
SCH1084
SCH0085
SCH1085
SCH0086
SCH1086
SCH0087
SCH1087
SCH0088
SCH1088
SCH0089
SCH1089
SCH0090
SCH1090
SCH0091
SCH1091
SCH0092
SCH1092
SCH0093
SCH1093
SCH0094
SCH1094
SCH0095
SCH1095
SCH0096
SCH1096
SCH0097
SCH1097
SCH0098
SCH1098
SCH0099
SCH1099
SCH0100
SCH1100
SCH0101
SCH1101
SCH0102
SCH1102
D DIA.
NOMINAL
NOZZLE
.625
L DIM.
WATTS
2.000
300
2.500
350
3.000
400
3.500
425
4.000
500
5.000
500
6.000
550
2.125
400
2.625
450
3.125
550
3.625
700
.875
1.500
4.125
800
5.125
900
6.125
1000
7.125
1100
4.000
1000
5.000
1030
6.000
1100
7.000
1000
8.000
1200
9.000
1200
10.000
1200
USED WITH
NOZZLE
SUB-ASSEMBLY
EHA0001
EHA1001
EHA0002
EHA1002
EHA0003
EHA1003
EHA0004
EHA1004
EHA0005
EHA1005
EHA0006
EHA1006
EHA0007
EHA1007
EHA0008
EHA1008
EHA0009
EHA1009
EHA0010
EHA1010
EHA0011
EHA1011
EHA0012
EHA1012
EHA0013
EHA1013
EHA0014
EHA1014
EHA0015
EHA1015
EHA0016
EHA1016
EHA0017
EHA1017
EHA0018
EHA1017
EHA0019
EHA1019
EHA0020
EHA1020
EHA0021
EHA1021
EHA0022
EHA1022
SERIES
250
ITEM
NUMBER
CIH0081S
CIH1081S
CIH0082S
CIH1082S
CIH0083S
CIH1083S
CIH0084S
CIH1084S
CIH0085S
CIH1085S
CIH0086S
CIH1086S
CIH0087S
CIH1087S
D DIA.
NOMINAL
NOZZLE
.625
CIH0088S
375
625
CIH1088S
CIH0089S
CIH1089S
CIH0090S
CIH1090S
CIH0091S
CIH1091S
CIH0092S
CIH1092S
CIH0093S
CIH1093S
CIH0094S
CIH1094S
CIH0095S
CIH1095S
CIH0104S
CIH1104S
CIH0096S
CIH1096S
CIH0097S
CIH1097S
CIH0098S
CIH1098S
CIH0099S
CIH1099S
CIH0101S
CIH1101S
CIH0102S
CIH1102S
CIH0103S
CIH1103S
L DIM.
WATTS
2.000
300
2.500
350
3.000
400
3.500
425
4.000
425
5.000
500
6.000
550
2.125
400
2.625
450
3.125
550
3.625
700
4.124
800
5.125
900
6.125
1000
7.125
1100
3.038
847
4.038
1000
5.038
1030
6.038
1100
7.038
1000
8.038
1200
9.038
1200
10.038
1200
.875
1.500
USED WITH
NOZZLE
SUB-ASSEMBLY
CIA0001S
CIA1001S
CIA0002S
CIA1002S
CIA0003S
CIA1003S
CIA0004S
CIA1004S
CIA0005S
CIA1005S
CIA0006S
CIA1006S
CIA0007S
CIA1007S
CIA0008S
CIA1008S
CIA0009S
CIA1009S
CIA0010S
CIA1010S
CIA0011S
CIA1011S
CIA0012S
CIA1012S
CIA0013S
CIA1013S
CIA0014S
CIA1014S
CIA0015S
CIA1015S
CIA0023S
CIA1023S
CIA0016S
CIA1016S
CIA0017S
CIA1017S
CIA0018S
CIA1018S
CIA0019S
CIA1019S
CIA0020S
CIA1020S
CIA0021S
CIA1021S
CIA0022S
CIA1022S
31
Hot Runner Systems
Standard Global Manifold Replacement Heaters
321 Stainless Steel
Ceramic
Image not to scale.
~6mm
Unflexible Unheated
(min. 30mm)
Flexible Heated Length
Unflexible Unheated
(min. 30mm)
Length (tolerance +/- 1.5%)
~20mm
DME Manifold Flexible Replacement Heaters

8.0mm diameter. Operating voltage 240 Volt. Threaded pins on both ends.
|
Hot Runner Systems
LOW-WATT FLEXIBLE TUBULAR HEATERS
ITEM NO.
HFH8030
LENGTH (mm)
300
WATTAGE
660
ITEM NO.
LENGTH (mm)
WATTAGE
HFL8040
400
339
HFH8035
350
675
HFL8045
450
364
HFH8040
400
795
HFL8050
500
410
HFH8045
450
910
HFL8055
550
458
HFH8050
500
1025
HFH8055
550
1145
HFL8060
600
504
HFH8060
600
1260
HFL8065
650
552
HFL8070
700
598
750
646
HFH8065
650
1380
HFH8070
700
1495
HFL8075
HFH8075
750
1615
HFL8080
800
692
HFH8080
800
1730
HFL8085
850
738
HFH8085
850
1845
HFL8090
900
784
HFH8090
900
1960
HFL8095
950
832
HFH8095
950
2080
HFL8100
1000
878
HFH8100
1000
2195
HFL8105
1050
926
HFH8105
1050
2316
HFH8110
1100
2430
HFL8110
1100
972
HFH8115
1150
2545
HFL8115
1150
1018
HFH8120
1200
2665
HFL8120
1200
1066
1250
1112
HFH8125
1250
2780
HFL8125
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

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.
Use a brass hammer to lightly tap a small piece of brass and
each retaining ring to secure the manifold heater.
OPTIONAL ITEM
RR-472-13000-100
Manifold Heater Retainer Clips
Heater Retainer Clips

Undercut Grooves
U.S. 800-626-6653
Canada 800-387-6600
Hot One Nozzles

Custom Hot
Runner Global
Systems
Manifold
Replacement
Products Heaters
| Standard
| New
HIGH-WATT FLEXIBLE TUBULAR HEATERS
32
Hot Runner Systems
Ceramic
Image not to scale.
321 Stainless Steel
~6mm
Unflexible Unheated
(min. 30mm)
Flexible Heated Length
Unflexible Unheated
(min. 30mm)
Length (tolerance +/- 1.5%)
~20mm
DME Manifold Flexible Replacement Heaters
Hot Runner Systems | Standard Global Manifold Replacement Heaters

Custom Hot Runner Systems | Index
8.5mm diameter. Operating voltage 230 Volt. Threaded pins on both ends.
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
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
HFH851450
1450
3840
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.
Use a brass hammer to lightly tap a small piece of brass and
each retaining ring to secure the manifold heater.
OPTIONAL ITEM
RR-472-13000-100
Manifold Heater Retainer Clips
Heater Retainer Clips

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) 516 18 12" LG. FLAT HEAD CAP SCREWS

D
X
F DIA.
C DIA.
D HEX.
(ACROSS FLATS)
SPH. RAD.
1.500
C
.218
L
.25 FOR EHN0011 & EHN0012
.38 FOR EHN0013 & EHN0014
THREAD UNF
SPH.
RAD.
EHN0011
EHN0012
EHN0013
EHN0014
.500
.750
.500
.750
C
DIM.
D
HEX.
E
DIA.
F
DIA.
.62
1.250
1.250
1.50
.363
.312
.75
1.750
1.500
1.88
.457
.375
THREAD
4 16
112
Nozzle Seat Machining
ITEM
NUMBER
D
DIA.
X
DIA.
Y
DIA.
A
DIM.
B
DIA.
C
DIM.
EHL0252
EHL0253
EHL0254
EHL0255
2.990
3.990
2.990
3.990
2.000
3.250
2.000
3.250
2.500
3.750
2.500
3.750
3.312
4.625
3.312
4.625
3.990
5.495
3.990
5.495
2.875
2.875
4.500
4.500
Locating Ring Machining

Relief in top of manifold for locating ring.
M THREAD SIZE
N DIA.
.12
.50
+.005
ITEM NUMBER
M THREAD SIZE
ITEM NUMBER
N DIA. .000
EHN0011
EHN0012
EHN0013
EHN0014
.687 DIA. HOLE .56 DEEP

3
416 UNF TAP .50 DEEP
.922 DIA. HOLE .69 DEEP
112 UNF TAP .62 DEEP
EHL0252
EHL0253
EHL0254
EHL0255
2.505
3.755
2.505
3.755
Drool Rings
Used in conjunction with nozzle seat and locating ring to prevent
nozzle purging and drooling from entering manifold area.
ITEM
NUMBER
B
DIA.
EHL1001
1.38
EHL1002
1.62
EHL1003
1.38
EHL1004
1.62
C
DIA.
2.19
B DIA.
C DIA.
.12
3.44
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
Hot OneHot
Nozzles
Replacement
PartsProducts
Detail
Custom
Runner| Systems
| New
ITEM
NUMBER
Y
A
B
E DIA.
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.
Hot One Components

Externally| Heated
Custom
Hot Runnerfor
Systems
Index Manifold Systems
| Components
DRILLED & C'BORED FOR

-20 LOW HEAD SCREW
"X" DEEP
ITEM
NUMBER
.78 DIA.
ERP1001
.500
.405
1.41 DIA.
ERP1002
.750
.655
ITEM
NUMBER
ERP1011
.500
.405
ERP1012
.750
.655
.19
.06
1.75 DIA.

-20 LOW HEAD SCREW
"X" DEEP
H
.78 DIA.
Center Support Pads and Tubular Dowels

Supports manifold center spacing, while minimizing heat transfer from manifold.
1.06 DIA.
.375 DIA.

-20 LOW HEAD SCREW
"X" DEEP 2 PLACES
H
.19
.06
.78 DIA.
ITEM
NUMBER
1.41 DIA.
ECB1001
.500
.405
1.75 DIA.
ECB1002
.750
.655
ITEM
NUMBER
L
LENGTH
.375 DIA.
.250 DIA.
3834TD
.750
38114TD
1.250
Hot One Nozzles
35
Parts Detail
Riser Pad
Supports manifold opposite nozzles. Prevents heat loss and
maintains spacing between manifold and clamping plate.
F
1.125
X
INCLUDES (2) #1024 LOW HEAD CAP SCREWS
G DIA.
ITEM NUMBER
ERP0163
ERP0167
ERP0164
ERP0165
ERP0168
ERP0166
X DIM. +.010
USED WITH
.000 L DIM. F DIM. G DIA.
.250
GATE-MATE 4,
.375
4.000 3.250 .625 250 SERIES AND
375 SERIES
.750
.250
5.000 4.000 .781
625 SERIES
.375
.750
Center Support Pad
Spacer Ring
Aligns and supports manifold center while minimizing heat

transfer from manifold.
Maintains spacing between manifold and nozzle plate.

.875
DIA.
P DIA.
FOR .250 DIA. DOWEL

ITEM NUMBER
P DIA.
2.500
2.500
1.500
1.500
A DIA.
X DIM.
ESR0157
ESR0158
ESR0159
ESR0160
Tapered Dowel Pin
+.010
.000
.250
.750
.250
.750
A DIA.
USED WITH
.406
GATE-MATE 4, 250
SERIES AND 375 SERIES
.531
625 SERIES
.162 DIA.
.193 DIA.
ITEM NUMBER
Aligns and prevents end plug from rotating. Tapered

dowel pin must conform to ANSI B18.8.2-1978 standard.
EDP0001
1.50
End Plug
End Plug Set Screw
Used to plug horizontal flow channels.
Used to secure end plug into manifold (2 required). End plug

set screw must conform to the following standards.
ANSI B1.1. ANSI B18.3 and ASTM F912.
Material : P20
H DIA. +.0000
<.0002
THREAD
J DIA.
+.001
K <.000
#1024 TAP
SERIES
GATE-MATE 4
250
375
625
ITEM NUMBER
EEP0002
EEP0001
EEP0002
EEP0003
H DIA.
.5615
.4365
.5615
.6875
J DIA. K DIM.
.800
.750
.675
.750
.800
.750
.894
1.125
M DIM.
1.500
1.500
1.500
1.875
SERIES
GATE-MATE 4
250
375
625
ITEM NUMBER
SSS7878
SSS3434
SSS7878
SSS11
THREAD
814 UNF-3A
3
416 UNF-3A
7
814 UNF-3A
112 UNF-3A
7
N DIM.
.875
.750
.875
1.000
Heater Stop Machining
Heater Puller Machining
Used for ECH-Series cartridge heaters.
Used for CHS-Series cartridge heaters recommended for

heaters installed in blind holes.
HEATER HOLE
.406
. 201 DIA. HOLE s .625 DEEP
1/420 UNC TAP s .50 DEEP
.687 DIA. HOLE s .75 DEEP

3
/4 16 UNF TAP s .68 DEEP
1/420 s .38 LG. BUTTON HEAD CAP SCREW

MOLDMAKER TO SUPPLY
U.S. 800-626-6653
Canada 800-387-6600
Nozzles
Detail
| Parts
Custom Hot
Hot One
Runner
Systems
Products
| New
X DIM. +.010
.000
.250
.750
.250
.750
ITEM NUMBER
ECB0161
ECB0162
ECB0163
ECB0164
36
Hot One Nozzles
Cartridge Heaters & Thermocouples

240 VAC, 36" Leads with 6" of Lead Protection
Cartridge Heater Power Leads are multi-colored
Although these heaters do not employ integral

thermocouples, theyre designed and constructed to run at
higher molding temperatures and provide longer life than
conventional heaters.
Cartridge Heaters
Shoulder Style Cartridge Heater
.500 DIAMETER NOMINAL
.500 DIA. NOMINAL
Shoulder Style Cartridge Heaters
Cartridge Heaters
Hot One Custom

NozzlesHot
CartridgeSystems
Heaters &| Thermocouples
| Runner
Index
Can be installed through hole

or installed using retainer plate
construction.
Shoulder Style Cartridge

Heaters
These heaters are used in
conjunction with heater pullers
to insure easy removal of blind
or through hole installations.
ITEM
NUMBER
L
IN
INCHES
WATTS
WATTS
PER
LIN. IN.
CHS0119
CHS0120
CHS0121
CHS0122
CHS0123
CHS0124
CHS0125
CHS0126
CHS0127
CHS0128
CHS0129
CHS0130
CHS0131
CHS0132
CHS0133
CHS0134
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
10.0
11.0
12.0
15.0
18.0
500
575
650
725
800
875
950
1025
1100
1175
1200
1350
1500
1650
2050
2500
125
128
130
132
133
135
136
137
138
138
133
135
136
137
137
139
*
*
*
*
*
*
Heater puller to be ordered separately.
Heater Puller (with Snap Ring)
PULLER WITH RING
Provides trouble-free removal of

Shoulder Style Cartridge Heater.
ITEM NUMBER
EHP0250
1.625
.500
REPLACEMENT
SNAP RINGS
.81
HEX
Snap Ring
(Included)
ITEM NUMBER*
*
*
*
EHP0001
-16 THREAD
.81
*Pkg. of 25
Manifold Thermocouples
Installed in manifold to maintain precise temperature control.
Flat Washer Type
Utilized in limited
space applications.
.28 DIA.
Threaded Type
Installed between heat
source and flow channel
for more precise control.
ITEM NUMBER
ITEM NUMBER
ETC0168
ETC0251
1/4 28 UNF
*
.375
ITEM
NUMBER
LENGTH
L
WATTS
WATTS
PER
LIN. IN.
ECH0103
ECH0119
ECH0104
ECH0138
ECH0105
ECH0139
ECH0120
ECH0148
ECH0106
ECH0140
ECH0107
ECH0121
ECH0108
ECH0141
ECH0109
ECH0122
ECH0149
ECH0110
ECH0142
ECH0111
ECH0123
ECH0124
ECH0112
ECH0113
ECH0114
ECH0125
ECH0126
ECH0115
ECH0128
ECH0127
ECH0116
ECH0144
ECH0146
ECH0145
ECH0129
ECH0117
ECH0147
ECH0130
ECH0118
4.0
4.0
4.5
5.0
5.0
5.0
5.0
5.5
5.5
6.0
6.0
6.0
6.5
7.0
7.0
7.0
7.5
7.5
8.0
8.0
8.0
8.0
8.5
9.0
10.0
10.0
11.0
11.0
12.0
12.0
12.0
12.0
14.0
14.0
15.0
15.0
18.0
18.0
18.0
500
750
575
500
650
750
1000
500
725
750
800
1000
875
600
950
1000
1000
1025
1000
1100
1500
2000
1175
1200
1350
1500
1000
1500
1000
1500
1650
2000
1000
2300
1500
2050
1500
1700
2500
125
188
128
100
130
150
200
91
132
125
133
167
135
86
136
143
133
137
125
138
188
250
138
133
135
150
91
136
83
125
137
167
71
164
100
137
83
94
139
NOTE: Sizes preceded by an * are the

newest additions.
See the Hot One Design and Machining
Guidelines at the end of this Hot One Nozzles
section for manifold size recommendation
and installation drawings.
37
Hot One Components
Cartridge Heaters
DME Standard Cartridge heaters employ a swaged

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

If temperatures will exceed this amount, leads must
be insulated.
38
Hot One Components
High Watt Density Cartridge Heaters
Hot One Components

Custom Hot Runner
Systems
Density| Cartridge
Index Heaters
| High Watt
Fit Tolerances
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 .004 undersize, held to a tolerance of .002.
This sizing is maintained for easy installation and for best
heat transfer. However, if close hole tolerances are not
maintained, operating life of the heater may be drastically
reduced. Also make sure that the heated area of the
cartridge does not extend beyond the hole.
DME High Watt Density Cartridge Heaters employ swaged

construction for maximum heat transfer and high watt density
for more demanding applications. Recommended for use when
IJHIUFNQFSBUVSFTBSFSFRVJSFE VQUP'
PSXIFSFIFBUFST
will be subjected to vibration. Furnished with 10" long flexible
lead wires. Special heaters are available on special order.
Thermocouple cartridge heaters are also available.
DIA.
Spacing of Heaters
As a general rule it is not recommended to space heaters
in a mold, die or platen any closer to each other than the
diameter of the heater.
1/4
Contamination
Contamination consists of any foreign matter such as
plastics, oil, grease, dirt or water entering through the
terminal end or the end opposite the terminal. Care must
be taken to protect the heater or these contaminants will
shorten the effective heater life.
Proper Care and Maintenance
3 /8
1/2
1. Heaters should be stored in a dry area, especially

during periods of excess humidity.
2. Protect leads from abuse, abrasion, fatigue, etc.
3. Maintain temperature controllers and accessories
in good working condition to avoid an overheating
condition.
4. Transferring heaters from one die or platen to another
is not recommended.
*See DME Equipment and Supplies Catalog for DME

machine reamers and DME straight shank long drills.
5 /8
3 /4
LENGTH
(INCHES)
1
1
11 /2
11 /2
2
2
3
3
4
5
2
3
4
5
6
2
3
4
5
6
8
10
12
2
4
6
8
9
10
14
2
4
6
10
14
VOLTS
120
240
120
240
120
240
120
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
240
WATTS
100
100
150
150
200
200
300
300
375
450
250
350
500
550
600
250
300
400
800
1000
1200
1500
2000
300
700
1000
1200
1400
1500
2000
300
750
1200
1600
2200
ITEM NUMBER
CM1001
CM1002
CM1121
CM1122
CM2021
CM2022
CM2031
CM2032
CM2042
CM2052
CM3022
CM3032
CM3042
CM3052
CM3062
CM4022
CM4032
CM4042
CM4052
CM4062
CM4082
CM4102
CM4122
CM5022
CM5042
CM5062
CM5082
CM5092
CM5102
CM5142
CM6022
CM6042
CM6062
CM6102
CM6142
NOTE: Lead wires can withstand temperatures up to 450F. If

temperatures will exceed this amount, leads must be insulated.
Hot One Components
39
Nozzle Heaters for Injection Molds
Features
Square coil design for improved heat transfer
High watt density on nozzle up to 106 watts/in2
Heat is conducted from entire heater circumference 360 heat
Unheated tail section reduces temperature at adapter
Moisture-resistant seal
Low profile
'NBYJNVNPQFSBUJOHUFNQFSBUVSF
Available for same-day shipping
All units have a resistance tolerance of 5% to provide

consistent operation and reduced adjustment time when
it is necessary to replace a heater or bushing.
430 SS Band Rolled Over to Retain Coil

3/16" Dia.
5.00" No-Heat Section
2F Style Lead
Orientation
Coil
Width
A stainless steel clamping band is installed on all units.

Identification
Data on
Heat Shrink
All units are stock coiled per the dimensions listed

below. All units have Teflon covered power leads and
fiberglass thermocouple leads as indicated.
.28"
Reinforcing Clamp Tab Retainers

Brazed Connection
.094" Dia. 304
SS Sheath
Coil I.D.
#6-32 Stainless Steel

Socket Head Cap Screws
PVC Heat Shrink

with FEP Melt Liner
22 Ga. Type E
Teflon Leads
Nozzle Heaters (240 VAC)

WATTS
COIL
I.D.
COIL
O.D.
COIL
WIDTH
LEAD
LENGTH
THERMOCOUPLE
ITEM
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 DMEs square coil design fit over

a nozzle. This heater was designed to fit any industry nozzle
as a replacement for runnerless molding.
*A thermocouple is externally spotwelded to the sheath.
U.S. 800-626-6653
Canada 800-387-6600
Hot One
Custom
Components
Hot Runner
Systems
Heaters
for Injection
ProductsMolds
| Nozzle
| New
As with all DME heaters, these new nozzle heaters

are designed to give long life even when operated at
'5IFTFBSFWFSZMPXQSPGJMFIFBUFSTUPGBDJMJUBUF
easy installation in the tight environment of multiple
gate molds.
This nozzle heater features a five-inch long unheated

tail section, and the adapter is provided with a moistureresistant seal. These two design advantages practically
eliminate failures in the adapter area due to overheating
and moisture contamination.
40
Hot One Components
High Watt Density Thermocouple Cartridge Heaters
These diagrams show typical installations of a

thermocouple replacement cartridge heater.
Hot One Components

Custom
Hot Runner
Watt Density
Systems
Thermocouple
| High
| Index Cartridge Heaters
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
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
installation and for best heat transfer. However, if
close hole tolerances are not maintained, operating
life of the heater may be drastically reduced. Also
make sure that the heated area of the cartridge does
not extend beyond the hole.
High Watt Density Thermocouple Cartridge Heaters

(240 VAC, Type J Thermocouple, 36" Long Leads)
LENGTHS
DIAMETER
Contamination
Contamination consists of any foreign matter such
as plastics, oil, grease, dirt or water entering through
the terminal end or the end opposite the terminal.
Care must be taken to protect the heater or these
contaminants will shorten the effective heater life.
Proper Care and Maintenance
3 /8"
(9.42mm)
1. Heaters should be stored in a dry area,

especially during periods of excess humidity.
2. Protect leads from abuse, abrasion, fatigue, etc.
3. Maintain temperature controllers and
accessories in good working condition to avoid
an overheating condition.
4. Transferring heaters from one die or platen to
another is not recommended.
*See DME Equipment and Supplies Catalog for DME
machine reamers and DME straight shank long drills.
1/2"
(12.50mm)
IN
CM
VOLTS
WATTS
ITEM
NUMBER
1 3 /4
4.445
240
200
TCH0001
5.08
240
250
TCH0002
2 1 /2
6.35
240
250
TCH0003
7.52
240
250
TCH0004
3 1 /2
8.39
240
320
TCH0005
TCH0006
10.15
240
370
4 1 /2
11.43
240
420
TCH0007
12.70
240
470
TCH0008
5 1 /2
13.97
240
525
TCH0009
15.24
240
575
TCH0010
6 1 /2
16.51
240
625
TCH0011
17.78
240
675
TCH0012
7 1 /2
19.05
240
725
TCH0013
20.32
240
775
TCH0014
3 1 /2
8.89
240
420
TCH0015
10.16
240
480
TCH0016
4 1 /2
11.43
240
550
TCH0017
12.70
240
625
TCH0018
5 1 /2
13.97
240
700
TCH0019
15.24
240
775
TCH0020
6 1 /2
16.51
240
850
TCH0021
7 1/
19.05
240
975
TCH0022
41
Hot One Components
Thermocouples
DME Bayonet Thermocouples are made of 20 gauge stranded

glass-insulated wires. The grounded hot junction is in the end
of a .188 O.D. stainless steel protecting tube for fast response
and long life. Tube features a round tip and is fitted with a
stainless steel spring loaded bayonet fitting. Lead wires are
protected by rugged .188 I.D. flexible armor (lead wire
calibration is ANSI Type J Iron/Constantan). Armor cable
is 47 long; spade lugs are attached at the end of the lead
wires for easy connection to terminal strip or plug.
DME Adjustable Bayonet Type Thermocouples fit hole depths

up to 101/2" and will conform to any angle.
DME Spade Type Thermocouples are used between band
heaters and machine nozzles in applications where space will
not permit bayonet-type thermocouples. The stainless steel
spade is only .025 thick and can be easily contoured to fit
various diameters.
Straight Type
47"
1-11/16
STAINLESS
STEEL BAYONET FITTING
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
45 BEND
STAINLESS STEEL
FLEXIBLE ARMOR
EN
SI
1- ON
11
/1
6
4"
47"
1/2
SPADE LUGS
STAINLESS STEEL
FLEXIBLE ARMOR
IM
LD
SPADE LUGS
4"
STAINLESS STEEL
BAYONET FITTING
ITEM NUMBER
TC2500
2 1 /2
TC3500
3 1 /2
TC6000
6"
45 Angle Type
ITEM NUMBER
TC2545
2 1 /2
TC3545
3 1 /2
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
47"
1/2
90 BEND
SPADE LUGS
1/2
1-11/16
L DIMENSION
STAINLESS STEEL
FLEXIBLE ARMOR
4"
STAINLESS STEEL
BAYONET FITTING
90 Angle Type
ITEM NUMBER
TC2590
2 1 /2
TC3590
3 1 /2
TC6090
6"
.188 O.D.
STAINLESS STEEL
PROTECTING TUBE
U.S. 800-626-6653
Canada 800-387-6600
Custom
Hot One
HotComponents
Runner Systems
| Thermocouples
| New Products
1/32
L DIMENSION
42
Hot One Components
Thermocouples and Accessories

Hole Depth Chart
L
THERMOCOUPLE
LENGTH
A
HOLE DEPTH FOR ADAPTER LENGTH
7/
1" TO 13 /8
31 /2
2" TO
6"
101 /2
ADJ.
23 /
1/
11 /
TO 7/8
41 /2 TO 47/8
4" TO 43 /8
1/
TO
101 /
9/32 DIA. (.281 DRILL SUGGESTED)

CAP
A
(HOLE DEPTH)
BAYONET
EDGE OF MOLD OR MACHINE
ADAPTER
L
(THERMOCOUPLE LENGTH)
TO 17/8
1/
TO 10"
By turning the adjustable

bayonet fitting along the
spring, the DME Adjustable
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
braid is 48" long with 21 /2" of lead
wires at the end and spade lugs
for ease of connection.
Adjustable Thermocouple
BAYONET FITTING
HOT JUNCTION
Hot One Components

Custom Hot Runner
Systems | and
Index
Accessories
| Thermocouples
TAP DRILL AS REQD

FOR ADAPTER
.265 O.D. SPRING
13 /8
21 /2
3/16 O.D. TUBING

(.185 TO .191)
.384 O.D.
48"
PROVIDES FOR HOLE DEPTHS FROM 1/2 TO 10-1/2
ITEM NUMBER
TC8000
Threaded Type Thermocouple

ITEM NUMBER
TCT4
48"
Threaded type thermocouple is

spring loaded and supplied with
cable and mini plug.
Bayonet Adapters
C
The stainless steel bayonet adapters

accommodate the spring loaded bayonet
fitting on the thermocouple, to bottom the
hot junction where temperature sensing
is desired. Adapter requires tapped hole
for mounting.
7/16
B
A
ITEM
NUMBER
BA1007
7/
.465
1/
NPT
BA1013
13 /
.934
1/
NPT
BA4007
7/
BA4013
13 /8
8
8
C
8-27
8-27
.465
3 / -24
8
NF
.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
x .025 thick and can be easily contoured
to fit various diameters.
ITEM
Thermocouple is Type J I/C.
NUMBER
Flexible stainless steel armor
cable is 48 long with 4 of
TC9000
lead wires at the end.
1-1/4"
48"
4"
1"
Plug (with Cable Clamp)
Jack (with Cable Clamp)
Mini Plug
ROUND PINS
AND
SOCKETS
(3/16 & 1/8)
Mini Jack
FLAT PINS
AND
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
Manifold with pre-machined horizontal flow channel
Pre-installed, replaceable tubular heaters
End plugs
End plug set screws
Ancillary Components
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
All nozzles have a selection of tip styles to suit
material flow and gate cosmetic requirements.
EHA AND CIA
METEOR
SYSTEM
250 SERIES
375 SERIES
METEOR 1
METEOR 2
More Solutions. More Choices. Always Quick Delivery.
Each Meteor manifold kit includes the following standard items:
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.
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 manifolds 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
Choose the Meteor System thats right for you
Customer machines vertical flow channel locations and end plugs for
maximum configuration flexibility
Customer can easily order a Meteor 1 manifold kit and select nozzles,
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
U.S. 800-626-6653
Canada 800-387-6600
More Solutions. More Choices. Always Quick Delivery.
Meteor 1
Standardized manifolds with machined horizontal flow channel
Meteor manifolds are

supplied with
replaceable,
press-fit tubular
heaters.
DME offers two quick-delivery hot runner systems with varying levels of
customization you pick the one that fits your needs.
Meteor 1 manifold
46
Meteor 1 In-Line and X-Style Manifolds

Meteor 1
Meteor 1 In-Line End Exit
THERMOCOUPLE LOCATION
TC
50.0mm/
1.968in
NL MIN
Meteor Hot Runner

Custom
Hot
Systems
Runner
Hot Runner
Meteor
Systems
1 In-Line
and X-Style Manifolds
| Systems
| Index
| Index
46mm/1.81in
NL MAX
O.A.L.
Meteor 1 In-Line Center Exit

31mm /1.22in
12mm/.47in RAD
74.0mm/
2.91in
50.0mm/
1.968in
NL MIN
46mm/1.81in
NL MAX
THERMOCOUPLE
LOCATION
TC
O.A.L.
MANIFOLD
TYPE
IN-LINE
END
EXIT
IN-LINE
CENTER
EXIT
X-STYLE
MANIFOLD KIT
ITEM NO.
MEM0100K
MEM0150K
MEM0200K
MEM0300K
MEM0400K
MEM0500K
MCM0100K
MCM0150K
MCM0200K
MCM0300K
MCM0400K
MCM0500K
MXM0100K
MXM0150K
MXM0200K
MXCM0300K
NL MIN.
MM
INCH
55
2.165
100
3.937
150
5.906
200
7.874
300
11.811
400
15.748
55
2.165
100
3.937
150
5.906
200
7.874
300
11.811
400
15.748
55
2.165
100
3.937
150
5.906
200
7.874
NL MAX.
MM
INCH
100
3.937
150
5.906
200
7.874
300
11.811
400
15.748
500
19.685
100
3.937
150
5.906
200
7.874
300
11.811
400
15.748
500
19.685
100
3.937
150
5.906
200
7.874
300
11.811
MM
195
245
295
395
495
595
195
245
295
395
495
595
195
245
295
395
O.A.L.
INCH
7.677
9.646
11.614
15.551
19.488
23.425
7.677
9.646
11.614
15.551
19.488
23.425
7.677
9.646
11.614
15.551
A
MM
44.5
44.5
44.5
44.5
50.8
50.8
44.5
44.5
44.5
44.5
50.8
50.8
44.5
44.5
50.8
50.8
B
INCH
1.75
1.75
1.75
1.75
2.00
2.00
1.75
1.75
1.75
1.75
2.00
2.00
1.75
1.75
2.00
2.00
MM
56.8
51.3
51.3
51.3
TC
INCH
2.236
2.020
2.020
2.020
MM
INCH
60
2.362
72.5
2.362
60
2.362
72.5
2.854
SEE X-STYLE
60
2.362
72.5
2.854
47
Meteor 1 In-Line and X-Style Manifolds

Meteor 1 X-Style
THERMOCOUPLE
LOCATION
THERMOCOUPLE
LOCATION FOR
MXM0100K
74.2mm/2.921in
NL MAX
NL MIN
TC
MOLD BASE
CENTER LINE
XY
MAX**
B
12mm/
.47in RAD
50mm/1.968in
O.A.L.
MOLD
BASE
CENTER
LINE
46mm/1.81in
NL MIN
NL MAX
O.A.L.
X and Y Coordinates Cross-Reference Chart

XY MIN*
XY MAX**
MANIFOLD KIT
ITEM NO.
MM
INCH
MM
INCH
MXM0100K
38.90
1.531
70.71
2.783
MXM0150K
70.71
2.783
106.07
4.176
MXM0200K
106.07
4.176
141.42
5.568
MXM0300K
141.42
5.568
212.13
8.352
Meteor 1 Manifold Kit Includes:

In-Line System:
(1) Manifold (center or end heater exit)
(2) Tubular heaters (installed)
(2) Tapered end plugs
(2) Set screws
X-Style System:
(1) Manifold
(2) Tubular heaters (installed)
(4) Tapered end plugs
(4) Set screws
MANIFOLD
TUBULAR HEATER
TAPERED END PLUG
SET SCREW
U.S. 800-626-6653
Canada 800-387-6600
Meteor HotCustom
Runner
Hot Runner
Hot
Systems
Runner
Systems
Meteor
In-Line
Products
and
Products
X-Style Manifolds
| Systems
| 1New
| New
XY
MIN*
48
Meteor 1 & 2 Ancillary Component Options

Meteor 2
LOCATING RING
DROOL RING
NOZZLE SEAT
RISER PAD
L.H.C.S.
TOP
METEOR 1 MANIFOLD KIT
Meteor Hot Runner

Custom
Systems
Hot Runner
Hot Runner
Systems
Systems
1 & |2 Ancillary
Index
| Meteor
| IndexComponent Options
WIRING KIT
BOTTOM
METEOR 1
MANIFOLD
MANIFOLD
KIT
TYPE
ITEM NO.
MEM0100K
MEM0150K
MEM0200K
IN-LINE
END EXIT MEM0300K
MEM0400K
MEM0500K
MCM0100K
MCM0150K
IN-LINE
MCM0200K
CENTER
MCM0300K
EXIT
MCM0400K
MCM0500K
MXM0100K
MXM0150K
X-STYLE MXM0200K
METEOR 2
MANIFOLD
KIT PLUS
ITEM NO.
MEM0100KP
MEM0150KP
MEM0200KP
MEM0300KP
MEM0400KP
MEM0500KP
MCM0100KP
MCM0150KP
MCM0200KP
MCM0300KP
MCM0400KP
MCM0500KP
MXM0100KP
MXM0150KP
MXM0200KP
MXM0300K MXM0300KP
MANIFOLD
TYPE
IN-LINE
END EXIT
METEOR 1
MANIFOLD
KIT
ITEM NO.
MEM0100K
MEM0150K
MEM0200K
MEM0300K
MEM0400K
MEM0500K
IN-LINE
CENTER
EXIT
MCM0100K
MCM0150K
MCM0200K
MCM0300K
MCM0400K
X-STYLE
MXM0100K
MXM0150K
MXM0200K
MCM0500K
MXM0300K
CENTER
SUPPORT
PAD
DOWEL
PIN
THERMOCOUPLE
DOWEL PIN
HOT RUNNER NOZZLES THAT
CAN BE USED WITH THE
METEOR 1 AND METEOR 2 KITS:
t4&3*&4&)""/%$*"
t4&3*&4&)""/%$*"
DESIGN CRITERIA
V VERTICAL
FLOW
CHANNEL DIA.
NOZZLE OPTIONS
MM INCH
250, EHA & CIA
SERIES
.354
375, EHA & CIA

SERIES
12
.472
250, EHA & CIA

SERIES
.354
375, EHA & CIA

SERIES
12
.472
250, EHA & CIA

SERIES
.354
375, EHA & CIA

SERIES
12
.472
METEOR 2
MANIFOLD THERMO- LOCATING
KIT PLUS
COUPLE
RING
ITEM NO.
ITEM NO. ITEM NO.
MEM0100KP
MEM0150KP
MEM0200KP ETC0252
EHL0253
EHL0255
MEM0300KP
(1 REQD.)
MEM0400KP
MEM0500KP (2ETC0252
REQD.)
MCM0100KP
MCM0150KP
MCM0200KP ETC0252
EHL0253
EHL0255
MCM0300KP
(1 REQD.)
MCM0400KP
MCM0500KP (2ETC0252
REQD.)
MXM0100KP
ETC0252
MXM0150KP
EHL0253
MXM0200KP
EHL0255
ETC0252 (1 REQD.)
MXM0300KP (2 REQD.)
DROOL
RING
ITEM NO.
Meteor 1 Manifold Kit includes manifold, tubular heaters

installed, two end plugs, and two set screws. The customer
machines the vertical flow channel locations and end plugs
for maximum configuration flexibility.
Meteor 2 Manifold Kit Plus includes the machining of the
vertical flow channels and the installation of the end plugs
and set screws by DME.
The customer provides DME with the gate locations on a
Meteor 2 Criteria Form.
ANCILLARY COMPONENT OPTIONS

CTR.
NOZZLE
RISER
SUPPORT
SEAT
PADS
PADS
ITEM NO. ITEM NO. ITEM NO.
DOWEL 1/4-20 X .50 WIRING

PINS
LG. L.H.C.S. KIT ITEM
ITEM NO. ITEM NO.
NO.
ERP1001
ERP1002
ERP1011
ERP1012
MNS0012 (2 OF SAME
REQD.)
DP820
ECB0468
DP828
ECB0469
1412LH
DP832
ECB0503 (2 OF
(2 REQD.)
SAME
(1 REQD.)
REQD.)
EHL1003
ERP1001
ERP1002
ERP1011
ERP1012
MNS0012 (2 OF SAME
REQD.)
DP820
ECB0468
DP828
ECB0469
1412LH
DP832
ECB0503 (2 OF
(2 REQD.)
SAME
(1 REQD.)
REQD.)
EHL1003
ERP1001
MNS0009 ERP1002
ERP1011
ERP1012
MNS0012 (4 OF SAME
REQD.)
DP820
ECB0468
DP828
ECB0469
1412LH
DP832
ECB0503 (2 OF
(2 REQD.)
SAME
(1 REQD.)
REQD.)
MNS0009
EHL1003
MNS0009
MWK1001
MWK1002
MWK1001
MWK1002
MWK1001
MWK1002
49

Locating Rings
X
00
D
C
.218
ITEM NO.
BOLT CIRCLE
117 MM 139.5 MM 73 MM
4.625 IN 5.495 IN 2.875 IN
101 MM 82.5 MM 95 MM
3.990 IN 3.250 IN 3.750 IN
117 MM 139.5 MM 114 MM

4.625 IN 5.495 IN 24.500 IN
EHL0255
101 MM 82.5 MM 95 MM
EHL0253
3.990 IN 3.250 IN 3.750 IN
Includes (2) 1/2 inch long, 5/16 Flat Head Cap Screws.
6.82mm/
.269in
SPH RAD.
28.58mm/
1.125in
M20 X 1.5
THREAD
31.75mm/1.25in
22.1mm /
.870in
ITEM NO.
E FLOW CHANNEL
MM
IN
SPHERICAL
RADIUS
MNS0009
9 MM
.354 IN
1/2 + 3/4 IN
MNS1009
9 MM
.354 IN
15.5 MM
MNS0012
12 MM
.472 IN
1/2 + 3/4 IN
MNS1012
12 MM
.472 IN
15.5 MM
NOTE: Machine nozzle tip orifice to be matched properly with

nozzle seat flow channel.
38.1
HEX
Center Support Pads

O.D.
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:
1. The M10 X 1.5 tapped hole is used to screw the center support
pad to a plate for machining the pad to the correct height.
2. An 8mm dia. dowel pin is required for assembly.
H +.13
.00
O.D.
M10 X 1.5 THRU
U.S. 800-626-6653
Canada 800-387-6600
Meteor Hot Runner

CustomSystems
Hot Runner
Systems
1 & |2 Ancillary
New Products
Component Options
| Meteor
Machine Nozzle Seats
50

Dowel Pins
L
8mm/.315in
Meteor Hot Runner

Custom
Systems
Hot Runner
Hot Runner
Systems
Systems
1 & |2 Ancillary
Index
| Meteor
| IndexComponent Options
ITEM NO.
MM
IN
DP820
20
.787
DP828
28
1.102
DP832
32
1.260
IN
.500
.750
MM
10
16.6
IN
.500
.750
MM
10
16.6
Drool Ring
.12
ITEM NO.
EHL1003
1.38
3.44
Manifold Thermocouple
M6 THREAD
ITEM NO.
ETC0252
Riser Pads and Screws
DRILLED AND CBORED FOR 1/4-20

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

LOW HEAD SCREW X DEEP
ITEM NO.
H
IN
.405
.655
1412LH
1/4-20 x 1/2 lg. LOW HEAD

CAP SCREW (L.H.C.S.)
.78
D M E H o t S p ru e Bu s h ings
Hot Sprue Bushings
52
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
Online Price Guide
U.S. 800-626-6653
Canada 800-387-6600
D -MA X High Per formance

Hot Sprue Bushings
WITH ENGINEERED AND

COMMODITY-GRADE RESINS
D-MAX High Performance Hot Sprue Bushings
HIGH-PERFORMANCE CAPABILITY
D-MAX Hot Sprue Bushings
54
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
MATERIAL
STANDARD
RESIN
SYMBOL
PROCESS
TEMPERATURE
MOLD
TEMPERATURE
HOT RUNNER
TEMPERATURE
[C]
[C]
[C]
[F]
[F]
[F]
DENSITY
MELTING
[g/cm3]
[Ibs/inch3]
SOLID
DENSITY
[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
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
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
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
Polyphenylene OxideStyrene
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
Polyoxymethylene
(Polyacetal)
POM
180
356
100
212
200
392
1.16
0.0419
1.42
0.0513
PMMA
235
455
70
158
250
482
1.09
0.0394
1.18
0.0426
ABS
225
437
70
158
250
482
0.95
0.0343
1.08
0.0390
Polymethyl Methacrylate
Acrylonitrile Butadiene
Styrene
NOTE: Temperature and density values shown above are

general, and may not apply to your application. Please refer
to proper processing data for the resin grade intended for
your specific application. Failure to use temperature settings
appropriate to the specific resin and resin grade intended for
your application may result in poor part quality, or inability to
produce acceptable molded parts.
U.S. 800-626-6653
Canada 800-387-6600
55
High Performance Hot Sprue Bushing 250 Series

NOTE: Dimensions shown in inches unless specified otherwise.
2.165 HEAD HEATER BORE
R0.24
0.33
R0.38
To compensate for nozzles growth when heat is applied, the

linear expansion of the nozzle (BE) at a given temperature
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
processing temperature.
0.33
1.656
0.75
1.57
CENTRAL
4.000 LOCATING RING BORE
For selection of gate diameter it is important to take into

consideration the material flow characteristics, share rate
of resin, molding conditions, fill time requirements, gate
vestige, wall thickness and configuration of parts to be
molded. Situations requiring high injection velocities must
be considered when selecting small gate diameters. High
injection rates may require larger gates due to shear heat
build up (e.g. high weight thin wall applications). See material
manufacturers literature for further information regarding
material to be molded.
3.50
1.50
1.575
+ 0.001
0.000
0.49
Head Bore
R0.50
0.31
R0.75
INSULATION SHEET
(OPTIONAL)
1.299
2
1
0.12
1.187 Min. 1.250 Max.
.50 MIN
0.16
R0.016 MAX
0.22 Min. - .55 Max.
+0.001
0.000
EXAMPLE: Given a 4.134 inch A dimension, with a set point

of 500F:
BE = 4.134 x 0.00000633 x (500 - 68) = 0.011
Thus A + BE will be 4.145
NOTE: 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.
O DIA.
UNFILLED RESIN
FILLED RESIN
*0.3750
A + BE
1/2-24 UN
TORQUE TO 30 FT/LBS
0.7505
1.0005
D-MAX High Performance Series 250
0.31 MIN
0.5005
0.062 Min.
0.028 Min.
WATER LINES
S DIA.
* Point Gate (Full Body) only.
BUSHING AND COMPONENT SPECIFICATIONS
2.165in (55.00mm)
2.657in (67.50mm)
3.150in (80.00mm)
3.642in (92.50mm)
4.134in (105.00mm)
5.118in (130.00mm)
6.102in (155.00mm)
POINT GATE
(BODILESS)
STD. SPRUE AND

POINT GATE
(FULL BODY)
1.187 MIN
80
1.187 MIN
30
U.S. 800-626-6653
1.187 MIN
30
30
+0.0005
0.0000
0.080 MIN.
+0.0005
0.0000
.005 LAND MAX

0.020 AT TANG.
0.100
0.180
0.3750
EXTENDED SPRUE AND

EXTENDED POINT GATE
(FULL BODY) ANGLE DESIGN
1.187 MIN
30
R0.010-0.015
R0.125
O
EXTENDED SPRUE AND

EXTENDED POINT GATE
(FULL BODY) RUNNER DESIGN
CUSTOMER
RADIUS TO
SUIT
S
* Locating
rings must
be ordered
separately.
+0.0005
0.0000
25 MAX
+0.0005
0.0000
0.080 MIN.
DMAX06055
DMAX06067
DMAX06080
DMAX06092
DMAX06105
DMAX06130
DMAX06155
ASSEMBLY COMPONENTS
BUSHING BODY HIGH PERFORMANCE
HEAD HEATER
THERMOCOUPLE
WATTAGE
WATTAGE
DETAIL #1
HEATER DETAIL #2
DETAIL #3
DETAIL #4
DEP06055
CIH0081S
440
DEP06067
CIH0082S
350
DEP06080
CIH0083S
400
RDP38021
500
DTC38001
DEP06092
CIH0084S
565
DEP06105
CIH0085S
500
DEP06130
CIH0086S
500
DEP06155
CIH0087S
550
0.080 MIN.
A
DIMENSION
ASSEMBLY
Canada 800-387-6600dme@milacron.comwww.milacron.com
NOTE:
MATCH MACHINE
NOZZLE TIP ORIFICE

BE = A dimension x 0.00000633 x nozzle set point - 68F
(assuming the mold is at 68F during operation). If mold
temperature is different, substitute 68F with actual mold
temperature.
(2) 5/16-18 UNC Tap

0.717
+ 0.001
0.000
56


consideration the material flow characteristics, share rate
2.913 HEAD HEATER BORE
R0.25
0.37
R0.38

1.656
0.37
0.75
1.57
CENTRAL
1.77
3.50
0.71
+ 0.001
2.008 0.000
Head Bore
NOTE:
MATCH MACHINE
NOZZLE TIP ORIFICE
R0.50
R0.75
0.47
EXAMPLE: Given a 2.362 inch A dimension, with a set point

of 500F:
BE = 2.362 x 0.00000633 x (500 - 68) = 0.0064
INSULATION SHEET
(OPTIONAL)
1.299
0.12
0.50 MIN
0.16
R0.016 MAX
1.437 Min. 1.625 Max.

0.22 Min. - .55 Max.
+0.001
0.000
O DIA.
A + BE
UNFILLED RESIN
FILLED RESIN
0.028 Min.
0.062 Min.
1
WATER LINES
0.31 MIN
S DIA.
0.5005
0.7505
1.0005
5/8-20 UN
TORQUE TO 30 FT/LBS
2.362in (60.00mm)
2.854in (72.50mm)
3.346in (85.00mm)
3.839in (97.50mm)
4.331in (110.00mm)
5.315in (135.00mm)
6.299in (160.00mm)
7.283in (185.00mm)
POINT GATE
(BODILESS)
STD. SPRUE AND

POINT GATE
(FULL BODY)
1.437 MIN
80
1.437 MIN
30
U.S. 800-626-6653
+0.0005
0.0000
Canada 800-387-6600
CUSTOMER
RADIUS TO
SUIT
S
* Locating
rings must
be ordered
separately.
EXTENDED SPRUE AND

EXTENDED POINT GATE
(FULL BODY) ANGLE DESIGN
1.437 MIN
30
30
0.080 MIN.
+0.0005
0.0000
DTC38001
1.437 MIN
30
R0.010-0.015
R0.187
O
0.5000
EXTENDED SPRUE AND

EXTENDED POINT GATE
(FULL BODY) RUNNER DESIGN
THERMOCOUPLE
DETAIL #4
+0.0005
0.0000
25 MAX
+0.0005
0.0000
0.080 MIN.
DMAX10060
DMAX10072
DMAX10085
DMAX10097
DMAX10110
DMAX10135
DMAX10160
DMAX10185
ASSEMBLY COMPONENTS
BUSHING BODY HIGH PERFORMANCE
HEAD HEATER
WATTAGE
WATTAGE
DETAIL #1
HEATER DETAIL #2
DETAIL #3
DEP10060
CIH0088S
400
DEP10072
CIH0089S
450
DEP10085
CIH0090S
550
DEP10097
CIH0091S
700
RDP50021
750
DEP10110
CIH0092S
800
DEP10135
CIH0093S
900
DEP10160
CIH0094S
1000
DEP10185
CIH0095S
1100
0.080 MIN.
A
DIMENSION
ASSEMBLY
0.005 LAND MAX

0.020 AT TANG.
0.100
0.180

temperature.
(2) 5/16-18 UNC Tap
+ 0.004
0.000
D-MAX High Performance Series 375
0.933
57

+0.001
0.000
2.756

consideration the material flow characteristics, shear rate
HEAD BORE
2.125 HEATER BORE

8.00 DWL
(OPTIONAL FOR
ANTI-ROTATION)
BUSHING HEATER
CABLE EXIT
0.75
1.174

(4) 5/16-18 UNC
3.50
1.174
1.378
R 0.750
INSULATION SHEET
(OPTIONAL)
0.625
EXAMPLE: Given a 3.543in A dimension, with a set point of

500F and mold temperature 68F:
BE = 3.543 x 0.00000633 x (500 - 68) = .010
1.743
S DIA.
A + BE
UNFILLED RESIN
FILLED RESIN
0.080 Min.
0.100 Min.
1.0005
1"-16 UN
TORQUE TO 30 FT/LBS
0.31 MIN.
WATER LINES
O DIA.

ASSEMBLY COMPONENTS
BUSHING BODY BUSHING HEAD CAST-IN HEATER
HEAD HEATER
THERMOCOUPLE
WATTAGE
WATTAGE
DETAIL #1
DETAIL #2
DETAIL #3
DETAIL #4
DETAIL #5
3.543in (90.00mm)
DEP16090
CIH0104-S
847
4.528in (115.00mm) DEP16115
CIH0096-S
1000
5.512in (140.00mm) DEP16140
CIH0097-S
1030
6.496in (165.00mm) DEP16165
CIH0098-S
1100
DBP16001
RDP38021
500
DTC62501
7.480in (190.00mm) DEP16190
CIH0099-S
1000
8.465in (215.00mm) DEP16215
CIH0101-S
1200
9.449in (240.00mm) DEP16240
CIH0102-S
1200
10.433in (265.00mm) DEP16265
CIH0103-S
1200
A
DIMENSION
ASSEMBLY
DMAX16090
DMAX16115
DMAX16140
DMAX16165
DMAX16190
DMAX16215
DMAX16240
DMAX16265
POINT GATE
(BODILESS)
EXTENDED SPRUE
RUNNER DESIGN
STD. SPRUE AND

POINT GATE
(FULL BODY)
2.125 MIN
80
2.125 MIN
EXTENDED SPRUE AND

ANGLE DESIGN
2.125 MIN
2.125 MIN
30
30
* Locating
rings must
be ordered
separately.
30
30
U.S. 800-626-6653
+.0005
-.0000
25 MAX.
+.0005
-.0000
0.08 MIN.
CUSTOMER
RADIUS TO
SUIT
0.08 MIN.
0.47
0.235
+.0005
-.0000
0.08 MIN.
O
+0.0005
0.6250 0.0000
0.125
R0.312
0.020 AT TANG.
R0.010-0.015
0.005 LAND MAX
R0.125
0.633 Min. - 1.283 Max.
0.06 X 45
0.06 X 45
2.125
MIN.
0.000
MIN. WIRE CHANNEL
0.06 X 45
0.375
R0.030

0.469 -0.001 HEAD CBORE
NOTE: MATCH MACHINE

NOZZLE TIP ORIFICE

temperature.
8 X18LG DWL
(OPTIONAL FOR
ANTI-ROTATION)
58
Gate Tip Detail

Sprue Gate/Extended Sprue Gate
SERIES
GATE TIP
ITEM NUMBER
EHT0010
EHT0011
EHT0012
EHT0013
EHT0014
EHT0015
EHT0016
EHT0017
EHT0018
EHT0019
EHT0020
EHT0021
EHT0022
EHT0023
SPRUE GATE
2.03
250
EXTENDED SPRUE GATE
SPRUE GATE
C
375
EXTENDED SPRUE GATE

T
SPRUE GATE
EXTENDED SPRUE GATE
625
5 PER SIDE
B DIA.
.080
.125
.187
T DIA.
.500
.750
1.000
.500
.750
1.000
.500
.750
1.000
.500
.750
1.000
1.000
.250
.375
.100
1.000
1.125
.850
.250
.375
1.000
1.125
.250
1.000
.500
1.250
(Add .750 to A dimension for extended sprue gate tips.)
Point Gate (Bodiless)

SERIES
GATE TIP
ITEM NUMBER
EHT0005
EHT1314
EHT1308
EHT1313
EHT0039
EHT1312
EHT1303
EHT1309
EHT1306
EHT1311
EHT1307
EHT1310
STANDARD
NEEDLE
250
WEAR RESISTANT
STANDARD
RETAINER TIP
375
WEAR RESISTANT
STANDARD
625
Gate Tip Detail
WEAR RESISTANT
INCLUDES
T DIA.
NEEDLE
EHN0015
.375
EHN0401
EHN0016
.500
EHN0400
EHN0019
.625
EHN0402
RETAINER TIP
EHT0024
EHT0324
EHT0324
EHT1324
EHT0025
EHT0325
EHT0325
EHT1325
EHT1354
EHT0326
EHT0326
EHT1354
Point Gate (Full Body)

SERIES
TYPE
STANDARD
250
NEEDLE
WEAR RESISTANT
RETAINER TIP
STANDARD
375
E
WEAR RESISTANT
O
T
625
STANDARD
WEAR RESISTANT
ITEM NUMBER
EHT2001
EHT2002
EHT2003
EHT2004
EHT2005
EHT2006
EHT2007
EHT2008
EHT2009
EHT2010
EHT2011
EHT2012
EHT2013
EHT2014
EHT2015
EHT2016
EHT2017
EHT2018
EHT2019
EHT2020
EHT2021
EHT2022
T DIA.
.375
.500
.375
.500
.500
.750
1.000
.500
.750
1.000
O DIA.
.060
.080
.060
.080
.060
.080
.060
.080
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.187
.230
1.000
.125
.250
T DIA.
O DIA.
INCLUDES
NEEDLE
RETAINER TIP
EHT0026
EHT0027
EHN0015
EHT0028
EHT0029
EHT1326
EHT1327
EHN0401
EHT1328
EHT1329
EHT0030
EHT0031
EHT0032
EHN0016
EHT0033
EHT0034
EHT0035
EHT1330
EHT1331
EHT1332
EHN0400
EHT1333
EHT1334
EHT1335
EHN0019
EHT0036
EHN0402
EHT1336
Point Gate (Full Body Extended)

SERIES
NEEDLE
TYPE
STANDARD
250
WEAR RESISTANT
RETAINER TIP
STANDARD
375
WEAR RESISTANT
E
0.750
O
5 PER SIDE
T
U.S. 800-626-6653
625
STANDARD
WEAR RESISTANT
SERIES
250
375
625
THREAD TYPE
1/2-24 UN
5/8-20 UN
1"-16 UN
ITEM NUMBER
EHT2301
EHT2302
EHT2303
EHT2304
EHT2305
EHT2306
EHT2307
EHT2308
EHT2309
EHT2310
EHT2311
EHT2312
EHT2313
EHT2314
EHT2315
EHT2316
EHT2317
EHT2318
EHT2319
EHT2320
EHT2321
EHT2322
Canada 800-387-6600
.375
.500
.375
.500
.500
.750
1.000
.500
.750
1.000
1.000
.060
.080
.060
.080
.060
.080
.060
.080
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.080
.100
.125
.938
.980
1.000
INCLUDES
NEEDLE
RETAINER TIP
EHT2326
EHT2327
EHN0015
EHT2328
EHT2329
EHT2326
EHT2327
EHN0401
EHT2328
EHT2329
EHT2330
EHT2331
EHT2332
EHN0016
EHT2333
EHT2334
EHT2335
EHT2330
EHT2331
EHT2332
EHN0400
EHT2333
EHT2334
EHT2335
EHN0019
EHT2336
EHN0402
59
250, 375 & 625 High Performance Locating Rings
DRILLED AND CBORED

FOR 5/16 DIA. SOCKET
HEAD CAP SCREW (4)
5/16-18 TAPPED THRU (2)

84.12 [3.312]
36.0 [1.42]
A
15.88 [0.625]
34.00 [1.339]
5/16-18 TAPPED THRU (2)

84.12 [3.312]
9.9 [0.39]
101.35 [3.990]
44.28 [1.743]
29.39 [1.157]
32.00 [1.260]
17.0 [0.67]
38.2 [1.50]
PML2505 & PML3751
PML6251
SECTION A-A
ITEM NUMBER
PML2505
34.00 (1.34")
PML3751
46.00 (1.81")
PML6251
63.00 (2.48")
NOTE: Dimensions shown in millimeters, inches in parentheses
U.S. 800-626-6653
101.35 [3.990]
45
DRILLED AND CBORED

FOR 5/16 DIA. SOCKET
HEAD CAP SCREW (2)
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.
See the DME Control Systems Catalog for Smart Series Single Zone Temperature Controllers.
Typical Applications
Mini and Jumbo Style Gate-Mate

Bushings Shown
BODY
SQUARE
COIL HEATER
TOP OF
MOLD
TIP
PART
CAVITY
Advantages
LOCATION
RING
Benefits
Eliminates sprues, reduces cycle time, improves

part quality, increases production
Provides optimum gate cosmetics
Plated copper alloy tip improves temperature

profile in gate area
Self insulating material layer surrounds tip for

better tip control and part cooling
Direct part gating eliminating a cold sprue to trim and no witness

lines on the molded part
Minimal gate vestige resulting in better part appearance
Faster start-ups providing positive temperature control of gate area
Reduced cycle times because the bushing allows cooling channels

to be placed closer to the gate area
Cooler cavities with no direct contact between bushing tip and cavity
Improved part quality with a shorter injection path and elimination

of sprue, meaning no regrind
Increased production with faster cycles and no sprue trimming

Easy installation and operation, and available in three standard
sizes suitable for most applications
Positive temperature control with J-Type thermocouple and
DME Smart-Series (and G-Series) controllers
Square coil heater and independent thermocouple

provide precise temperature control
Optional cast in heater available for Mini

Gate-Mate bushing
U.S. 800-626-6653
Gate-Mate Applications and Benefits
NOTE: Mini Gate-Mate is also available with a

cast-in heater with integral thermocouple.
THERMOCOUPLE
CORE
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.
62
Mini Gate-Mate
Radius Type
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
provides better heater control, and the overall body design improves
thermal insulation. Square coil heater, thermocouple and tip are
all replaceable.
Flat Type
Sub-assemblies include square coil heater and thermocouple or cast-in

heater with integral thermocouple. Tip to be ordered separately.
12 " SPH. Radius Type Bushing
Flat Type Bushing
Mini Gate-Mate
1.500
.625
.250
1.187
HEATER
1.375
.281
.6250 DIA.
Dimensions same as radius type bushing
/2 SPH. RADIUS BUSHING

SUB-ASSEMBLY
FLAT BUSHING
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
NUMBER
1
TIP
STYLE
-20
1.086
GMT0100
STANDARD
GMT4101
WEAR RESISTANT
Contact for DME for tip recommendations

and assistance with your application.
.010 DIA.
U.S. 800-626-6653
Canada 800-387-6600
63
Mini Gate-Mate Machining Dimensions

Machining Dimensions for Bushings
+.001
1.501 .000 DIA.

1.125 DIA.
.625 WIRE CHANNEL
.125 RAD.
4.000 DIA.
.219 MIN.
.719 MAX.
118
+.0005
.0000
.6250 DIA.
+.0005
.0000
.6250 DIA.
.125
.125 RAD.
.80
INCL
.125 RAD.
1.375 + BE
SEE NOTE
.400
.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
point - 68F (assuming the mold is at 68F during
operation). If mold temperature is different,
substitute 68F with actual mold temperature.
Replacement Parts
SUB-ASSEMBLY
REFERENCE
GMB0111
THERMOCOUPLE
(36" LEADS)
2 RADIUS
(CAST IN)
CIH0100
N/A
(INTEGRAL TO HEATER)
(SQUARE COIL)
SCH0004
TCG0100
GMB0112
GMB0116
FLAT
2 RADIUS
GMB0117
FLAT
Mini Gate-Mate Bushing Locating Ring

1.500
5
16
-18 TAPPED THRU
ITEM
NUMBER
2.375
.53
1.50 DIA.
1.250
3.990 DIA.
.218
U.S. 800-626-6653
6548
NOTES:
1. Two (2) 516-18 S.H.C.S. are included with Locating Ring
2. Two (2) Drilled and Cbored holes for 516-18 S.H.C.S. are
on a 1.656 circle radius in Locating Ring
3. Cbore depth in Top Clamp Plate and Cbore depth in
Locating Ring can be altered to suit application

5
16 -18 S.H.C.S.
32
Mini Gate-Mate Machining Dimensions
HEATER TYPE
(240 VAC, 250 WATT)
EXAMPLE:
Given a setpoint of 500F: BE = 1.375 .0000063
(500 68) = .004 thus 1.375 + .004 = 1.379.
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.
BODY
TYPE
.030
.005 LAND (MAX.)
.187 SPH. RAD.
.030 MIN.
.125 MIN.
.407 MAX.
64
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.
Medium Gate-Mate
2.156 DIA.
BUSHING ASSEMBLY
(INCLUDES GMT2 TIP)
.250
1.062
.250
1.062
ITEM
NUMBER
.562
.562
GMB5232
2.375 3.437
GMB5332
3.375 4.437
DUAL
SPH. RAD.
1
/2 & 3/4
BUSHING SUB-ASSEMBLY
(ORDER TIP SEPARATELY)
ITEM
NUMBER
.730
.730
.024 DIA.
7500 DIA.
GMB0020
2.375 3.437
GMB0030
3.375 4.437
DUAL
SPH. RAD.
2 & 34
7500 DIA.
Medium Gate-Mate Tips

STANDARD
WEAR RESISTANT
SUPER SHARP
SUPER SHARP WEAR RESISTANT
NO HOLE
TIP
STYLE
THRU HOLE
THRU HOLE WEAR RESISTANT
2 -20
(typ.)
TIP
LENGTH
TIP ITEM
NUMBER
O
DIA.
STANDARD
GMT2
.044 MIN.
WEAR RESISTANT
GMT0400
.055 MIN.
SUPER SHARP
GMT0301
.030 MIN.
SUPER SHARP
WEAR RESISTANT
GMT0401
.055 MIN.
THRU HOLE
GMT0302*
.030 MIN.
.050 MAX
TIP
TIP
LENGTH DIA.
HOLE
DIA.
.024
1.730
N/A
.010
1.690
.090
.050
1.730
.024
N/A
THRU HOLE
GMT0402* .055 MIN.
WEAR RESISTANT
NO HOLE
TIP DIA.
.118
10 0"
TYPICAL .125 DIA. HOLE
MOLDMAKER TO MACHINE
.044 MIN.
NOTES:
1. Thru-hole tip is designed .040 shorter in length to be a direct
replacement for the standard tip; use a .030 to .060 diameter gate
2. A .030 minimum diameter gate is recommended when using the
super sharp tip
3. Contact DME for tip recommendations and assistance with
your application
HOLE DIA.
*Contact DME for details to modify thru-hole tips for larger O diameters.
U.S. 800-626-6653
GMT0303
TIP DIA.
TIP DIA.
Canada 800-387-6600
65
Medium Gate-Mate Machining Dimensions

Improved tip insulation, elimination of material degradation in
threaded area of tip, and faster color changes can be achieved
through use of a Gate Shell Insulator.
2.187 DIA.
+.002
2.157 .000 DIA.
1.625 DIA.
.563
.625 WIRE CHANNEL

.125 RAD.
4.000 DIA.
.219
+.0005
.0000
90
+.0005
.0000
.140
.7500 DIA.
.125 RAD.
.7500 DIA.
A + BE
SEE NOTE
30
.375 RAD.
TO SUIT
.044 MIN.
(.030 MIN. FOR
SUPER SHARP TIP)
.31 MIN. DISTANCE BETWEEN

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.
Formula for determining this expansion is as follows: BE = A dimension x 0.00000633
x nozzle set point - 68F (assuming the mold is at 68F during operation). If mold
temperature is different, substitute 68F with actual mold temperature.
ITEM NUMBER
REFERENCE
BUSHING
ASSEMBLY
BUSHING
SUB-ASSEMBLY
GMB5232
GMB0020
2.375
GMB5332
GMB0030
3.375
EXAMPLE:
Given a 2.375 inch A dimension, with a Bushing Set Point temp. of 500F:
BE = 2.375 .0000063 (500 68) = .006 thus A + BE will be 2.381.
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.
.030
.005 LAND (MAX.)
.187 SPH. RAD.
SQUARE COIL HEATERS

(240 VAC)
BUSHING
SUB-ASSEMBLY
BUSHING
ASSEMBLY
ITEM
NUMBER
THERMOCOUPLE
(TYPE J, 36" LEADS)
WATTS
LENGTH
ITEM
NUMBER
LENGTH
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
.53
2.216 DIA.
1.250
3.990 DIA.
.218
32
U.S. 800-626-6653

5
16 -18 S.H.C.S.
6545
NOTES:
1. Two (2) 516 -18 S.H.C.S. are included with
Locating Ring
2. Two (2) Drilled and Cbored holes for
5
16 -18 S.H.C.S. are on a 1.656 circle radius
in Locating Ring
3. Cbore depth in Top Clamp Plate and Cbore
depth in Locating Ring can be altered to
suit application
Medium Gate-Mate Machining Dimensions
Replacement Parts
ITEM NUMBER
REFERENCE
.875
.80
INCL
66
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.
Jumbo Gate-Mate
2.625 DIA.
BUSHING ASSEMBLY
(INCLUDES GMT0004 TIP)
.500
1.062
ITEM
NUMBER
.500
1.062
.562
.562
SPH. RAD.
GMB0008
2.500 3.562
GMB0009
3.500 4.562
/2 & 3/4
BUSHING SUB-ASSEMBLY
|
ITEM
NUMBER
.855
.855
.030 DIA.
1.2500 DIA.
SPH. RAD.
GMB0113
2.500 3.562
GMB0114
3.500 4.562
/2 & 3/4
1.2500 DIA.
Jumbo Gate-Mate Tips

THRU HOLE
THRU HOLE WEAR RESISTANT
STANDARD
WEAR RESISTANT
4 -16
(typ.)
TIP
LENGTH
TIP
STYLE
ITEM
NUMBER
STANDARD
GMT0004
WEAR RESISTANT
GMT0406
THRU HOLE
GMT0007
THRU HOLE
WEAR RESISTANT
GMT0407
TIP
LENGTH
TIP
DIA.
HOLE
DIA.
1.855
.030
N/A
1.815
.140
.100
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
your application
TIP DIA.
TIP DIA.
HOLE DIA.
U.S. 800-626-6653
Canada 800-387-6600
67
Jumbo Gate-Mate Machining Dimensions

90
+.0005
.0000
2.750 DIA.
+.002
2.626 .000 DIA.
1.2500 DIA.
.80
INCL
2.000 DIA.
.563
.625 WIRE CHANNEL.

.125 RAD.
4.000 DIA.
.219
.375 RAD.
.030
+.0005
.0000
TO SUIT
.070 MIN.
.140
1.2500 DIA.
.125 RAD.
.005 LAND (MAX.)

.187 SPH. RAD.
A + BE
SEE NOTE
ITEM NUMBER REFERENCE
1.000
.31 MIN. DISTANCE BETWEEN

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. Formula for determining this expansion is
as follows: BE = A dimension x 0.00000633 x nozzle set point - 68F
(assuming the mold is at 68F during operation). If mold temperature is
different, substitute 68F with actual mold temperature.
BUSHING
ASSEMBLY
BUSHING
SUB-ASSEMBLY
GMB0008
GMB0113
2.500
GMB0009
GMB0114
3.500
EXAMPLE:
Given a 2.500 inch A dimension, with a Bushing Set Point temp. of 500F:
BE = 2.500 .0000063 (500 68) = .007 thus A + BE will be 2.507.
Please note that this 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.
Replacement Parts
30
ITEM NUMBER
REFERENCE
SQUARE COIL HEATERS

(240 VAC)
THERMOCOUPLE
(TYPE J, 36" LEADS)
BUSHING
ASSEMBLY
BUSHING
SUB-ASSEMBLY
ITEM
NUMBER
WATTS
LENGTH
ITEM
NUMBER
LENGTH
GMB0008
GMB0113
SCH0002
600
1.70
TC0002
1.18
GMB0009
GMB0114
SCH0001
800
2.70
TC0001
2.18
Jumbo Gate-Mate Locating Ring

1.50
5
16
-18 TAPPED THRU
ITEM
NUMBER
GMB0007
2.687 DIA.
3.990 DIA.
.218

5
16 -18 S.H.C.S.
32
U.S. 800-626-6653
NOTES:
1. Two (2) 516 -18 S.H.C.S. are included
with Locating Ring
2. Two (2) Drilled and Cbored holes for
5
16 -18 S.H.C.S. are on a 1.656 Circle
radius in Locating Ring
3. Cbore depth in Top Clamp Plate and
Cbore depth in locating ring can be
altered to suit application
Jumbo Gate-Mate Machining Dimensions
Improved tip insulation,

elimination of material
degradation in threaded area
of tip, and faster color changes
can be achieved through use
of a Gate Shell Insulator.
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
are available as S-type
S Type (Standard Tip Configuration)
.062 or .125 DIA. Tips with .08 Land area
Seven shoulder lengths from 78 to 378

.500 And .750 Spherical radius for machine nozzle
EXAMPLE:
Given a setpoint of 500F:
BE = 1.375 .0000063 (500 68) = .004 thus 1.375 + .004 = 1.379.
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.
Replaces conventional cold sprue bushings to reduce

cycle time and save material costs
Efficiently processes commodity or engineering grade resins
Provides low vestige gate cosmetics (.062 or .125 Gate

diameters available)
High-watt density heater with distributed wattage

to help prevent tip freeze-offs
1.995 DIA.
+.000
.005
5.00
(S-TYPE)
1.995 DIA.
+.000
.005
.08
.08
.312 DIA.
R.750
R.500
.17
1.000 DIA.
"0" DIA.
.015 RELIEF
A= 7 8
TO 3 7 8
1.000 DIA.
"0" DIA.
.62
BUSHING ASSEMBLY
O
DIA.
.062
.125
SHOULDER
LENGTH
A
A= 7 8
TO 3 7 8
REPLACEMENT PARTS
BUSHING
ASSEMBLY
ITEM
NUMBER
SHOULDER
BUSHING
ITEM
NUMBER
HPS0607S2
HPS1007
1 8
HPS0613S2
HPS1013
178
HPS0617S2
HPS1017
238
HPS0623S2
HPS1023
278
HPS0627S2
HPS1027
338
HPS0633S2
HPS1033
378
HPS0637S2
HPS1037
HPS1207S2
HPS1007
138
HPS1213S2
HPS1013
178
HPS1217S2
HPS1017
2 8
HPS1223S2
HPS1023
278
HPS1227S2
HPS1027
338
HPS1233S2
HPS1033
378
HPS1237S2
HPS1037
TIP
ITEM
NUMBER
RETAINER
ITEM
NUMBER
BODY
ITEM
NUMBER
SPACER
ITEM
NUMBER
HEATER
ITEM
NUMBER
THERMOCOUPLE
ITEM
NUMBER
HPT0001
HPT0601
HPS0001
HPT1001
HPS2001
HPS3001
HPT0002
HPT1201
HPS0001
HPT1001
HPS2001
HPS3001
NOTE: High-Performance Series Straight-Shot Hot Sprue Bushings heater has voltage of 240 VAC, 700 watts. Thermocouple is J type.
U.S. 800-626-6653
Straight-Shot
Sprue Bushings
Series
Straight-Shot
| High-Performance
Hot RunnerHot
Systems
8-Zone Timer-Based
Sequencers
| 4-Zone and
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:
temperature.
70
High-Performance Series Straight-Shot

E Type (Extended Tip Configuration)
High-Performance
Straight-Shot Bushings
are available as E-type
Hot RunnerHot
Systems
8-Zone Timer-Based
Sequencers
| 4-Zone and
Straight-Shot
Sprue Bushings
Series
Straight-Shot
| High-Performance
.277 MAX.
DEPTH
FIG. 1
.277 MAX.
DEPTH
FIG. 2
FIG. 3
15 MAX.
.277 MAX.
MAX.
3 MIN.
GATE
FIG. 4
3 MIN.
GATE
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 78 to 378
.500 And .750 Spherical radius for machine nozzle
Always machine runner or part contour to the .277 maximum depth at centerline of gate. However,
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
molded (Figure 3). Machine a 3 minimum taper to the gate for a reverse taper sprue on the part being
molded (Figure 4). Retainer material is H-13 steel 46-52 HRC.
NOTE:
The expansion factor must be taken
into consideration prior to machining
R.750
E-TYPE (EXTENDED TIP
for and installation of the bushing.
R.500
CONFIGURATION)
.17
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 - 68F (assuming
.312 DIA.
the mold is at 68F during operation). If mold temperature is
5.28
different, substitute 68F with
(E-TYPE)
actual mold temperature.
.015 RELIEF
.62
EXAMPLE:
CUSTOMER MAY ALTER
(.500 MAX.) TO ACCOMMODATE
BE = 1.375 .0000063 (500 68) =
NON-STANDARD "A" LENGTHS
.004 thus 1.375 + .004 = 1.379.
.36
A = 7 8 TO 3 7 8
Please note that the above
information is given as an example.
Variations may occur based on mold
"0" DIA.
configuration and cooling factor. In
1.000 DIA.
some instances, it may be necessary
1.995 DIA. +.000
.005
BUSHING ASSEMBLY
O
DIA.
SHOULDER
LENGTH
A
REPLACEMENT PARTS
BUSHING
ASSEMBLY
ITEM
NUMBER
SHOULDER
BUSHING
ITEM NUMBER
TIP
ITEM
NUMBER
RETAINER
ITEM
NUMBER
BODY
ITEM
NUMBER
SPACER
ITEM
NUMBER
HEATER
ITEM
NUMBER
THERMOCOUPLE
ITEM
NUMBER
7
8
HPS0607E2
HPS2007
138
HPS0613E2
HPS2013
178
HPS0617E2
HPS2017
.062
238
HPS0623E2
HPS2023
HPT0001
HPT0602
HPS0001
HPT1001
HPS2001
278
HPS0627E2
HPS2027
338
HPS0633E2
HPS2033
378
HPS0637E2
HPS2037
7
8
HPS1207E2
HPS2007
138
HPS1213E2
HPS2013
178
HPS1217E2
HPS2017
HPT0002
HPT1202
HPS0001
HPT1001
HPS2001
.125
238
HPS1223E2
HPS2023
278
HPS1227E2
HPS2027
338
HPS1233E2
HPS2033
HPS1237E2
HPS2037
378
NOTE: High-Performance Series Straight-Shot Hot Sprue Bushings heater has voltage of 240 VAC, 700 watts. Thermocouple is J type.
U.S. 800-626-6653
Canada 800-387-6600
HPS3001
HPS3001
71
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.
5.09
A=
TO 3
+.000
1.995 DIA. .005
.19
.19
1.000
DIA.
.16
DIA.
.31 DIA.
.015
RELIEF
.62
.015
RELIEF
.340
NOTE:
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 - 68F (assuming
the mold is at 68F during operation). If mold temperature is different,
EXAMPLE:
BE = 1.375 .0000063 (500 68) = .004 thus 1.375 + .004 = 1.379.
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.
WITH 120 VOLT

WITH 240 VOLT
SHOULDER
HEATER
HEATER
LENGTH
A
ITEM NUMBER
ITEM NUMBER
SSBT4507S1
SSBT4507S2
SSBT4513S1
1 8
SSBT4513S2
SSBT4517S1
178
SSBT4517S2
SSBT4523S1
238
SSBT4523S2
SSBT4527S1
278
SSBT4527S2
SSBT4533S1
338
SSBT4533S2
SSBT4537S1
3 8
SSBT4537S2
SSBT6507S1
SSBT6507S2
SSBT6513S1
138
SSBT6513S2
SSBT6517S1
178
SSBT6517S2
SSBT6523S1
238
SSBT6523S2
SSBT6527S1
2 8
SSBT6527S2
SSBT6533S1
338
SSBT6533S2
SSBT6537S1
378
SSBT6537S2
U.S. 800-626-6653
The helical tubular heater (120 or 240 volt) is

thermocouple equipped so temperature can be
closely controlled using a DME single-zone Closed
Loop Temperature Controller.
The standard S-Series Straight-Shot is designed
for direct part gating or for feeding half-round or
trapezoidal runners. It is supplied with a .16 diameter
gate and no gate land. Available in seven standard
shoulder lengths with either a 12" or 34" spherical
radius and 120 or 240 volt heater. The S-Series
Straight-Shot can be retrofitted to almost any mold
that uses a conventional sprue bushing.
NOTE: 5 heater lead is standard. For 90 lead, add 90
to end of item number (e.g., SSBT4507S190).
Typical Applications
DIRECT PART GATING
FEEDING A TRAPEZOIDAL RUNNER
Hot Sprue
Bushings
Straight-Shot
Hot Straight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
| S-Series
| 4-Zone
The bushings feature an unrestricted straightshot channel to feed the part or runner. Material
in the channel is heated by a special helical tubular
heater which surrounds the melt stream. This heater
distributes heat uniformly throughout the bushing
and is virtually impervious to moisture, gases and
plastics contamination.
U.S. Patent No. 4,273,525
72
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
molding application.
Long Style
See DME Control Systems Catalog for temperature controllers.
Hot Straight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
Hot Sprue
Bushings
Straight-Shot
| 4-Zone
| E-Series
E-Series (Long Style)

NOTE:
Must always be
altered as shown
in Figures 1 thru 6
(see next page).
5.34
.25 LAND
A=
TO 3
+.000
.005
.19
.31 DIA.
1.995 DIA.
.44
.06 DIA.
.06
1.000 DIA.
DIA.
.015
RELIEF
.25
ENLARGED VIEW AS SUPPLIED
NOTE:
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 - 68F (assuming
the mold is at 68F during operation). If mold temperature is different,
NOTE: 5 heater lead is standard. For 90 lead, add 90 to end of item

number (e.g., SSBT4507E190).
Canada 800-387-6600
WITH 120 VOLT

HEATER
ITEM NUMBER
The DME standard E-Series Straight-Shot (Long Style) is

available in seven standard shoulder lengths with either
a " or " spherical radius and 120 or 240 volt heater. The
E-Series Straight-Shot (Long Style) can be retrofitted to suit
the particular molding application.
.340
E-Series Straight-Shot (Long Style)

Hot Sprue Bushings
EXAMPLE:
BE = 1.375 .0000063 (500 68) = .004 thus 1.375 + .004 = 1.379.
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.
U.S. 800-626-6653
.015
RELIEF
.62
SHOULDER
LENGTH
A
WITH 240 VOLT

HEATER
ITEM NUMBER
SSBT4507E1
SSBT4507E2
SSBT4513E1
138
SSBT4513E2
SSBT4517E1
1 8
SSBT4517E2
SSBT4523E1
238
SSBT4523E2
SSBT4527E1
278
SSBT4527E2
SSBT4533E1
338
SSBT4533E2
SSBT4537E1
378
SSBT4537E2
SSBT6507E1
SSBT6507E2
SSBT6513E1
138
SSBT6513E2
SSBT6517E1
178
SSBT6517E2
SSBT6523E1
238
SSBT6523E2
SSBT6527E1
278
SSBT6527E2
SSBT6533E1
338
SSBT6533E2
SSBT6537E1
3 8
SSBT6537E2
73
E-Series Straight-Shot
The DME standard E-Series StraightShot (Short Style) is intended to suit
the requirements of smaller injection
molding machines and is supplied with
a 7/8" A dimension. The A dimension can
be altered to suit the particular molding
application.
E-Series Straight-Shot Hot

Sprue Bushings (Short Style)
WITH 240 VOLT
HEATER
ITEM NUMBER
SSBT4407E2
SSBT0407E2
E-Series (Short Style)
3.22
+.000
A = 78
1.995 DIA. .005
.25 LAND
.19
.25 DIA.
.25
.44
.340
SSBT4407E2
NONE
SSBT0407E2
NOTE: Must always be altered as shown in Figures 1 thru 6 (see below).
EXAMPLE:
BE = 1.375 .0000063 (500 68) =
.004 thus 1.375 + .004 = 1.379.
information is given as an example.
Variations may occur based on mold
configuration and cooling factor. In
some instances, it may be necessary
Design Guidelines for Altering E-Series Straight-Shot Hot Sprue Bushings

(Long and Short Styles)
Always remove the .25 extra stock allowance and alter the
A dimension to suit whenever gating into a flat part surface.
Minimum stock removal of .25 provides an approximate .06
gate diameter (Figure 1).
.25
MIN.
DEPTH
Maximum stock removal of .268 provides an approximate

.08 gate diameter (Figure 2). Maximum stock removal of
.268 is recommended for gate diameters larger than .08
(Figures 3 and 4).
.268
MAX.
DEPTH
.268
MAX.
DEPTH
FIG. 1
.12 DIA.
.09 DIA.
.08 DIA.
.06 DIA.
.268
MAX.
DEPTH
FIG. 2
Always machine runner profile or part contour to the

.268 maximum depth at centerline of gate (Figures 5
and 6). However, do not weaken the bushing face by
exceeding this maximum dimension.
FIG. 3
FIG. 4
.268
MAX.
DEPTH
.268
MAX.
DEPTH
*GATE DIA.
*GATE DIA.
* Resultant gate diameter may be enlarged to suit the particular

FIG. 5
U.S. 800-626-6653
FIG. 6
Hot Sprue
Bushings
Straight-Shot
| E-Series
HotStraight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
| 4-Zone
.015 RELIEF
.06
1.000 DIA.
DIA.
A
DIMENSION
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 - 68F (assuming
the mold is at 68F during
operation). If mold temperature
is different, substitute 68F with
actual mold temperature.
Short Style
See the DME Control Systems Catalog for
temperature controllers.
NOTE: 5 heater lead is standard. For 90 lead,

add 90 to end of item number (e.g.,
SSBT4407E290).
.06 DIA.
74
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.
HotStraight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
Hot Sprue
Bushings
Straight-Shot
| 4-Zone
| ER-Series
The ER-Series design can also be used when a reverse taper

will benefit a particular application. These bushings are supplied
with a .12 diameter orifice and a .50 long reverse taper. The
orifice may be enlarged and the taper increased to suit.
(Long Style)
ER-Series (Long Style)

5.34
A = 7 8 TO 3 7 8
.12
DIA.
1.995 DIA. +.000

.005
.19
.31 DIA.
.50
1.000
DIA.
5
.44
.015
RELIEF
.015
RELIEF
.62
.340
NOTE: For minimum projection on runner/part,

alter the bushing face (See figures 1 thru 3 on next page).
ER-Series Straight-Shot (Long Style)

Hot Sprue Bushings
WITH 120 VOLT
HEATER
R
ITEM
NUMBER
SSBT4507ER1
EXAMPLE:
BE = 1.375 .0000063 (500
68) = .004 thus 1.375 + .004
= 1.379.
information is given as an
example. Variations may occur
based on mold configuration
and cooling factor. In some
instances, it may be necessary
WITH 240 VOLT

HEATER
SHOULDER
LENGTH
A
ITEM
NUMBER
SSBT4507ER2
SSBT4513ER1
1 8
SSBT4513ER2
SSBT4517ER1
1 8
SSBT4517ER2
SSBT4523ER1
238
SSBT4523ER2
SSBT4527ER1
278
SSBT4527ER2
SSBT4533ER1
338
SSBT4533ER2
SSBT4537ER1
3 8
SSBT4537ER2
SSBT6507ER1
SSBT6507ER2
SSBT6513ER1
138
SSBT6513ER2
SSBT6517ER1
178
SSBT6517ER2
SSBT6523ER1
238
SSBT6523ER2
SSBT6527ER1
2 8
SSBT6527ER2
SSBT6533ER1
338
SSBT6533ER2
SSBT6537ER1
378
SSBT6537ER2
U.S. 800-626-6653
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
- 68F (assuming the mold is
at 68F during operation). If
mold temperature is different,
substitute 68F with actual
mold temperature.
The DME standard ER-Series Straight-Shot

(Long Style) is available in seven standard
shoulder lengths with either a 1/2" or 3/4"
spherical radius and 120 or 240 volt heater.
The ER-Series Straight-Shot (Long Style)
can be retrofitted to suit the particular
NOTE: 5 heater lead is standard. For 90
lead, add 90 to end of item number
(e.g., SSBT4507ER190).
Canada 800-387-6600
75
The DME standard ER-Series Straight-Shot (Short Style) is intended to suit
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
Short Style
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 - 68F
(assuming the mold is at 68F during operation). If mold temperature is different, substitute 68F
with actual mold temperature.
WITH 240 VOLT

HEATER
ITEM NUMBER
SSBT4407ER2
SSBT0407ER2
3.22
A=
1.995 DIA. +.000

.005
NONE
NOTE:
For minimum
projection on runner/
part, alter the bushing
face (See figures
1 through 3 below).
.25 DIA.
5
.12
DIA.
A
DIMENSION
.19
.015 RELIEF
1.000
DIA.
.44
.50
.340
SSBT4407ER2
SSBT0407ER2
Design Guidelines for Altering ER-Series Straight-Shot Hot Sprue Bushings

(Long and Short Styles)
FIG. 1
.25
.25
MIN.
.25
FIG. 2
.25
MIN.
RUNNER
PART
.25
.25
MIN.
FIG. 3
RUNNER/PART
U.S. 800-626-6653
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
of the 2.00 diameter bushing shoulder.
Hot Sprue
Bushings
Straight-Shot
HotStraight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
| ER-Series
| 4-Zone
EXAMPLE:
Given a setpoint of 500F: BE = 1.375 .0000063 (500 68) = .004 thus 1.375 + .004 = 1.379.
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.
ER-Series (Short Style)
Hot Sprue Bushings (Short Style)
76
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:
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:
temperature.
5.09
HotStraight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
| 4-Zone
Hot Sprue
Bushings
Straight-Shot
| T-Series
No. 10-24 1 2 LONG

F H S (2) INCLUDED
.97
.97
+.0000
.0005
A = 178
1.995 DIA.
+.000
.005
.19
.16
DIA.
R
.31 DIA.
1.4995
DIA.
1.69 DIA.
.25
EXAMPLE:
BE = 1.375 .0000063 (500 68) = .004 thus 1.375 +
.004 = 1.379.
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
.340
T-Series Straight-Shot Hot Sprue Bushings

WITH 120 VOLT
HEATER
Typical Application
WITH 240 VOLT

HEATER
L
ITEM
NUMBER
1
3
MOLD
OPEN
2
4
SSBT4517T107
SSBT4517T113
SSBT6517T107
SSBT6517T113
ITEM
NUMBER
8
SSBT4517T207
138
SSBT4517T213
SSBT6517T207
138
SSBT6517T213
Replacement
Stripper Bushings
ITEM
NUMBER*
SSSB07
L
8
SSSB13
1 8
*Includes mounting screws.
3
X-2
PLATE
X-1
PLATE
A-CLAMPING
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
77
TR-Series Straight-Shot
The DME standard TR-Series Straight-Shot Hot Sprue Bushing,
like the standard T-Series, improves the performance of threeplate runner molds by minimizing the length of protrusion on the
runner system. This bushing features a reverse taper design that
originates from under the heat source, providing easier start-ups.
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:
temperature.
The TR-Series design can also be used when a reverse taper will
benefit a particular application. The bushing is supplied with a .12
diameter orifice and a .25 long reverse taper. The orifice may be
enlarged and the taper increased to suit. The bushing 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.
5.09
TR-Series Straight-Shot Hot Sprue Bushings

A =1
WITH 120 VOLT
HEATER
R
SSBT4517TR107
SSBT6517TR107
ITEM
NUMBER
WITH 240 VOLT

HEATER
ITEM
NUMBER
SSBT4517TR207
1 8
SSBT4517TR213
SSBT6517TR207
138
SSBT6517TR213
SSBT4517TR113
SSBT6517TR113
.97
+.0000
.0005
1.4995
DIA.
.97
U.S. 800-626-6653
A-CLAMPING
PLATE
.19
.12
DIA.
.31 DIA.
5
.25
1.69 DIA.
.340
MOLD
OPEN
X-1
PLATE
1.995 DIA. .005
.25
Typical Application
.25
MIN.
+.000
No. 10-24 x 1 2 LONG

F H S (2) INCLUDED
NOTE:
5 heater lead is standard. For 90 lead, add 90 to end of
item number (e.g., SSBT4517TR10790).
X-2
PLATE
Important:
To prevent pushback of the hot sprue
bushing due to injection pressure and
assure a positive tapered seal with the
stripper plate bushing secure the hot sprue
bushing to the A-Clamping Plate. A dowel
or flat key installed under the locating ring
(shown) or clamping-type locating ring may
be used.
For Improved Performance and
Increased Productivity:
Use DME standard T-Series (3-Plate)
Mold Bases (see DME Mold Bases and
Plates Catalog)
Hot Sprue
Bushings
Straight-Shot
HotStraight-Shot
Runner Systems
and 8-Zone
Timer-Based
Sequencers
| TR-Series
| 4-Zone
EXAMPLE:
BE = 1.375 .0000063 (500 68) = .004 thus 1.375 + .004 = 1.379.
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.
78
Straight-Shot Bushings Replacement Parts
Replacement Heaters for Straight-Shot Hot Sprue Bushings Standard

ITEM
NUMBER*
VOLTS
WATTS
BUSHING SERIES
SSTC31
120
300
458
S, E & ER (Long Style), T & TR
SSTC32
240
300
4 8
S, E & ER (Long Style), T & TR
250
212
E & ER (Short Style)
Hot Runner
8-Zone Timer-Based
Sequencers Parts
| 4-Zone| and
Straight-Shot
HotSystems
Sprue Bushings
Straight-Shot
Bushings Replacement
SSTC42
240
* Includes installation wrench.
5 heater lead, with 48"

long shielded leads
5
Straight-Shot Heater Installation

and Removal Wrench
ITEM
NUMBER
USED WITH
(Included with heaters above).
WR0875
SSTC31 & 32 Series
WR0874
SSTC42 Series
Available On Request:
Heaters with 90 exit leads. Add
90 to item number.
Example: SSTC3190
L
ID
OD
/2
/4
90
Replacement Parts for Discontinued Hot Sprue Bushings (HBT6630 through 6636),
Temperature Controllers (PFC5) and Control Modules (FC5)
Thermocouple Cartridge Heaters
Cartridge Heaters
DIA.
LENGTH
WATTS
VOLTS
1/
4
21/2
240
200
1/
4
3 /4
240
ITEM
NUMBER
300
DIA.
LENGTH
VOLTS
WATTS
ITEM
NUMBER
HBC2022*
21/2
240
200
HBTC2022*
HBC2032**
33/4
240
300
HBTC2032**
/4
/4
* Used with Hot Sprue Bushings 5 316 long; heater

supplied with leads 48" long.
** Used with Hot Sprue Bushings 6 316 long; heater
supplied with leads 46" long.
THERMOCOUPLE
48"
ITEM
NUMBER
AMPS
ABC5
Replacement Fuses for Temperature

Control Modules (FC5) and Temperature
Controllers (PFC5)
13X5
See the DME Control Systems Catalog for new controllers.
U.S. 800-626-6653
Canada 800-387-6600
Threaded type thermocouple is

spring loaded and supplied with
cable and mini plug.
ITEM
NUMBER
TCT4
Integrally Heatedtext
Hot Sprue Bushings
Integrally Heated Sprue Bushings
79
.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 products advanced heat transfer capability is attributed to its integrally heated design, resulting in a more
uniform heat profile. Maximum heat 600F.
A replaceable thermocouple is strategically located near the melt flow channel to optimize processing conditions
with all thermoplastics.
Features and Benefits:
Tip Styles and Flow Diagrams
Maximum heat 600F

Sprue Tip
Extra Stock Sprue Tip
Recommended for
Commodity Resins
Only
Direct Gating Diagram

Insulating Washer
Locating Ring
Wire Channel
Power & T/C Bushing Leads
Insulating Washer
Water Line
U.S. 800-626-6653
Heated Hot| Sprue

Features andSequencers
Benefits
HotIntegrally
Runner Systems
4-ZoneBushings
and 8-Zone| Timer-Based
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.
High-grade alloy steel construction increases durability and longer life.
Replaceable thermocouple allows for Type J or K.
Integrally Heated Hot Sprue Bushings
80
.750" SERIES USER GUIDE

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 Bushings 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.
Users Guide
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
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.
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 Resin Compatibility
Resin Viscosity
Gating Options
High
Medium
Low
Sprue
50g
150g
300g
Extra Stock Sprue
50g
150g
300g
Contact DME when exceeding minimum shot weight and process heat
temperature at 600F.
Gating
Options
Sprue
Extra Stock Sprue
Commodity
Resin
a a
.750" Series Maximum Shot Weights (0.080" Gate)
= Recommended
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.
U.S. 800-626-6653
Canada 800-387-6600
81
.750" SERIES
Head Options
.500 Radius Style
.750 Radius Style

1.9900 dia.
(50.55mm)
.190
(4.8mm)
.125
(3.2mm)
.440
(11.2mm)
1.060 dia.
(26.9mm)
.635 dia.
(16.1mm)
.190
(4.8mm)
.8750
(22.23mm)
.500 R
(12.7mm)
.750 R
(19.1mm)
1.9900 dia.
(50.55mm)
Gating Options / Bushing Dimensions

Extra Stock Sprue Gate
Sprue Gate
L2 dim.
.080 dia.
(2.0mm)
.25
(6.3mm)
.187
(4.7mm)
.187 dia.
(4.7mm)
Flow Channel
.375
(9.5mm)
Note***
L2 dim.
Note*
.75
(19.1mm)
Note**
.7500 dia.
(19.05mm)
.500 (12.7mm)
Extra Length
6
.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
U.S. 800-626-6653
Options and Dimensions
L dim.
L dim.
Note*
.740 dia.
(18.8mm)
82
Gate Style
L Dim.
Sprue
Gate Style
Specifications
.750 Radius Head
Watts
Thermocouple
(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
.500 Radius Head
.750 Radius Head
Watts
Thermocouple
L2 Dim.
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
4.875"
(123.8)
4.000"
(101.6)
SB031036
SB031037
535
MT020021
All specifications are subject to change without notification.

Right (Standard)*
|
.500 Radius Head
2.375"
L Dim.
Extra Stock Sprue
L2 Dim.
.750" SERIES SPECIFICATIONS
* 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
CKPTIC1
Mold Power-Thermocouple Input Connector

A Single-Zone Power-Thermocouple Input Connector is
available for mounting in or on the mold to accept the powerthermocouple cable from the mainframe. The water-resistant
connector has an integral retaining latch for a secure cable
connection and numbered screw-type terminals for power
and thermocouple lead wires.
*Can be mounted on top of mold
Recommended Mold Pocket Layout

For Mold Power-Thermocouple
Input Connector (CKPTIC1)
3.50
1.50
1.36
0.91
0.46
0.32
ITEM NUMBER
MPTC10
MPTC20
Armored Mold Power-Thermocouple Cables

Single-Zone Mold Power-Thermocouple Cables are
constructed of special lead wire for use in high temperature
environments, and are available to connect the mainframe to
the input connector on the mold. Available in lengths of 10 or
20 feet. Integral retaining latches on the mainframe and mold
connections provide secure cable connections. Connector
configurations ensure proper insertion of cable.
0.14
REF
2.00
1.00
NO. 4-40 NC-2B TAP

.50 DEEP MIN. (2) PLACES
0.25 R
1.180
0.90
0.25 R
1.45
0.55
MOLD SURFACE
REF
2.00
MOUNTING SURFACE
4.00 MIN.
For complete information on temperature controls, please see DME Control Systems Catalog.
U.S. 800-626-6653
Canada 800-387-6600
83
.750" SERIES
.750" Series Bore & Gate Dimensions

Insulating Washer Option
Insulating Washer Specifications

Top
Bottom
MAX10015
MAX10027
1.99
(50.5mm)
1.99
(50.5mm)
I.D.
1.07
(27.2mm)
.810
(20.6mm)
Thickness
.125
(3.2mm)
.125
(3.2mm)
Item Number
O.D.
Standard Bore
2.05 dia.
(52.1mm)
.8752
a
(22.23mm)
.860 dia.
(21.8mm)
Top Washer
.760
(19.3mm)
.125
(3.2mm)
Bottom Washer
.110
(2.8mm)
1.125
(28.6mm)
Note: Insulating Washers are not required,

but are recommended for high temperature applications.
.125
(3.2mm)
.235
(6.0mm)
.080
(2.0mm)
b
L2 dim. .125 + Exp.

L2 dim. (3.2mm) + Exp.
{See page 4 for L2 dim.}
Water Line
L2 dim. + exp.
(See page 4 for L2 dim.)
.500 min.
(12.7mm)
Thermal Expansion (Exp.) Formulas

Gate
-6
Exp. in = L2 in. 6.88 10 (Processing Temp. 70F)
1.9910 dia.
b
(50.57mm)
Exp. mm = L2 mm 13 10-6 (Processing Temp. 21C)

Ref: 10-6 = 0.000001
All specifications are subject to change without notification.
Extra Stock Sprue Gate
Sprue Gate
.860 dia.
(21.8mm)
.860 dia.
(21.8mm)
.118
(3.0mm)
.493 max.
(12.5mm)
30 max.
a
.7505 dia.
a
(19.06mm)
Bore & Gate Tolerances

Tol. a Table
in: + 0.0005
0
mm: + 0.01
0
Tol. b Table
in: + 0.0010
0
mm: + 0.02
0
Dimensions are inches. Millimeters are in parentheses.
U.S. 800-626-6653
Machining Dimensions
.118 min.
(3.0mm)
.7505 dia.
a
(19.06mm)
.125
(3.2mm)
84
.750" SERIES
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 200F (93.3C) 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.
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.
*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 600F

Locating Ring Dimensions
ITEM
NUMBER
ML010012
1.135
(28.8mm)
5/16 - 18 THD
Jack Screw location
(2 places)
L.R.D.
3.990
(101.3mm)
5.490 dia.
(139.4mm)
Locating Ring & Keying Options
Power Requirements
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

U.S. 800-626-6653
Canada 800-387-6600
D M E H o t Ru n n e r S e rvices
TOTAL SUPPORT FOR YOUR

HOT RUNNER SYSTEMS
Hot Runner
textServices
86
Moldflow Services Optimize Part and Mold Design

Comprehensive Analysis and Modeling
With todays 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 Moldflows silver certification in this advanced technology.
A Competitive Advantage
Runner
Systems
and 8-Zone
Timer-Based
Sequencers
Hot Hot
Runner
Services
Optimize
Part and
Mold Design
| 4-ZoneServices
| Moldflow
Predictive analysis, utilizing Moldflow software, yields tremendous

benefits, including:
Optimize part design

Reduce time-to-market
Save cost and time on mold tryouts
Lower development and production costs
Provide a framework to establish reputable processes
Improve product quality
Decrease cycle times
What is Moldflow?
DME uses Moldflow Plastics Insight (MPI) software which is an
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.
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,
and quick part design validation. DME is a certified, licensed provider of
Moldflow analysis services.
Grill stack
mold
Mold Fill Analysis

The Mold Fill module uses predictive technology to simulate the filling
process. Key analyses include:
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
Warp Analysis
Building on the results of a Mold Fill analysis, the Mold Pack

module optimizes the packing phase to ensure a uniform packing
condition. As an indication of part warpage, volumetric shrinkage
is evaluated and the pack pressure profile is optimized. The result
is minimized warpage with an improved surface appearance.
Using the results from the Fill and Cool analyses,

the Warp Analysis module enables prediction of
plastic part shrinkage and warpage. Warp Analysis
diagnoses the cause(s) of warping and recommends
the appropriate solution, such as gate location
changes, design parameter changes, and reduction
of wall thickness variations.
Mold Cool Analysis

The Cool Analysis module assesses an existing cooling layout
to determine potential molding problems. Steel types, cooling
channel sizes, bubblers, baffles, coolant temperatures, and flow
rates are all evaluated. Using this analysis, the Mold Cool module
recommends practical tooling design changes to ensure uniform
cooling. Mold Cool takes into account:
MPI 3D
MPI 3D addresses a class of problems previously
unsolvable using traditional Finite Element Analysis
techniques. In thick-walled parts, molten plastic can
flow in all directions. Using a proven methodology
based on a solid tetrahedral, finite element volume
mesh, MPI 3D enables true, three-dimensional
simulations on thick-walled parts.
Number, location, depth, and pitch of cooling channels
Steel types
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.
U.S. 800-626-6653
Runner
Systems
and 8-Zone
Timer-Based
Sequencers
Hot Hot
Runner
Services
Optimize
Part and
Mold Design
| 4-ZoneServices
| Moldflow
Mold Pack Analysis
Hot Runner
textServices
88
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
HotServices
Runner Systems
and
Sequencers
Hot Runner
Request
for8-Zone
Data Timer-Based
Mold Filling/Mold
Cooling Analysis
| 4-Zone
| Customer
Fax completed form to 248-544-5707 or

email dme_appl_eng@milacron.com
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, were 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 were centrally located, we can get your system back in your shop quickly and cost-effectively.
Unrivaled Support When and Where You Need It

Since the 1970s, DME has developed and marketed a full spectrum of hot
runner systems and components. From Moldflow analysis to turnkey hot half
systems and everything in between, the DME family of hot runner products
and services offers a comprehensive array of solutions for a wide range of
applications. Whether your need is for standard, off-the-shelf components,
customer engineered manifolds, or fully assembled systems ready for bolt-on
installation, DME has a proven solution to match your application.
The DME family of

hot runner products
and services offers
a comprehensive
array of solutions
for a wide range
g of
applications.
Moldflow Services
As the first mold technologies supplier to earn Moldflows silver certification,
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,
Mold Cool or Warp analyses, DME can assist you in maximizing the results of
your next application.
Applications Engineering and Technical Service
Our dedicated and experienced team of mold designers and applications
engineers assists DME customers with product selection, system design, performance analysis and technical advice. DME technical service representatives
are globally located for complete coverage and quick availability no matter
where your hot runner production takes place. Technical experts employed
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.
U.S. 800-626-6653
Hot Runner
Systems
and Hot
8-Zone
Timer-Based
Sequencers
Hot Runner
Services
Runner
Service Center
| 4-Zone
| DME
Hot Runner Services Overview
Hot Runner
textServices
90
Hot Runner
Systems
and Hot
8-Zone
Timer-Based
Sequencers
Hot Runner
Services
Runner
Service Center
| 4-Zone
| DME
DME Hot Runner Service Center

A Wide Range of Services
Rebuilds Ensure Performance
We recognize the value of your time - thats why weve

developed a comprehensive suite of hot runner services to provide a single source for maintenance and
optimization of your system, even our competitors
systems.
Key services include:
t System evaluations
t Repairs
t System cleaning and rewiring of all hot runner
systems - including complete bake-out
t Total system rebuild
t Total restoration of flooded systems
t Re-configuration
t Operating training
t All machining capabilities
After tens of thousands of cycles you may have noticed your

system just doesnt perform the way it used to. Or maybe youve
run high-temperature engineered materials and the tolerances
just arent as tight. Key benefits of system rebuilds include:
Cost-Effective Reconfiguration
When your process needs change, without a significant
tooling change, we can adapt your hot runner to the new
process. Whether its a material switch, or a part design
change, DME can help reconfigure your existing system.
Training Maximizes Productivity, Speeds Set-Up

The DME Hot Runner Service Center can provide
comprehensive operator training in start-up or prototyping.
Our hands-on programs help your operators get up-to-speed,
or stay current on hot runner technology.
Cost savings of at least 40% as compared to new systems

Extended life for your tool
Maximizing system uptime and performance
Improved finished part quality
Whether you need a total system rebuild, or a simple cleaning
and inspection DME can help. System rebuilds can be performed
on any brand of hot runner system and typically include:
Complete bake-out cleaning
Check and replace heaters and thermocouples
Inspect and correct wiring
Replace seals and bushings
Clean or replace nozzle components
Check all dimensions and re-assemble system
t
t
t
t
t
t
Repairs Get You Back Up Quickly

Time is money. When a critical tool is out of commission,
productivity is lost and production schedules can be
threatened. We understand this at DME. Thats why our
team of hot runner repair specialists are always available
to get you back in service.
Preventative Maintenance (PM)
Whether youre experiencing leaks, heating issues, flow

problems, or would simply like a system bake-out, well repair
your system quickly and cost-effectively.
It is important to protect and update your hot runner

system to ensure it is running at the highest efficiency.
The PM Program is designed to prevent system equipment failure before it occurs. We will enhance equipment reliability by replacing worn components before
they fail.
Standard turnaround for repairs on systems from 1-12 drops

(depending on parts availability for non-DME systems) is
5 working days or less. If your system has over 12 drops,
contact us for an estimated turnaround time. And, we offer
emergency 24-hour turnaround service.
t
t
t
t
t
Maximizes system performance

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

or by scheduled PM
U.S. 800-626-6653
Canada 800-387-6600
DM E Obsolete R eplacement Parts
REPLACEMENT PARTS FOR OBSOLETE

HOT RUNNER SYSTEMS & NOZZLES
Obsolete Replacement Parts

Obsolete Replacement
Parts
text
92
92
page content
content
Mini page
Gate-Mate Nozzles
NOZZLE
SUB-ASSEMBLY
INCLUDES
1
ITEM
NUMBER
HEATER
TYPE
NOZZLE
BODY
HEATER
GMB0110
CAST-IN
GMB0105
CIH0100
250
SQUARE COIL GMB0105
SCH0004
250
GMB0118
Mini Gate-Mate Tips

Contact DME for tip
recommendations and assistance
with your application.
WATTS
/2 SPH. RADIUS BUSHING

SUB-ASSEMBLY
THERMOCOUPLE
SEAL
RING
N/A
(INTEGRAL) EHR7155
TCG0100
FLAT BUSHING
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 Bushing Locating Ring
ITEM
NUMBER
TIP
STYLE
GMT0100
STANDARD
GMT4101
WEAR RESISTANT
ITEM
NUMBER
6548
Gate-Mate 4 Nozzles and Tips
Gate-Mate Nozzles
INCLUDES
NOZZLE
NOZZLE SUB
ASSEMBLY ASSEMBLY
(INCLUDES (TIP ORDERED
GMT2 TIP) SEPARATELY)
2.000
GMB0050
GMB0150
GMB0060
SQUARE
COIL
HEATER
SCH0060
2.500
GMB0051
GMB0151
GMB0061
SCH0061
NOZZLE
BODY
WATTS
THERMOCOUPLE
SEAL
RING
250
TCG0060
300
TCG0061
3.000
GMB0052
GMB0152
GMB0062
SCH0062
350
TCG0062
3.500
GMB0053
GMB0153
GMB0063
SCH0063
400
TCG0063
4.000
GMB0054
GMB0154
GMB0064
SCH0064
425
TCG0064
5.000
GMB0055
GMB0155
GMB0065
SCH0065
500
TCG0065
6.000
GMB0056
GMB0156
GMB0066
SCH0066
500
TCG0066
Gate-Mate 4 Tips
INCLUDES
1
NOZZLE
BODY
FRONT LOAD
WATTS
HEATER
SEAL
RING
GMB0060
GMB0061
GMB0062
GMB0063
GMB0064
GMB0065
GMB0066
SCH1060
SCH1061
SCH2061
SCH1062
SCH2062
SCH1063
SCH2063
SCH1064
SCH2064
SCH1065
SCH2065
SCH1066
SCH2066
250
Replacement
Seal Rings
ITEM NUMBER
EHR7155
300
TIP
STYLE
TIP ITEM
NUMBER
STANDARD
GMT2
WEAR RESISTANT GMT0400

SUPER SHARP
GMT0301
SUPER SHARP
GMT0401
WEAR RESISTANT
350
400
EHR7155
NOTES:
1. Items 1 thru 4 are available separately
for replacement purposes
2. Items 2 is 240 VAC, 36" leads, 34" fiberglass
lead protection
3. Item 3 is type J, with 36" leads, 34"
fiberglass lead protection
4. Item 4 (for replacement) is sold in packs
of 4 only
THRU HOLE
GMT0302*
EHR7155
O
DIA.
TIP
LENGTH
.044 MIN.
.024
.055 MIN.
.030 MIN.
TIP HOLE
DIA. DIA.
1.730
N/A
.010
.055 MIN.
.030 MIN.
.050 MAX
1.690
.090
.050
1.730
.024
N/A
THRU HOLE
GMT0402* .055 MIN.
WEAR RESISTANT
425
NO HOLE
GMT0303
.044 MIN.
500
500
NOTES:
1. Items 1, 2 and 3 are available separately for
replacement purposes
2. Item 2 is 240 VAC, type J thermocouple, 36" leads, 34"
Teflon lead protection
3. Item 3 (for replacement) is sold in packs of 4 only
U.S. 800-626-6653
NOTES:
1. Thru hole tip is designed .040 shorter in length to be a direct
replacement for the standard tip; use a .030 to .060 diameter
gate
2. A .030 minimum diameter gate is recommended when using
the super sharp tip
your application
*Contact DME for details to modify thru hole tips for larger O
diameters
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
D DIA.
GATE SHELL
INSULATOR
FOR BUSHING OR
NOZZLE STYLE
FOR TIP STYLE
ITEM
NUMBER
Gate-Mate 4
Nozzle
Standard, Super Sharp, No Hole
GSI0001
Thru Hole
GSI0002
Jumbo Gate-Mate
Bushing or Nozzle
Standard
GSI0003
Thru Hole
GSI0004
Standard, Super Sharp, No Hole
GSI0005
Thru Hole
GSI0006
Medium Gate-Mate
Bushing
D
DIA.
.748
1.248
.748
ITEM
NUMBER
GSI0001
GSI0002
GSI0003
GSI0004
GSI0005
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
U.S. 800-626-6653
Gate
Shell
Insulators
Hot RunnerCustom
Systems
Hot| Runner
4-Zone
Systems
and
8-Zone
New ProductsSequencers
| Timer-Based
Typical Application

Parts
text
94
94
94
page
Components for Micro Cool

Onecontent
Split Plate/Solid Block Designs
page
content
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
(AMPS)*
.375
(10 AMP)
DIA
(AMPS)*
HCTC034
5.000
4.000
320
HCTC0375
OVERALL
LENGTH
8.500
HCTC0345
5.500
4.500
340
HCTC038
9.000
8.000
550
HCTC039
HCTC0310
10.000
11.000
9.000
10.000
650
710
HCTC0311
12.000
11.000
720
HCTC0312
HCTC0313
13.000
14.000
12.000
13.000
760
810
OVERALL
LENGTH
ITEM NUMBER
HEATED
LENGTH
WATTS
HCTC035
6.000
5.000
400
HCTC0355
6.500
5.500
430
HCTC036
HCTC0365
HCTC037
7.000
7.500
8.000
6.000
6.500
7.000
450
470
480
.375
(10 AMP)
ITEM NUMBER
HEATED
LENGTH
7.500
WATTS
515
Hot Runner
Systems
andSystems
8-Zone
Timer-Based
Sequencers
Custom
Runner
| Hot4-Zone
Internally
Heated
Hot
Runner
Systems
Cool One
| Indexfor Micro
| Components
*(AMPS) = Amperage requirement for temp. control module.
Distributor Tubes
ITEM NUMBER
LENGTH
End Cap
MATERIAL: AISI 4140 STEEL

HARDNESS: 28-35 HRC
HT050312
11.82
HT050316
15.76
ITEM NUMBER
EC1105
Components for Micro Cool One

Solid Block Designs
Auto-fixed Integral Heater Micro Probes (240 VAC, T/C Type J, 48" Leads)
MATERIAL: AISI D-2 STEEL
HARDNESS: 50-55 HRC
ITEM NUMBER*
AFIP331090
AFIP336090
AFIP341090
AFIP346090
A
3.095
3.595
4.095
4.595
B
2.720
3.220
3.720
4.220
WATTS
110
130
150
170
NOTE: Probes are special order only
A
.312 DIA
Replacement Thermocouple
ITEM NUMBER
TC9900
LEAD LENGTH
48"
Register Ring
ITEM NUMBER*
MATERIAL: AISI H-13 STEEL

HARDNESS: 48-52 HRC
I.D. = .313
O.D.= 1.000
U.S. 800-626-6653
.375
RAF3062
*Package of 10.
Canada 800-387-6600

Parts
text
95
95
The Cool One Heated

Nozzle
Locator Replacement Parts
page
content
Heated Nozzle Locator Assemblies
HNL462 and HNL662 assemblies include:
HNC46 or HNC66 core, respectively
SSTC6290 heater
HNS67 spacer
1
2
34
ITEM
NUMBER
HNL462
HNL472
HNL662
HNL672
HNL472 and HNL672 assemblies include:

HNC47 or HNC67 core, respectively
SSTC7290 heater
HNS67 spacer
Cores
R
1
2
34
ITEM
NUMBER
HNC46
CORE
HNC47
HNC66
HNC67
Thermocouple Heaters
(240 VAC, 250 WATTS T/C type J 36" leads)
ITEM
USED WITH
NUMBER
CORES
SSTC6290
HNC46 & 66
SSTC7290
HEATER
HNC47 & 67
Spacer
SPACER
ITEM
NUMBER
HNS67
ITEM NUMBER
NL6702
2
34
NL6703
U.S. 800-626-6653
Internally
Hot
Runner
Systems
Cool
OneProducts
Heated
Nozzle Locators
Hot Heated
RunnerCustom
Systems
Hot| Runner
4-ZoneSystems
and
8-Zone
New
Sequencers
| The
| Timer-Based

Parts
text
96
96
The Cool One End

Caps
and Distributor Tubes
page
content
End Caps (for use with solid distributor block designs)
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
ITEM
NUMBER
+ .000
.002
A DIA.
B DIA.
+ .002
.000
DIA.
A
Internally Heated Hot Runner Systems
DIA.
B
THREAD
EC1207
1.249
0.875
EC2015
1.999
1.625
34"- 10
8"- 11
USED WITH
DIST. BORE/TUBE
1.25 DIA./.87 O.D.
2.00 DIA./1.62 O.D.
THREAD
Distributor Tubes
MATERIAL: AISI P-20 STEEL
HARDNESS: 28-35 HRC
LENGTH
.03 45 TYP.
The Cool One End Caps & Distributor Tubes
.56
O.D.
I.D.
USED WITH 2.00 DIAMETER

DISTRIBUTOR BORE/CHANNEL
USED WITH 1.25 DIAMETER

DISTRIBUTOR BORE/CHANNEL
LENGTH
I.D. = .50 O.D. = .87
LENGTH
I.D. = .62 O.D. = 1.62
ITEM NUMBER
ITEM NUMBER
HT07046
10"
HT150510
10"
HT070410
18"
HT150518
16"
HT070416
24"
HT150524
20"
HT070420
29"
HT150529
HT070424
34"
HT150534
29"
HT070429
40"
HT150540
34"
HT070434
46"
HT150546
6"
24"
NOTES:
Stainless Steel Distributor Tubes available on special order for molding highly
corrosive plastics materials.
U.S. 800-626-6653

Parts
text
97
page content
The Cool One Thermocouple
Distributor Tube Heaters
Thermocouple (T/C) Distributor Tube Heaters
(240 VAC, T/C type J, 34" leads)
.500
(10 AMP)
.625
(10 AMP)
ITEM
NUMBER
LENGTH
WATTS
HCTC044
4"
380
HCTC0511
11"
1430
HCTC045
5"
500
HCTC0512
12"
1570
HCTC046
HCTC047
HCTC048
HCTC049
6"
7"
8"
9"
600
700
820
920
HCTC0410
10"
1030
HCTC0513
HCTC0514
HCTC0515
HCTC0516
HCTC0517
13"
14"
15"
16"
17"
1700
1840
1980
2110
2250
HCTC0411
HCTC0412
HCTC0413
11"
12"
13"
1140
1250
1350
HCTC0518
18"
2390
HCTC0414
14"
1460
HCTC0415
HCTC0416
HCTC0417
15"
16"
17"
1570
1680
1780
HCTC0519
HCTC0520
HCTC0521
HCTC0522
19"
20"
21"
22"
2520
2660
2800
2930
HCTC0418
18"
1900
HCTC0419
HCTC0420
HCTC0421
HCTC0422
19"
20"
21"
22"
2010
2110
2220
2330
HCTC0529
29"
3900
HCTC0423
23"
2400
HCTC0530
30"
4020
HCTC0424
HCTC0425
HCTC0426
24"
25"
26"
2400
2400
2400
HCTC0531
HCTC0532
31"
32"
4160
4300
HCTC0534
34"
4570
HCTC0427
27"
2400
HCTC0535
35"
4710
HCTC0428
HCTC0429
HCTC0430
HCTC055
HCTC056
HCTC057
HCTC058
HCTC059
HCTC0510
28"
29"
30"
5"
6"
7"
8"
9"
10"
2400
2400
2400
620
750
880
1020
1160
1300
DIA.
(AMPS)*
.625
(10 AMP)
.625
(15 AMP)
.625
(30 AMP)
ITEM
NUMBER
LENGTH
WATTS
HCTC0523
23"
3070
HCTC0524
HCTC0525
HCTC0526
24"
25"
26"
3200
3340
3480
HCTC0527
27"
3620
HCTC0528
28"
3750
HCTC0536
36"
4840
HCTC0537
HCTC0538
HCTC0539
37"
38"
39"
4980
5120
5250
HCTC0540
40"
5390
HCTC0541
HCTC0542
HCTC0543
41"
42"
43"
5520
5520
5520
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.
U.S. 800-626-6653
Internally Heated
Hot Runner
Systems
Cool
One
Thermocouple
Distributor Tube Heaters
Hot Runner
Custom
Systems
Hot| Runner
4-Zone
Systems
and
8-Zone
New
ProductsSequencers
| The
| Timer-Based
DIA.
(AMPS)*

Parts
text
98
98
page
The Cool
Onecontent
Components
Auto-Fixed Integral Heater Probes (240 VAC, T/C Type J Grounded, 48" Leads)
HARDNESS: 50-55 HRC

STRAIGHT
.720 DIA.
.030 R
.312 R.
AVAILABLE WITH
STRAIGHT OR 90
EXIT HEATER LEADS
45
20
.005 DIA.
+ .000
.001
.384 DIA.
+ .000
(.490 DIA.)
.001
.394 DIA.
(.500 DIA.)
.157
90
.500 REF.
These probes feature a swaged in heating element which

is an integral part of the probe. A separate replaceable
thermocouple is installed in each probe as supplied. The
integral heater design provides highly efficient heat transfer,
uniform heat distribution and is guaranteed for one year.
.625
.500
Important: Dimensions shown in parentheses apply to larger probes

AFIP5372 thru 622 only. Tolerances shown also apply to dimensions in parentheses.
AFIP4 SERIES PROBES
ITEM NUMBER**
.394 (10 mm) DIAMETER
STRAIGHT
90 EXIT
A
B
WATTS
EXIT LEADS
LEADS
DIM.
DIM.
AFIP4322
AFIP432290
3.220
2.720
135
AFIP4372
AFIP437290
3.720
3.220
160
AFIP4422
AFIP442290
4.220
3.720
185
AFIP4472
AFIP447290
4.720
4.220
210
**lncludes probe, integral heater, thermocouple, adjustment ring and
hold down nut.
ITEM NUMBER**
STRAIGHT
EXIT LEADS
AFIP5372
AFIP5422
AFIP5472
AFIP5522
AFIP5572
AFIP5622
90 EXIT
LEADS
AFIP537290
AFIP542290
AFIP547290
AFIP552290
AFIP557290
AFIP562290
AFIP5 SERIES PROBES

.500 (12.9 mm) DIAMETER
A
B
WATTS
DIM.
DIM.
3.720
3.220
200
4.220
3.720
230
4.720
4.220
265
5.220
4.720
295
5.720
5.220
325
6.220
5.720
360
The Cool One Components
NOTE: Probes are special order only
Replacement Thermocouples
ITEM NUMBER
TC9900
(ALL PROBES)
LEAD LENGTH
48"
+ .005
.000
Gate Inserts
.062
(GRIND TO SUIT)
I.D.
Hardness can be increased to a higher

value by heat treatment, if desired.
ITEM
NUMBER
AFGI04N
AFGI10N
(Packaged with all probes)

I.D.
O.D.
MATERIAL: AISI S-7 STEEL (pre-hardened)

HARDNESS: 30-34 HRC
Adjustment Rings
.375
R.
2.500
O.D.
I.D.
USED WITH
1.625
1.750
.875
1.000
AFIP4 SERIES
AFIP5 SERIES
.625
.187
SPH. R.
45
ITEM NUMBER
RAF4062
RAF5062
I.D.
.469
.565
USED WITH
AFIP4 SERIES
AFIP5 SERIES
Bag of 5 rings.
Hold-Down Nut
Register Rings
15 TYP.
.06 TYP.
MATERIAL: AISI H-13 STEEL

HARDNESS: 48-52 HRC
+ .000
.001
A DIA.
.125
120 TYP.
+ .001
.000

THICKNESS = .500
THREAD = 1"- 8
HEX FLAT = 916
ITEM NUMBER
AFN100
C DIA.
ITEM NUMBER
AFRR04N
AFRR05N
Hold-Down Nut Wrench*
+ .000
.001
B DIA.
A DIM.
1.062
1.187
U.S. 800-626-6653
B DIM.
.865
.937
C DIM.
.387
.493
USED WITH
AFIP4 SERIES
AFIP5 SERIES
ITEM NUMBER
WR916
*Required for straight exit leads only.

Parts
text
99
99
99
content
The Cool Onepage
Probes
and Probe Heaters
page
content
Auto-Fixed Probes (3" to 6" long)
HARDNESS: 50-55 HRC
LENGTH
ITEM NUMBER **
A
2.893
AFP310
3.625
AFP410
4.625
AFP510
5.609
AFP610
**Includes probe, stop sleeve
and hold down nut only.
.250
heater chart below. Gate inserts (shown on next page),

pre-machined for use with these probes, can save
valuable machining time and help assure optimum
probe performance.
Auto-Fixed Finless Probes (3" to 6" long)

HARDNESS: 50-55 HRC
LENGTH
ITEM NUMBER **
A
2.893
AFPN310
3.625
AFPN410
4.625
AFPN510
5.609
AFPN610
**Includes probe, stop sleeve
and hold down nut only.
.250
|
NOTE: Due to minimum distance requirements specified, the AFPO310
and AFPN310 probes cannot be used in a Cool One system. They
may, however, be used in an insulated runner system.
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)
FOR PROBE
AFP(N)310
AFP(N)410
AFP(N)510
AFP(N)610
WATTS
150
220
275
350
LENGTH
3.00
3.75
4.75
5.75
ITEM NUMBER
AFC2132
AFC2142
AFC2152
AFC2162
FOR PROBE
AFP(N)310
AFP(N)410
AFP(N)510
AFP(N)610
WATTS
150
220
275
350
LENGTH
3.00
3.75
4.75
5.75
Thermocouple (T/C) Probe Heaters are guaranteed for one year from date of shipment.
U.S. 800-626-6653
Canada 800-387-6600
The Cool One Probes and Probe Heaters
These finless style Auto-Fixed probes are available in the

same sizes as the finned probes above and also in lengths
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.
ITEM NUMBER
AFTC2132
AFTC2142
AFTC2152
AFTC2162
These finned style Auto-Fixed probes employ a precision

engineered tip configuration that automatically fixes the
relationship between probe tip and gate, centering the probe
and limiting tip protrusion into the gate. Thermocouple
heaters are guaranteed for one year as detailed under the

Parts
text
100
100
The Cool One Accessories

and Replacement Parts
page content
Accessories/Replacement Parts for 3" to 6" Long Auto-fixed Probes
Hold-Down Nut
Stop Sleeve
Register Ring

Thickness = .50
Thread = 1"-8
Hex Flat = 916

Length = 1.375
Thread = 38"-24
Dia. = .375
(For Finless Probes Only)

AISI H-13 STEEL
48-52 HRC
I.D. = .562
O.D. = 1.375
Thickness = .125
ITEM NUMBER
ITEM NUMBER
AFN100
AFSS38
ITEM NUMBER
AFRR10N
Gate Inserts
Adjustment Rings

HARDNESS: 30-34 HRC
For simplified counterbore depth adjustment

(No change from previous rings).
Hardness can be increased to a

higher value by heat treatment, if
desired.
I.D. = .687 O.D. = .868
I.D. = 1.000 O.D. = 1.750 Height = 2.500

ITEM NUMBER
AFGI10
AFGI10N
FOR PROBE
AFP310 thru 610
AFPN310 thru 610
Gate inserts are

supplied premachined.
See design and machining
guidelines at the end of this
Internally Heated Hot Runner
Systems section.
The Cool One Accessories and Replacement Parts
See design and machining guidelines at the end of this Internally Heated Hot Runner Systems section.
ITEM NUMBER*
THICKNESS
RAF002
.002
RAF003
.003
RAF005
.005
RAF007
.007
RAF032
.032
RAF062
.062
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
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
HEATERS
ITEM
NUMBER
AFTC2022
NON T/C
HEATERS
ITEM
NUMBER
AFC2022
FOR
PROBE
WATTS
LENGTH
AFP300
200
2"
AFTC2032
AFC2032
AFP400
300
3"
AFTC2042
AFTC2052
AFC2042
AFC2052
AFP500
AFP600
375
475
4"
5"
U.S. 800-626-6653

text
Parts
101
101
101
page
The Cool One Accessories
and Replacement Parts
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
**Includes probe, stop sleeve and hold down nut only.
.375
Hold-Down Nut
Stop Sleeve
Register Ring

Thickness = .50
Thread = 1"-12
Hex Flat = 58

Length = 1.375
Thread = 12"-20
Dia. = .500
AISI H-13 STEEL

48-52 HRC
I.D. = .693
O.D. = 1.500
ITEM NUMBER
ITEM NUMBER
AFN125
AFSS12
ITEM NUMBER
AFRR20N
Thermocouple (T/C) Probe Heaters
Gate Insert

HARDNESS: 30-34 HRC
ITEM NUMBER
AFTC3272
AFTC3282
AFTC3292
AFTC32102
FOR PROBE
AFPN720
AFPN820
AFPN920
AFPN1020
WATTS
645
760
870
980
LENGTH
7.15
8.15
9.15
10.15
Thermocouple (T/C) Probe Heaters are guaranteed for one year from date
of shipment.
Hardness can be increased to a

higher value by heat treatment, if
desired.
I.D. = 1.125 O.D. = 2000 Height = 2.500
ITEM NUMBER
AFGI20N
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
102
Hot Runner Systems
Modular Components Deliver High-Performance Solutions
Todays increasingly feature-packed plastic products benefit tremendously 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.
Modular Components Deliver High-Performance Solutions
Get the modular advantage with DME hot runner systems

DMEs newest family of hot runner systems are built on an architecture of modular components so we can quickly custom configure a
system that is ideal for your application. With the tremendous time
pressures on moldmakers today, our modular architecture enables
industry-leading delivery times. This modular approach shortens
delivery, improves cost-effectiveness and optimizes performance.
DMEs 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.
Hot Runner Systems
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.
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
Online Price Guide

U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
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
Intuitive, leading edge touch screen display with adjustable viewing angle
Automatically employed diagnostics to ensure optimal hardware configuration

and performance
Advanced micro controller technology
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 Features and Benefits
TSP USER-FRIENDLY PERFORMANCE
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.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
text
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
0.5C / 1F
Control Accuracy
+/- 0.5C / 1F
Power Response Time
8.3 ms at 60 Hz
Control Algorithm
Adaptive PID 2 with auto-tuning

Software selectable
Thermocouple
J- or K-Type, software selectable
Operating Range
0 - 472C or 32 - 882F
Output Voltage
Maximum 264 VAC
Supply Voltage
200/240 Delta or 380/440V 3 Star
Supply Breaker
40A 3-phase breaker for 6- and 12-zone control units

63A 3-phase breaker for 18- to 48-zone control units
Frequency
50 - 60 Hz automatic switching
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
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
SLOTS
ITEM NUMBER
# OF ZONES
AVAILABILITY
ITS-06-15
Special order; contact DME
ITS-12-15
12
In stock
ITS-18-15
18
ITS-24-15
24
In stock
ITS-30-15
30
ITS-36-15
36
ITS-42-15
42
ITS-48-15
48
In stock
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
TSP Specifications
5 - 45C (41 - 113F)
Humidity Range
Ambient Temperature Range
Degree (F or C)
text
TSP Temperature
textControl System
108
TSP Component Ordering Information

Mold Power Cables (15 AMP Max)
ITEM
NUMBER
MPC12C10G
10 FOOT LONG
MPC12C10G
TO FRAME
ITEM
NUMBER
ITEM
NUMBER
20 FOOT LONG 30 FOOT LONG

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

ITEM
NUMBER
TC12C10G
Control
Systems
blank
TSP Temperature Control
System
Ordering Information
| TSP |Component
10 FOOT LONG
TC12C10G
TO FRAME
ITEM
NUMBER
ITEM
NUMBER

TC12C20G
NUMBER
OF ZONES
(MAX.)
FROM 15 AMP
FRAME (S)
12
12 ZONE
TC12C30G
TO THERMOCOUPLE
CONNECTOR
FOR CONNECTIONS
MTC12G
TO MOLD
ZONES
CONTROLLER
CABLES
TERMINAL MOUNTING BOX
MPC12C10G
12 ZONES
OF CONTROL
(15 AMP)
(1 each)
PTC12TBTS
(1 each)
PTC12TBTS
(2 each)
PTC12TBTS
(4 each)
TC12C10G
ITS-12-15
MPC12C10G
24 ZONES
OF CONTROL
(15 AMP)
(2 each)
TC12C10G
ITS-24-15
MPC12C10G
48 ZONES
OF CONTROL
(15 AMP)
(4 each)
TC12C10G
ITS-48-15
Module Replacement Fuses

(sold in packs of 5)
RPM0124
ITEM
ITEM NUMBER
DESCRIPTION
ITSTROLLEY
RPM0123
POWER FUSE
15
RPM0124
TC FUSE
.062
U.S. 800-626-6653
Canada 800-387-6600
AMPS
dme@milacron.com
www.milacron.com
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
t
t
t
t
t
t
t
t
t
Automatic Leak detection

Enhanced 7 Color Touch screen
Storage : up to 100 Tools
Full IO function card with 4 input + 4 output for communication
Optional Thermocouple to monitor steel temperature and alarm if cooling is off
Accuracy 0.01 oF
Ability to control Small Mass / High Watt density nozzles
Field selectable PID (parameters) to optimize control process
APS technology (Adaptive Process System)
SPI communication Protocol via RS232/RS485 included
SLOTS
# OF ZONES
ITSP-12-15
ITSP-24-15
ITSP-48-15
2
4
8
12
24
48
Custom zone configurations available upon request
DESCRIPTION
ITEM NUMBER
ITSCGR-A
PCB replacement card, 6

zones @ 15 AMP
See reverse side for accessories
ROBUST, HIGH-QUALITY DESIGN

t $PNQBDU TPMJE NFUBM FODMPTVSF XJUI IFBWZEVUZ
JOEVTUSJBM DPOOFDUPST
t .PME BOE DPOUSPMMFS QSPUFDUJPO GFBUVSFT
t 0OCPBSE IFBUFS BOE UIFSNPDPVQMF GVTFT
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.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
TSP Plus
PLUG-AND-PLAY SYSTEM ARCHITECTURE

t 1BUFOUFEiBMMJOPOFwDPOUSPMDBSEEFTJHOFEGPSSFMJBCJMJUZ
t .PEVMBS[POFDBSETBNQTQFS[POF
t 'JFMEDBMJCSBUJPONPEF
t 6OJWFSTBMQPXFSTVQQMZ
OPTIMIZES PERFORMANCE FOR ALL HOT

RUNNER SYSTEMS
t 6OJRVF MPX WPMUBHF TPGUTUBSU GFBUVSF NBYJNJ[FT
IFBUFS MJGF
t 6OJGPSN TUBSUVQ GFBUVSF SFEVDFT TDSBQ BOE FOFSHZ
VTBHF
t 1SPQSJFUBSZ BEBQUJWF BVUPUVOJOH DPOUSPM BMHPSJUIN
t 1IBTF BOHMF PS CVSTU GJSJOH NPEFT UJNF
QSPQPSUJPOBM [FSPDSPTTJOH
SMART SERIES USER-FRIENDLY PERFORMANCE

t *OUVJUJWF MFBEJOHFEHFUPVDITDSFFOEJTQMBZXJUIBEKVTUBCMF
WJFXJOHBOHMF
t "VUPNBUJDBMMZFNQMPZFEEJBHOPTUJDTUPFOTVSFPQUJNBM
IBSEXBSFDPOGJHVSBUJPOBOEQFSGPSNBODF
t "EWBODFENJDSPDPOUSPMMFSUFDIOPMPHZ
t $POUJOVPVTHSPVOEGBVMUBOEDVSSFOUNFBTVSFNFOU
ITEM NUMBER
text
TSP Temperature
textControl System
110
TSP Plus Component Ordering Information

ITEM
NUMBER
MPC12C10G
10 FOOT LONG
MPC12C10G
TO FRAME
ITEM
NUMBER
ITEM
NUMBER

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

ITEM
NUMBER
TC12C10G
10 FOOT LONG
TC12C10G
TO FRAME
ITEM
NUMBER

TC12C20G
NUMBER
OF ZONES
(MAX.)
FROM 15 AMP
FRAME (S)
12
12 ZONE
TC12C30G
TO THERMOCOUPLE
CONNECTOR
FOR CONNECTIONS
MTC12G
TO MOLD
ZONES
Control Systems
TSP Temperature
Control System
| blank| TSP Plus
ITEM
NUMBER
CONTROLLER
CABLES
MPC12C10G
12 ZONES
OF CONTROL
(15 AMP)
(1 each)
PTC12TBTS
(1 each)
PTC12TBTS
(2 each)
PTC12TBTS
(4 each)
TC12C10G
ITSP-12-15
MPC12C10G
24 ZONES
OF CONTROL
(15 AMP)
(2 each)
TC12C10G
ITSP-24-15
MPC12C10G
48 ZONES
OF CONTROL
(15 AMP)
(4 each)
TC12C10G
ITSP-48-15
ITEM
ITEM
ITSPTROLLEY
ITSPALRMLT

(sold in packs of 5)
U.S. 800-626-6653
ITEM NUMBER
DESCRIPTION
RPM0123
POWER FUSE
15
RPM0124
TC FUSE
.062
Canada 800-387-6600
RPM0124
AMPS
dme@milacron.com
www.milacron.com
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

%.&PGGFST BOE[POFTUBOEBSENBJOGSBNFTGPS"PQFSBUJPOBOE BOE
[POFTUBOEBSENBJOGSBNFTGPS"PQFSBUJPO$PNQPOFOUTMJTUFEJOUIJTDBUBMPHTBUJTGZBMM
JOUFSOBUJPOBMDPNQMJBODFT5IJTJODMVEFT3P)4 3FTUSJDUJPOPG)B[BSEPVT4VCTUBODFT
UIBU
QSPIJCJUTPSSFTUSJDUTUIFVTFPGTJYQPUFOUJBMMZIBSNGVMNBUFSJBMTJOFMFDUSPOJDFRVJQNFOU BOE
8&&& 8BTUF&MFDUSJDBMBOE&MFDUSPOJD&RVJQNFOU
UIBUSFRVJSFTFRVJQNFOUNBEFBGUFS"VHVTU
UPCFUBLFOCBDLBOESFDZDMFECZUIFNBOVGBDUVSFS SBUIFSUIBOKVTUiUISPXOBXBZw
Two-Year Warranty
Advanced Temperature Control for Hot Runner Systems
"MM%.&UFNQFSBUVSFDPOUSPMMFSTBSFOPXDPWFSFECZBUXPZFBSXBSSBOUZ FYDMVEJOHGVTFTBOE
USJBDT
Electrical Noise Immunity

5PFOIBODFJNNVOJUZGSPNFMFDUSJDBMOPJTF QPXFSBOEUIFSNPDPVQMFXJSFBSFIBSOFTTFE
JOTFQBSBUFXJSFXBZTXJUIJOUIFCPEZPGUIFGSBNF"EEJUJPOBMOPJTFJNNVOJUZJTQSPWJEFE
UISPVHIUIFVTFPGTIJFMEFEUIFSNPDPVQMFXJSFT
5IF%.&4NBSU4FSJFTJTUIFSFTVMUPGJOUFOTJWFBOEEFEJDBUFESFTFBSDIXJUIBHPBMPG
EFTJHOJOHUPEBZTNPTUWFSTBUJMFBOESFMJBCMFMJOFPGUFNQFSBUVSFDPOUSPMMFST%.&BDIJFWFE
UIJTHPBMCZOPUPOMZJODPSQPSBUJOHUIFMBUFTUUFDIOPMPHZ CVUCZBMTPNBLJOHDFSUBJOUIBUFBDI
DPOUSPMMFSJTFBTZUPJOTUBMMBOEBCPWFBMMyFBTZUPPQFSBUF
Heavy Duty Welded Construction
Smart Series
8JUIZFBSTPGFYQFSJFODFCFIJOEJUTEFTJHO UIF4NBSU4FSJFTMJOFJTCVJMUUPMBTUVOEFSUIF
NPTUSJHPSPVTDPOEJUJPOT5IFNBJOGSBNFTXFMEFEHBVHFTUFFMDPOTUSVDUJPOFOTVSFTMPOH
MJGFBOEQFBLQFSGPSNBODF$PPMJOHGBOTJOUIFGSBNFBSFTUSBUFHJDBMMZMPDBUFEUPJODSFBTFBJS
WFOUJMBUJPO NBJOUBJODPPMFSSVOOJOHDPOEJUJPOT BOEQSPNPUFDPOUSPMNPEVMFSFMJBCJMJUZ
Q
Z
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
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
IFBUFSESZPVUDJSDVJUSZ UIFSNPDPVQMFGBVMUEJTQMBZTBOEBVUPNBOVBMNPEFTPGPQFSBUJPO5IF44.
GFBUVSFTBVUPNBUJDPSNBOVBMCVNQMFTTUSBOTGFSXIJDI JOUIFFWFOUPGBUIFSNPDPVQMFGBVMU QSPWJEFT
TXJUDIPWFSUPNBOVBMNPEFBUUIFQSPQFSQPXFSTFUUJOHUPDPOUJOVFNPMEJOHVOUJMUIFGBVMUDBOCF
DPSSFDUFE5IJTNPEVMFDBOBMTPUSJHHFSSFNPUFTUBOECZIFBU JEMF
CPPTU PGG BOEBMBSNGVODUJPOTXIFO
VTFEXJUIUIF5"4NPEVMF
DSS (15 and 30 AMP): 'PSUIPTFXIPSFRVJSFJOEFQFOEFOUEVBMEJTQMBZTGPSQSPDFTTBOETFUQPJOU
UFNQFSBUVSFT UIF%44JTUIFJEFBMDIPJDF5IF%44NPEVMFBMTPGFBUVSFTBVUPNBUJDPSNBOVBMCVNQMFTT
USBOTGFS5IJTNPEVMFJTBMTPGVMMZDPNQBUJCMFXJUIUIF5"4NPEVMFGPSTUBOECZIFBUBOEBMBSNGVODUJPOT
Accessory Modules
TAS: 5IF5"4NPEVMFQSPWJEFTPWFSVOEFSWJTVBMBOEBVEJCMFBMBSNT CPPTU BOETUBOECZIFBUDPOUSPM
XJUIDPOUSPMNPEVMFTBTTUBUFEBCPWF5IF5"4NPEVMFDBOBDDPNNPEBUFVQUP[POFTPGDPOUSPM
"MBSNJTBDUJWBUFEBU'4FFQBHFTGPSEFUBJMT
SSM1512
Smart Series
NOTE: 5IF5"4BDDFTTPSZNPEVMFSFRVJSFTUIFVTFPGi.'$wTUZMFDPNNVOJDBUJPOTNBJOGSBNFT

/PODPNNVOJDBUJPOTGSBNFTNBZCFVQHSBEFEPOTJUFXJUIJOTUBMMBCMFLJUT
|
Concern for user convenience didnt stop with improved operation features. DME
went one step beyond
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.
DSS1512
SSH Controller (10 AMP)

5IF44)JTBTUBOEBMPOFTJOHMF[POFDPOUSPMMFSJEFBM
GPSVTFXJUIIPUTQSVFCVTIJOHTPSNBDIJOFOP[[MFT
SSH1022
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
CE COMPLIANT! Control Modules
Simplified Power Hook-Up
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
11 Control Modules
TABLE OF CONTENTS
PAGE
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
10 Module Replacement Fuses
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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
115
Typical System Configurations

SSM1512
DSS1512
5 Zones of Control (15 AMP)
MPC5C10G
PTC5TBTS
MFP5G
MFS512G
X5
TC5C10G
SSM1512
DSS1512
MPC8C10G
PTC8TBTS
MFP8G
MFS512G
SSM1512
DSS1512
Smart Series
TC8C10G
X8
MPC12C10G
PTC12TBTS
MFP12G
SSM3012
DSS3012
MFS512G
TC12C10G
X12
2 or 3 Zones of High Power Control (30 AMP)

MTC5G
MPCH23C10G
MFHP2G
MFHP3G
X2 or 3X
SSM3012
DSS3012
PTCH23TBG
MFS512G
PICH23G
TC5C10G
5 Zones of High Power Control (30 AMP)

MTC5G
MPCH5C10G
MFHP5G
PTCH5TBG
MFS512G
X5
U.S. 800-626-6653
TC5C10G
Canada 800-387-6600
PICH5G
dme@milacron.com
www.milacron.com
Typical System Configurations
116
Smart Series
RoHS/WEEE Compliant
Smart Series Single Zone Temperature Controller
SSH1022/21 (10 AMP)
Smart Series
t
t
t
t
t
t
t
$PNQBDU
&BTZUPVTF
*ODMVEFTOFX JNQSPWFEBOEVOJRVFGFBUVSFT
1SPWJEFTNJDSPQSPDFTTPSCBTFE1*%DPOUSPM
.PSFBDDVSBUFUIBOBOBMPHPSWBSJBDDPOUSPMMFST
#VJMUJOUIFSNPDPVQMFEJBHOPTUJDT
* EFBMGPSVTFXJUIBIPUTQSVFCVTIJOH
or a machine nozzle
Key Features
Operational Refinements
t Large Digital Display

-'PSFBTJFSSFBEBCJMJUZPGUFNQFSBUVSF QPXFSBOEGBVMUT
t Setpoint Pushwheel
'PSTFUUJOHEFTJSFETFUQPJOUUFNQFSBUVSF
"MMPXTBEKVTUNFOUPGTFUQPJOUCFGPSFUVSOJOHQPXFSPO
t AUTO % Power Display
4IPXTQPXFSPVUQVUXIJMFJO"650NPEF
*OEJDBUFTBWFSBHFQPXFSSFRVJSFNFOUPOUIFSNPDPVQMF
GBJMVSF
"EJBHOPTUJDUPPMGPSTPMWJOHQSPCMFNT
t Improved SmartStart
"NPSFHSBEVBMUFNQFSBUVSFSJTFMFBETUPBNPSFFGGFDUJWF
IFBUFSESZPVUQFSJPE
UIFSFCZFYUFOEJOHIFBUFSMJGF
4NBSU4UBSUOPXBWBJMBCMFBTBOPQUJPOJONBOVBMNPEF
t SelectiveCycle
"WFSZIJHITQFFEQPXFSPVUQVUBQQSPBDI
&OBCMFTBDDVSBUFUFNQFSBUVSFDPOUSPMBOEMPOHFSIFBUFSMJGF
t Bumpless Transfer
8IFOBUIFSNPDPVQMFGBJMVSFPDDVST PQFSBUJPOJTBVUPNBUJDBMMZ
DPOUJOVFEXJUIBMFBSOFEQPXFS
6OJRVFTPGUXBSFBDDVSBUFMZBTTJHOTQFSDFOUQPXFSTFUUJOH
t Third Fuse
"MMPXTGPSEJTQMBZPGMPXUFNQFSBUVSFBMBSNXIFOUIFMPBE
GVTFTBSFCMPXO
Switchable Options
t Shorted Thermocouple Sensitivity Adjustment
0QFSBUJPODBOCFUBJMPSFEUPGBTUPSTMPXSFBDUJPOUJNFT
4FOTJUJWJUZDBOCFBEKVTUFEXJUIJOUFSOBMTXJUDIFT
7FSZVTFGVMGPS[POFTXJUIMPOHTUBSUVQUJNFT
t Switchable C/F Operation
4DBMFJOEJDBUFEBUTUBSUVQ
t K Type Thermocouple Support
t Cut Feature
(BJODVUGFBUVSFGPSTNBMMOP[[MFTBOEIFBUFSTXJUI
VOHSPVOEFEJOUFSOBMUIFSNPDPVQMFT
Front Panel Digital LED Indicators
BACKWARD
THERMOCOUPLE
SHORTED
THERMOCOUPLE
U.S. 800-626-6653
OPEN
THERMOCOUPLE
BUMPLESS
TRANSFER
FRONT PANEL
LOCKOUT
Canada 800-387-6600
TEMP MODE
FAHRENHEIT
TEMP MODE
CENTIGRADE
PROCESS
TEMP
dme@milacron.com
MANUAL
% POWER
LOCKOUT
ERROR
www.milacron.com
Smart Series
117
RoHS/WEEE Compliant
SSH1022/21 (10 AMP)

$POUSPMMFSJODMVEFTGPPUQPXFSDPSE NBUJOHNPMEQPXFSBOEUIFSNPDPVQMFDPOOFDUPS
$,15.
BOEUXPTQBSFGVTFT "#$
"EEJUJPOBMDBCMFTBOEPSDPOOFDUPSTNVTUCF
PSEFSFETFQBSBUFMZ4FF1BHFGPSEFUBJMFEJOGPSNBUJPOPODBCMFTBOEDPOOFDUPST
Warranty: Two year (excluding triac and fuses).
CONTROLLER
ITEM NUMBER
SSH1022
VOLTS
(VAC)
240
SSH1021
120
CABLE*
ITEM NUMBER
MPTC10
LENGTH
(FEET)
10
MPTC20
20
4
6
4FFQBHF
3
5
MOLD POWER AND

THERMOCOUPLE CONNECTOR*
ITEM NUMBER
2. Temperature Deviation Lights:

*OEJDBUFTEFWJBUJPOGSPNTFUQPJOU0VUFSMJHIUTCMJOLBUNPSFUIBO' $

GSPNTFUQPJOU
CKPTIC1
3. Auto / Manual / % Auto Power Switch:

4FMFDUT"650PS."/6"-DPOUSPMNPEF4IPXTQPXFSXIFOQSFTTFEJOUP
i"650wQPTJUJPO
4FFQBHF
4. LED Mode Indicators:

-FGU-&%JMMVNJOBUFTEVSJOHNBOVBMNPEF3JHIU-&%JMMVNJOBUFTXIFOQPXFS
JTTVQQMJFEUPIFBUFS3JHIU-&%CMJOLTEVSJOH4NBSU4UBSU
5. Setpoint Pushwheel:
5ISFFEJHJUTXJUDIQSPHSBNTTFUQPJOUJO"650NPEF3JHIUUXPEJHJUTQSPHSBN
QPXFSJO."/6"-NPEF
6. Power On/Off Switch:
$POUSPMT"$QPXFSUPNPEVMF
* ITEMS ORDERED
SEPARATELY
Rear Panel
1. Mold Power and Thermocouple Output Connector:
$,15*$DPOOFDUTUPUIFIFBUFSBOEUIFSNPDPVQMF.BUJOHDPOOFDUPS
$,15.JTTVQQMJFEXJUIDPOUSPMMFS
2. Power Input Cord:

/JOFUFFOGPPUDPSETVQQMJFTQPXFSUPDPOUSPMMFS1MVHTVQQMJFEXJUI
44) 7"$
VOJUT/PQMVHTVQQMJFEXJUI44)
3. Load Fuse Receptacles:
1SPWJEFTTBGFBOEFBTZSFQMBDFNFOUPGMPBEGVTFT
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
1. Process Temperature Display:

4IPXTQSPDFTTUFNQFSBUVSF UIFSNPDPVQMFGBVMUTBOEPUIFSPQFSBUJPOBMNPEFT
%JTQMBZTQPXFSXIFOTXJUDI
JTQSFTTFEEPXO
Front Panel Controls and Indicators
Smart Series
CKPTM1
INCLUDED
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(

MFP1G
MFP1G1
A
B
A: "$' 1PXFSUP.BJOGSBNF

Smart Series
Smart Series Single and 2-Zone Mainframes
"$'TVQQMJFEXJUI.'1(
6TFSNVTUJOTUBMM"#$ ".1
GVTFTJOUIF".1DPOUSPMNPEVMFTUPQSPUFDUUIFNBJOGSBNF
Single and Two-Zone 10 AMP Mainframes

(50-60 Hz, single phase)
ZONES
ITEM
NUMBERS **
VOLTS
WATTS
PER ZONE
CONNECTORS
SUPPLIED
MFP1G1
120
1200
(1) AC1512F (POWER IN)

(1) CKPTM1 (POWER-T/C OUT)
MFP1G
240
2400

MFPR2G
240
2400

B: $,15. $POOFDUPSUPIFBUFS
5IJTTJOHMF[POFDPOUSPMMFSJTJEFBMGPS
VTFXJUI4USBJHIU4IPUBOE(BUF.BUF
IPUTQSVFCVTIJOHT
*ODMVEFTGSBNFBOEDPOOFDUPSTMJTUFE.PEVMFTBOEDBCMFTPSEFSFETFQBSBUFMZ.
NOTE: 3FQMBDFNFOUQPXFSDPOOFDUPSTJOGSBNFBSFBMTPBWBJMBCMFPOTQFDJBMPSEFS
Recommended Mold Pocket Layout

(For Mold Power-Thermocouple Input Connector CKPTIC1)
MFPR2G
A
B
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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
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
"4JOHMF;POF1PXFS5IFSNPDPVQMF*OQVU$POOFDUPSJTBWBJMBCMFGPSNPVOUJOHJOPSPO
UIFNPMEUPBDDFQUUIFQPXFSUIFSNPDPVQMFDBCMFGSPNUIFNBJOGSBNF8BUFSSFTJTUBOU
UIFDPOOFDUPSIBTBOJOUFHSBMSFUBJOJOHMBUDIGPSBTFDVSFDBCMFDPOOFDUJPOBOEOVNCFSFE
TDSFXUZQFUFSNJOBMTGPSQPXFSBOEUIFSNPDPVQMFMFBEXJSFT
$BOCFNPVOUFEPOUPQPGNPMEGPSVTFXJUIIPUTQSVFCVTIJOHT
ITEM
NUMBER
CKPTIC1
Armored Mold Power-Thermocouple Cables

ITEM
NUMBER
MPTC10
MPTC20
Replacement Connector Kits (for Controller & Cables)
FEMALE POWER T/C CONNECTORS:

$,15'JTPO.15$$BCMFT
.BUFTXJUI.PMEPS$,15.-POMZ
$,15'-.BUFTXJUI$,15.POMZ
CKPTF1
CKPTM1
AC1512F
MALE
5
4
2
+
GPS$,15*$
- BOE$,15.
PS$,15.-
CKPTM1L
AC2024F
CKPTF1L
ITEM
NUMBER
VOLTS
ITEM
NUMBER
AC1512F
120
CKPTM1
CKPTF1
CKPTM1L
CKPTF1L
AC2024F
240
ITEM
NUMBER
ITEM
NUMBER
CKPTOC1
ITEM NUMBER
PTC210TBGTS
ITEM
NUMBER
FEMALE
5
1
PTC210
4
3
-
Terminal Mounting
Boxes Prewired
(10 AMP) 5 Pin
1PXFS5IFSNPDPVQMF0VUQVU
$POOFDUPS GPS.BJOGSBNF#VMLIFBE
U.S. 800-626-6653
PTC210
2
+
B
GPS$,150$
BOE$,15'
PS$,15'-
5FSNJOBM.PVOUJOH#PYFTQSPWJEFUIFFBTJFTUBOENPTU
FDPOPNJDBMNFUIPEPGNPVOUJOHQPXFSBOEUIFSNPDPVQMF
DPOOFDUPSTPOUIFNPME$POTUSVDUFEPGQMBUFEIFBWZHBVHF
TUFFM FBDICPYJTQSFDVUBOEESJMMFEGPSRVJDLNPVOUJOHPG
UIFCPYUPUIFNPME [POF QSFXJSFEUFSNJOBMNPVOUJOH
CPYXJUIUFSNJOBMTUSJQTIPXOXJUIDPWFSQMBUFSFNPWFE

Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series Single and 2-Zone Mainframe Accessories
1PXFS*OQVU$POOFDUPST
'PS.BJOGSBNF
MALE POWER T/C CONNECTORS:

$,15.JTPO.15$$BCMFT
.BUFTXJUI'SBNFPS$,15'-POMZ
$,15.-.BUFT8JUI$,15'POMZ
Smart Series
4JOHMF;POF.PME1PXFS5IFSNPDPVQMF$BCMFTBSFDPOTUSVDUFEPGTQFDJBMMFBEXJSFGPS
VTFJOIJHIUFNQFSBUVSFFOWJSPONFOUT BOEBSFBWBJMBCMFUPDPOOFDUUIFNBJOGSBNFUPUIF
DPOOFDUPSPOUIFNPME"WBJMBCMFJOMFOHUITPGPSGFFU*OUFHSBMSFUBJOJOHMBUDIFT
POUIFNBJOGSBNFBOENPMEDPOOFDUJPOTQSPWJEFTFDVSFDBCMFDPOOFDUJPOT$POOFDUPS
DPOGJHVSBUJPOTFOTVSFQSPQFSJOTFSUJPOPGDBCMF
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)
AC1240F
1240F
AC1524M
NOTE: 3FQMBDFNFOUQBSUTJOGSBNFBSFBMTPBWBJMBCMFCZTQFDJBMPSEFS
N
4FFQBHFT
M2MJ
FRAME DIMENSIONS:
8Y)Y%
)EJNFOTJPOEPFTOPU
ITEM NUMBERS
DESCRIPTION
AC1240F*
Female 240 VAC twist-lock power input connector

(mates with male frame power input)
AC1524M*
Male 240 VAC power output connector

(mates with female frame power outputs)
M2MJ*
PTC2TBGTS
Thermocouple mini-plug
(mates with frame jack strip connector)
2 zone, pre-wired terminal mounting box with terminal strip
(mounts to mold; mates with PTC0110 or PTC0129 cables)
*ODMVEFEXJUI.''13(
Armored Mold Power

Thermocouple Cables (15 AMP)
ITEM NUMBER
Smart Series
Smart Series 2-Zone Mainframes and Accessories
**ODMVEFTGSBNFBOEDPOOFDUPSTMJTUFE.PEVMFTBOEDBCMFTPSEFSFETFQBSBUFMZ
PTC0110
4JOHMF;POF.PME1PXFS5IFSNPDPVQMF$BCMFJT
DPOTUSVDUFEPGTQFDJBMMFBEXJSFGPSVTFJOIJHI
UFNQFSBUVSFFOWJSPONFOUT5IJTDBCMFDPOOFDUT
UIFNBJOGSBNFUPUIFDPOOFDUPSPOUIFNPME
"WBJMBCMFJOMFOHUITPGPSGFFU3FUBJOJOH
MBUDIFTPOUIFNPMEDPOOFDUPSQSPWJEFTFDVSF
DBCMFDPOOFDUJPOT
PTC0120
'PSVTFXJUI.''13(POMZ
Terminal Mounting Boxes

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

ITEM NUMBER
PTC2TBGTS
NOTE: QJODPOOFDUPSTBOEQJOTBSFBWBJMBCMFBTBTQFDJBMPSEFSPOMZ5IFTFBSFDSJNQ
DPOUBDUT 4FFQBHFTGPSNPVOUJOHEJNFOTJPOT
'PSVTFXJUI.''13(POMZ
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
121
Smart Series Single Zone

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

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

PTCH1TBG
$POOFDUPSTTIPXOBSF
PSEFSFETFQBSBUFMZ
D: TCS1
E: AC1240MI
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
122
Smart Series
Smart Series Mainframes (15 AMP)

WIDTH (W)
Cooling Fan
Smart Series Mainframe (15 AMP Max.)

Configurations
5IFDPOGJHVSBUJPOTJMMVTUSBUFECFMPXQSPWJEFBXJEFTFMFDUJPOPG[POFDBQBDJUJFT
UPTVJUNPTUDPOUSPMBQQMJDBUJPOT5IF BOE[POFGSBNFT .'1 BOE(

VTFJOEJWJEVBMGSBNFTFDUJPOT5IFUISV[POFGSBNFTVTF PSGSBNFTFDUJPOT
SJHJEMZGBTUFOFEUPHFUIFSJOUPPOFQSFXJSFEJOUFHSBMVOJUXIJDISFRVJSFTPOMZPOFNBJO
"$QPXFSJOQVUDPOOFDUJPO5IF$VSSFOU7PMUBHFNPOJUPSPQUJPOXJMMCFGBDUPSZJOTUBMMFE
XIFOPSEFSFEBUTBNFUJNFBT.BJOGSBNF$POUSPMNPEVMFT DBCMFT NPMEDPOOFDUPST
BOEPUIFSBDDFTTPSJFTBSFPSEFSFETFQBSBUFMZ TFFUBCMFPOOFYUQBHF

Main AC power
input strain relief
Thermocouple
input with
retaining
latch
Smart Series
Smart Series Mainframes
Power output
with retaining
latch
&BDIGSBNFTFDUJPO
.'1( .'1(
BOE.'1(
IBT
JUTPXODPPMJOHGBO
.VMUJTFDUJPOGSBNF
IFJHIUTBSFNVMUJQMFT
PGIFJHIUTIPXO
FH.'1(JT
IJHI

.BJO"$JOQVU
TIPXOXJMMBMXBZT
CFJOCPUUPNGSBNF
TFDUJPO'PSIJHIFS
QPXFSSFRVJSFNFOUT
JOEJWJEVBMQPXFS
JOQVUTBOEDJSDVJU
CSFBLFSTDBOCF
GBDUPSZJOTUBMMFEJO
FBDITFDUJPOPGB
TUBDLGSBNFPOB
TQFDJBMPSEFSCBTJT
9"
12"
WORLDWIDE WIRING
CAPABILITIES
6OMFTTPUIFSXJTFTQFDJGJFE BMM
4NBSU4FSJFT.BJOGSBNFTXJMMCF
TVQQMJFEUPBDDFQU7"$ QIBTF
XJSF )[JOQVUQPXFS8JSJOH
EJBHSBN JODMVEFEPOUIFBDDFTTDPWFS

JMMVTUSBUFTUIFWBSJFUZPGPUIFSWPMUBHF
QIBTFBOEMPBECBMBODJOHBSSBOHFNFOUT
QPTTJCMF TVDIBT 7 QIBTF
XJSF )[
7 TJOHMF
QIBTF XJSF )[
BOE 7
TJOHMFQIBTF XJSF )[

These wiring adjustments can be
performed in the field to suit the
requirements of the application.
If specified at the time of original
order, DME will supply the
Mainframe required.
MOLD POWER CABLE (10, 20 OR 30 FOOT)
ITEM NUMBER
W*
.'1(

.'1(

.'1(

THERMOCOUPLE CABLE (10, 20 OR 30 FOOT)
%JNFOTJPOEPFTOPUJODMVEF
DPOOFDUPST
NOTE: $PNCJOBUJPOGSBNFTUP
BDDPNNPEBUFCPUIBOE
".1NPEVMFT XJUIPS
XJUIPVUDPNNVOJDBUJPOT

BSFBWBJMBCMFCZTQFDJBMPSEFS
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
123
Smart Series
Smart Series Mainframes (15 AMP)

SMART SERIES MAINFRAMES
Optional Current Voltage Monitor
is Factory Installed in CV-Style Frames
CABLES AND MOLD CONNECTORS REQUIRED

(Not included with Mainframes and Must be Ordered Separately)
MOLD POWER CABLES

THERMOCOUPLE CABLES
MOLD POWER INPUT
Z MFP TYPE FOR MFP TYPE WITH MFCP TYPE FOR MFCP TYPE WITH
THERMOCOUPLE
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.
O
CONNECTORS
POWER
CONTROL
MONITOR
COMMUNICATIONS
MONITOR
(SELECT
LENGTH
DESIRED)
(SELECT
LENGTH
DESIRED)
CRIMP
CONNECTORS)
N
E
ITEM
ITEM NUMBER
ITEM
ITEM NUMBER
ITEM
ITEM
ITEM
ITEM
QTY.
QTY.
QTY.
QTY.
S
NUMBER
(CV-STYLE)
NUMBER
(CV-STYLE)
NUMBER
NUMBER
NUMBER
NUMBER
5
.'1(
.'1($7
.'$1(
.'$1($7
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
.'$1(
.'$1($7
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
.'$1(
.'$1($7
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
16
.'1(
.'1($7
.'$1(
.'$1($7
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(

.'$1(
.'$1($7

1*$(
and
1*$(
.'1($7
5$$( $(PS$(
and
5$$( $(PS$(
.'1(
.1$$( $(PS$(
and
.1$$( $(PS$(
20
.5$(
and
.5$(
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
.1$$( $(PS$(
and
.1$$( $(PS$(
5$$( $(PS$(
and
5$$( $(PS$(
1*$(
and
1*$(
.5$(
and
.5$(
1*$(
and
1*$(
5$$( $(PS$(
and
5$$( $(PS$(
.1$$( $(PS$(
and
.1$$( $(PS$(
.5$(
and
.5$(
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
.1$$( $(PS$(
and
.1$$( $(PS$(
5$$( $(PS$(
and
5$$( $(PS$(
1*$(
and
1*$(
.5$(
and
.5$(
1*$(
and
1*$(
5$$( $(PS$(
and
5$$( $(PS$(
.1$$( $(PS$(
and
.1$$( $(PS$(
.5$(
and
.5$(
.1$$( $(PS$(
5$$( $(PS$(
1*$(
.5$(
24
.'1(
.'1($7
.'$1(
.'$1($7
28
.'1(
.'1($7
.'$1(
.'$1($7

32
.'1(
36
.'1($7
.'1(
40
.'$1(
.'1($7
.'1(
.'$1($7
.'$1(
.'1($7
.'$1($7
.'$1(
.'$1($7

44
.'1(
48
.'1($7
.'1(
.'$1(
.'1($7
.'$1($7
.'$1(
.'$1($7
NOTE:'PSEFUBJMTPODBCMFTBOEDPOOFDUPST TFFQBHFT

ORDER ITEMS A and B or C

Z
O
N
E
S
(A)
FOR POWER INPUT
CONNECTORS
(B)
FOR THERMOCOUPLE CABLES
CONNECTORS
(C)
COMBINATION
POWER & TC
QTY.
ITEM
NUMBER
QTY.
ITEM
NUMBER
QTY.
ITEM
NUMBER
1*$5#(
.5$5#(
15$5#(
1*$5#(
.5$5#(
15$5#(
12
1*$5#(
.5$5#(
15$5#(
16
1*$5#(
.5$5#(
15$5#(

20
.5$5#(
and
.5$5#(
15$5#(
and
15$5#(
.5$5#(
15$5#(
.5$5#(
and
.5$5#(

15$5#(
and
15$5#(
1*$5#(
24
1*$5#(
28
1*$5#(
Z
O
N
E
S
(A)
FOR POWER INPUT
CONNECTORS
QTY.
ITEM
NUMBER
1*$5#(
(B)
FOR THERMOCOUPLE CABLES
CONNECTORS
QTY.

32
36
40
1*$5#(
15$5#(
and
15$5#(
.5$5#(
15$5#(
.5$5#(
and
.5$5#(
15$5#(
and
15$5#(
.5$5#(
and
.5$5#(
15$5#(
and
15$5#(
.5$5#(
15$5#(
48
1*$5#(
1*$5#(
ITEM
NUMBER
1*$5#(
QTY.
.5$5#(
and
.5$5#(
44
ITEM
NUMBER
(C)
COMBINATION
POWER & TC
NOTES: $PNCJOBUJPOUFSNJOBMNPVOUJOHCPYFTBSFBWBJMBCMFXJUIDPOOFDUPSTQSFXJSFEUPUFSNJOBMTUSJQT4FFQBHFGPSEFUBJMT

4FFQBHFGPSEJNFOTJPOBMEFUBJMT'PSCFMPXGMVTINPVOUJOHPGDPOOFDUPST TFFNPMEQPDLFUMBZPVUTPOQBHFT
4FFQBHFGPSDVSSFOUWPMUBHFNPOJUPS
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series Mainframes
.'1($7
.'1($7
.'1(
.'1(
Smart Series
8
12
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)
(USE 5-ZONE CABLE)
9"
HIGH POWER
MOLD POWER
INPUT CONNECTOR
THERMOCOUPLE CONNECTOR
TERMINAL MOUNTING BOX (OPTIONAL)
(14 3/16" WIDE)
INSULATED
CRIMP
CONNECTORS
(INCLUDED WITH
MOLD POWER
INPUT
CONNECTOR)
50 AMP 3-PHASE
CIRCUIT BREAKER
MAINFRAME WITH CIRCUIT BREAKER
DISCONNECT IS STANDARD; CURRENT
VOLTAGE MONITOR IS OPTIONAL
9"
5IFDPOGJHVSBUJPOTJMMVTUSBUFEBUMFGUQSPWJEF PS[POFTPG".1DPOUSPMGPS
IJHIFSXBUUBHFIFBUFSBQQMJDBUJPOT5IF$VSSFOU7PMUBHFNPOJUPSPQUJPOXJMMCFGBDUPSZ
JOTUBMMFEXIFOPSEFSFEBUUIFTBNFUJNFBT.BJOGSBNF$POUSPMNPEVMFT DBCMFT NPME
DPOOFDUPSTBOEPUIFSBDDFTTPSJFTBSFPSEFSFETFQBSBUFMZ
Smart Series
Smart Series High Power Mainframes
(20 3/16" WIDE)

70 AMP 3-PHASE
CIRCUIT BREAKER
SMART SERIES HIGH POWER MAINFRAMES

Optional Current Voltage Monitor is Factory Installed in CV-Style Frames
9"
(28 3/16" WIDE)
DIMENSIONS ABOVE DO
NOT INCLUDE CONNECTORS
BMMGSBNFTBSFEFFQ
Z
O
N
E
S
MFHP TYPE FOR

TEMP. CONTROL
MFHP TYPE WITH

CURRENT VOLTAGE MONITOR
MFCHP TYPE FOR TEMP.

CONTROL AND COMMUNICATIONS
MFCHP TYPE WITH CURRENT

VOLTAGE MONITOR
ITEM
NUMBER
ITEM NUMBER
(CV-STYLE)
ITEM
NUMBER
ITEM NUMBER
(CV-STYLE)
.')1(
.')1($7
.'$)1(
.'$)1($7
.')1(
.')1($7
.'$)1(
.'$)1($7
.')1(
.')1($7
.'$)1(
.'$)1($7
CABLES AND MOLD CONNECTORS REQUIRED

(Not included with Mainframes and Must be Ordered Separately)
NOTE: #MBOLQBOFMTDPWFS
VOVTFE[POFTJOGSBNFT
TIBEFEQBOFMTBCPWF
'PS
DPNNVOJDBUJPOT .'$)1

UZQFGSBNFT UIFTF
[POFTNBZCFVTFEGPS
DPNNVOJDBUJPONPEVMFT
THERMOCOUPLE CABLES
C10=10 FT. C20=20 FT. C30=30 FT.
(SELECT LENGTH DESIRED)
MOLD POWER CABLES

Z
C10=10 FT. C20=20 FT. C30=30 FT.
O
(SELECT LENGTH DESIRED)
N
E
ITEM
S QTY.
NUMBER
MOLD POWER INPUT

CONNECTORS
(INCL. CRIMP CONNECTORS)
THERMOCOUPLE
CONNECTORS
QTY.
ITEM
NUMBER
QTY.
ITEM
NUMBER
QTY.
ITEM
NUMBER
.5$(
.1$)$( $(PS$(
5$$( $(PS$(
1*$)(
.1$)$( $(PS$(
5$$( $(PS$(
1*$)(
.5$(
.1$)$( $(PS$(
5$$( $(PS$(
1*$)(
.5$(
NOTE: 'PSEFUBJMTPODBCMFTBOEDPOOFDUPST TFFQBHFT
NOTE: $PNCJOBUJPOGSBNFT
UP BDDPNNPEBUF
CPUIBOE".1
NPEVMFT XJUIPSXJUIPVU
DPNNVOJDBUJPOT
BSF
BWBJMBCMFCZTQFDJBMPSEFS
U.S. 800-626-6653
Z
O
(A)
N
FOR POWER INPUT CONNECTORS
E
ITEM
S QTY.
NUMBER
(B)
FOR THERMOCOUPLE CABLES CONNECTORS
(C)
COMBINATION POWER & TC
QTY.
ITEM
NUMBER
QTY.
ITEM
NUMBER
1*$)5#(
.5$5#(
15$)5#(
1*$)5#(
.5$5#(
15$)5#(
1*$)5#(
.5$5#(
15$)5#(
NOTE: 4FFQBHFGPSEJNFOTJPOBMEFUBJMT'PSCFMPXGMVTINPVOUJOHPGDPOOFDUPST TFF

NPMEQPDLFUMBZPVUTPOQBHFT
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
125
Smart Series Digital Current/Voltage Monitor

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

5PNPOJUPSUIFDVSSFOUTVQQMZUPFBDI[POF TJNQMZTFUUIFSPUBSZTFMFDUPSTXJUDI
UPUIFEFTJSFENPEVMF[POFOVNCFS5IFi".14wGVODUJPOJTUIFOBVUPNBUJDBMMZ
TFMFDUFEBOEJTJOEJDBUFECZUIFMFUUFS"KVTUUPUIFSJHIUPGUIFOVNCFSTJOUIF
EJTQMBZXJOEPX5IFNFUFSEJTQMBZTUIFDVSSFOUCFJOHEFMJWFSFEUPUIFIFBUFSMPBE
JOBNQFSFT
Input Voltage From Each Phase
4FUUIFSPUBSZTFMFDUPSUPUIFEFTJSFEQIBTFWPMUBHFQPTJUJPO5IJTBVUPNBUJDBMMZ
TFMFDUTUIFAWPMUTGVODUJPOXIJDIJTJOEJDBUFEXIFOUIFMFUUFSA7BQQFBSTUPUIF
SJHIUPGUIFOVNCFSTJOUIFEJTQMBZXJOEPX5IFNFUFSXJMMEJTQMBZUIFMJOFWPMUBHF
PGUIFTFMFDUFEQIBTF
Smart Series Digital Current/Voltage Monitor
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
Voltmeter Accuracy
PGSFBEJOH UP)[
Maximum Voltmeter Input
7"$
Input Voltage
Ammeter Range
Ammeter Accuracy
7"$ UP)[
UPUPUPANQFSFT
!UP%VUZ$ZDMF )[
Maximum Ammeter Input
"NQFSFT
U.S. 800-626-6653
Canada 800-387-6600
Smart Series
NOTE: 5IF%JHJUBM$VSSFOU7PMUBHF.POJUPS
JTBGBDUPSZJOTUBMMFEPQUJPOXIJDI
SFQMBDFTUIFTUBOEBSEDJSDVJU
CSFBLFSEJTDPOOFDU BOEJTTVQQMJFE
XIFOi$7TUZMFwNBJOGSBNFT
BSFPSEFSFE
See pages 123 and 124 for
appropriate mainframe
item numbers.
dme@milacron.com
www.milacron.com
126
Smart Series
Smart Series Accessories

Universal Floor Stand
3 SECTIONS
1 SECTIONS
2 SECTIONS
4 SECTIONS
46"
'MPPSTUBOE
XJEUIBEKVTUT
GPSBOE
[POF
NBJOGSBNFT
5IF6OJWFSTBM'MPPS4UBOEXJMMBDDPNNPEBUFBMMPSBNQ
.BJOGSBNFTGSPNPOFUPGPVSTFDUJPOTIJHI4UBOEJTNBEFGSPN
IFBWZHBVHFTUFFMBOEJODMVEFTMPDLJOHDBTUFST MCSBUJOH

"MMBTTFNCMZBOE.BJOGSBNFNPVOUJOHIBSEXBSFJTJODMVEFE
)FBWZEVUZGMPPSTUBOEBWBJMBCMFGPSMBSHFSTZTUFNT MCSBUJOH

ITEM NUMBER
RATING
.'4(
-#4
.'4()%
-#4
)%TUBOEOPUTIPXO
'MPPSTUBOEDPNFTXJUIQMBUFTGPS[POFGSBNFNPVOUJOH
PO[POFiYwQBUUFSO
25 3/4"
28 1/4
Step-Down Transformer Kits (from 480 VAC to 240 VAC)
Smart Series Accessories
5SBOTGPSNFS,JUTBSFQSFXJSFEBOEJODMVEFFODMPTFEUSBOTGPSNFS 7"$JOQVU 7"$PVUQVU

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

BOEBMMNPVOUJOHCSBDLFUTBOEIBSEXBSFSFRVJSFE4IJQQFEXJUIJOTUSVDUJPOTGPSFBTZBTTFNCMZ
4JOHMFTFDUJPOGSBNFTNPVOUUPGSPOUPSSFBSPGTUBOE
RATING
5,"(
,7"
5,"(
,7"
5,"(
,7"
5,"(
,7"
Also Available:
5SBOTGPSNFSPOMZ
5SBOTGPSNFSBOEDBCMFTPOMZ
5SBOTGPSNFSTXJUIPUIFSWPMUBHF
PSDVSSFOUDBQBDJUJFT
*TPMBUJPO5SBOTGPSNFST
$POUBDU%.&GPSEFUBJMTBOEQSJDFT
.BJOGSBNFOPUJODMVEFE
"EBQUFSQMBUFTGPSOBSSPXFSGSBNFTBWBJMBCMFCZTQFDJBMPSEFS
$PNFTXJUIQMBUFTGPSNPVOUJOH[POFPO[POFiYwQBUUFSO
4VQQMJFEXJUI.'4()%GPSUIJTUSBOTGPSNFSTJ[FPSMBSHFBOEUSBOTGPSNFSTNPVOUFEGMBU
NOTE: 1PXFSDBQBDJUZOFFEFEEFQFOETPOUPUBMMPBEPGTZTUFN
JFOVNCFSPG[POFTBOEIFBUFSMPBEQFS[POF

|
Smart Series
ITEM NUMBER
Mainframe
Blank Panels
6TFEUPDPWFSVOVTFE
[POFTJONBJOGSBNFT
1VTIQVMMGBTUFOFST
JODMVEFEJOQBOFM
MFBP10G DPWFST
POFAMP[POF
MFBP30G DPWFST
POFAMP[POF PS
UXPAMP[POFT

Insulated Crimp Connectors
(sold in packages of 5)
'PSDPOOFDUJPOPGNPMEQPXFSJOQVUDPOOFDUPSMFBET
UPIFBUFSMFBET '$NBYJNVNUFNQFSBUVSF
ITEM NUMBER
AMPS
"#$
"#$

ITEM NUMBER
AMPS
RATING
"#$

)8$$ #BHPG

3&%
9

)8$$ #BHPG

#-6&
)8$$ #BHPG

:&--08
ITEM NUMBER
9

.'#1(
31.

.'#1(
31.

U.S. 800-626-6653
Canada 800-387-6600
NOTE: *OJUJBMTVQQMZJTQSPWJEFEXJUINPMEQPXFS
JOQVUDPOOFDUPST
dme@milacron.com
www.milacron.com
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
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
BETWEEN BLK & WHITE LEADS.
CHECK CONNECTIONS OF BLACK
Wiring Diagram with Smart Series Mold Connectors
NOTES: "MMHSPVOETNVTUCFDPOOFDUFEUPNPMEUPFOTVSFPQFSBUPSTBGFUZ

"MMDSJNQDPOOFDUJPOTDBOCFFMJNJOBUFECZVTJOHUFSNJOBMNPVOUJOHCPYXJUIUFSNJOBMTUSJQ4FFQBHF
Smart Series
BLK
BLK
BLACK (+)
WHITE (+)
BLK
128
Smart Series
Wiring Diagram for DME Hot Runner Molding System

with Smart Series Mold Connectors
www.milacron.com
dme@milacron.com
www.milacron.com
BLACK
WHITE
NOTES: "MMHSPVOETNVTUCFDPOOFDUFEUPNPMEUPFOTVSFPQFSBUPSTBGFUZ

"MMDSJNQDPOOFDUJPOTNBZCFFMJNJOBUFE4JNQMZSFNPWFMFBETGPSN1*$DPOOFDUPSTBOEXJSFEJSFDUMZ
USE OHM METER TO MEASURE BETWEENF BLACK AND WHITE LEADS .
CHECK CONNECTIONS OF BLACK AND WHITE LEADS TO ENSURE
Wiring Diagram with High Power Smart Series Mold Connectors
Canada 800-387-6600
Smart Series
U.S. 800-626-6653
WHITE (+)
BLACK (+)
Smart Series
129
Wiring Diagram for DME Hot Runner Molding System

with High Power Smart Series Mold Connectors
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

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

5IF.1$$( (PS(.PME1PXFS$BCMFBMTPTFSWFTBTBVOJWFSTBMDBCMFGPSDPOOFDUJOH
BOZ".14NBSU4FSJFT.BJOGSBNFUPBOZ".1.PME1PXFS*OQVU$POOFDUPS5IFNBYJNVN
OVNCFSPG[POFTXJMMCFEFUFSNJOFECZUIFDPOOFDUPSJOUIFNPME
Smart Series
ITEM
NUMBER
ITEM
NUMBER
ITEM
NUMBER
.1$$(
.1$$(
.1$$(
.1$$(
.1$$(
.1$$(
.1$$(
NUMBER
OF ZONES
(MAX.)
FOR CONNECTIONS
FROM 15 AMP
FRAME (S)
TO POWER INPUT
CONNECTOR
;0/&
1*$(
.1$$(
;0/&
1*$(
.1$$(

;0/&
1*$(

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

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

;0/&
.5$(
6TFEXJUIBMM".1.BJOGSBNFT
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
131
RoHS/WEEE Compliant: Mold Power Input Connectors

For 15 AMP
Applications
.PME1PXFS*OQVU$POOFDUPSTBSFNPVOUFEPOUIFNPMEUPBDDFQUQPXFSDBCMF T
GSPN
UIF.BJOGSBNF5IFZBSFTVQQMJFEXJUITJYJODIFTPGOVNCFSFEMFBETBOEBHSPVOEXJSF
"MMUISFF".1DPOOFDUPSTBSFUIFTBNFQIZTJDBMTJ[FBOEVTFHBVHFXJSF0OMZUIF
OVNCFSPGBDUJWFQJOTDIBOHF5IF".1DPOOFDUPSTBSFTVQQMJFEXJUIHBVHFMFBET
BOEBSFBUUBDIFEUPTDSFXUFSNJOBMT&BDIJTFRVJQQFEXJUIBOJOUFHSBMSFUBJOJOHMBUDIUP
QSPWJEFBTFDVSFDBCMFDPOOFDUJPO$POOFDUPSDPOGJHVSBUJPOFOTVSFTQSPQFSJOTFSUJPOPG
DBCMF4QMJDJOHPGMFBETUPIFBUFSQPXFSMFBETJTFBTJMZBDDPNQMJTIFEXJUIUIF*OTVMBUFE
$SJNQ$POOFDUPSTTVQQMJFE
PIC5G
NOTE: (SPVOEXJSFNVTUCF
DPOOFDUFEUPNPMEUP
FOTVSFPQFSBUPSTBGFUZ
PIC8G
Mold Power Input Connectors
Smart Series
PIC12G
NOTE: %JNFOTJPOTTIPXONBZWBSZTMJHIUMZ
PICH23G
Insulated Crimp Connectors
PICH5G
NOTES:
$POOFDUPS1*$)(JT
EJNFOTJPOBMMZJEFOUJDBMUP
UIFSNPDPVQMFDPOOFDUPS
.5$(4FFOFYUQBHF
NOTE: *OJUJBMTVQQMZJTQSPWJEFEXJUI
NPMEQPXFSJOQVUDPOOFDUPST
"MTP TFFQBHF
'PS1*$)(BOE1*$)(
EJSFDUXJSJOHXJUIPVUDSJNQ
DPOOFDUPSTJTQPTTJCMFCZ
SFNPWJOHMFBET.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Mold Power Input Connectors
NOTE: 3FQMBDFNFOUQBSUTBOE
FYUSBDUJPOUPPMTDBOCF
GPVOEPOQBHF
For 30 AMP
Applications
132
Smart Series
RoHS/WEEE Compliant: Mold Thermocouple Connectors
5IFSNPDPVQMF$POOFDUPSTBSFNPVOUFEPOUIFNPMEUPVTFXJUIUIFSNPDPVQMF
DBCMF T
GSPNUIF.BJOGSBNF4DSFXUZQFUFSNJOBMTGPSVTFXJUIJSPO
BOE
DPOTUBOUBO
UIFSNPDPVQMFMFBETBSFOVNCFSFEBOEDPEFEPOUIFTJEFBOECPUUPN
PGFBDIDPOOFDUPS"MMUISFFDPOOFDUPSTBSFFRVJQQFEXJUIJOUFHSBMSFUBJOJOHMBUDIFT
UPQSPWJEFBTFDVSFDBCMFDPOOFDUJPO$POOFDUPSDPOGJHVSBUJPOFOTVSFTQSPQFS
JOTFSUJPOPGDBCMF1JOTBSFNBEFPGDPQQFSBMMPZBOEBSFTJMWFSQMBUFE&YQFSJFODF
IBTQSPWFOUIBUJSPOBOEDPOTUBOUBOBSFOPUSFRVJSFE
MTC5G
NOTE: .0-%108&3*/165$0//&$5031*$)(*4%*.&/4*0/"--:*%&/5*$"-50.5$(
MOLD THERMOCOUPLE CONNECTOR
MTC5G
MTC8G
MTC12G
MTC12G
MOLD POWER AND THERMOCOUPLE

CONNECTOR TPC0001
Smart Series
Mold Thermocouple Connectors
MTC8G
TPC0001
6TFXJUI BOE[POF ".1

NBJOGSBNFT
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
133
Mold Connector Pocket Layouts

NOTE: %SBXJOHEFQJDUT
CFMPXGMVTINPVOUJOH
%JTSFHBSEEJNFOTJPOT
NBSLFEXJUIGPS
TVSGBDFNPVOUJOH
8IFSFTQBDFPSNPMEIBOEMJOHBOETUPSBHFSFRVJSFNFOUTEPOPUQFSNJUUIFVTFPG
5FSNJOBM.PVOUJOH#PYFT UIFDPOOFDUPSTDBOCFCFMPXGMVTIPSTVSGBDFNPVOUFE
4FFESBXJOHTCFMPXBOEOFYUQBHFGPSEJNFOTJPOT
Smart Series
|
NOTE: %JTSFHBSEEJNFOTJPOT
NBSLFEXJUIGPS
TVSGBDFNPVOUJOH
NOTE: .PMEQPXFSJOQVUDPOOFDUPS1*$)(JT
EJNFOTJPOBMMZJEFOUJDBMUP.5$(
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
134
Smart Series
NOTE: %SBXJOHEFQJDUTCFMPXTVSGBDFNPVOUJOH%JTSFHBSEEJNFOTJPOTNBSLFEXJUIGPSTVSGBDFmounting.
Smart Series
6TFQPDLFUEJNFOTJPOTTIPXOPOQBHFTBTEFUBJMFEGPSUIFSNPDPVQMFDPOOFDUPS.5$(
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
135
RoHS/WEEE Compliant: Terminal Mounting Boxes
Pre-wired Combination Terminal Mounting Boxes

*ODMVEFTUFSNJOBMTUSJQGPSFBTFPGXJSJOH BMMOFDFTTBSZDPOOFDUPSTJOTUBMMFE BOEQPXFS
DPOOFDUPSQSFXJSFEUPBUFSNJOBMTUSJQ"MMVOJUTTIPXOXJUIPVUDPWFST
PTC12TBGTS
PTC8TBGTS
PTC5TBGTS
PTC5TBTS
PTC8TBTS
PTC12TBTS
Smart Series
Combination Terminal Mounting Boxes with Terminal Strip

ITEM NUMBER
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

.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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
PTC210TBGTS
15$5#(54JTOPUUPCFVTFEXJUI44)
44) .'1( .'1( .'1(
.'13(DPOUSPMTNBJOGSBNFT
136
Smart Series
PTC8TBG
PTC0012
Overall dimensions shown include allowances for hardware (assembly screws) but not connectors
(example: For Item Number PTC0012 the X dimension is 4.29 not including screw heads)
* Used with 2-zone, 15 AMP mainframe MFFPR2G
** Used with 1-zone, 30 AMP mainframe MFHP1G
Smart Series
PTC5TBG
PIC512TBG
PTC210
5FSNJOBM.PVOUJOH#PYFTQSPWJEF
UIFFBTJFTUBOENPTUFDPOPNJDBM
NFUIPEPGNPVOUJOHQPXFSBOE
UIFSNPDPVQMFDPOOFDUPSTPOUIF
NPME$POTUSVDUFEPGQMBUFEIFBWZ
HBVHFTUFFM FBDICPYJTQSFDVU
BOEESJMMFEGPSRVJDLNPVOUJOHPG
UIFDPOOFDUPSUPUIFCPY BOECPY
UPUIFNPME$POOFDUPSNPVOUJOH
IBSEXBSFJTTVQQMJFE$POOFDUPST
BSFPSEFSFETFQBSBUFMZ
U.S. 800-626-6653
NOTE: Overall dimensions

shown include allowances
for hardware (assembly
screws) but not connectors
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
137
RoHS/WEEE Compliant: Microprocessor-Based Temperature Control

Modules with Digital Display and Setpoint Pushwheel
SSM1512/11 (15 AMP) & SSM3012 (30 AMP)
COMPATIBLE WITH TAS0512

ALARM AND SYSTEM CONTROL
FUNCTIONS. SEE PAGES 143-144.
5IF44.JTUIFTFDPOEHFOFSBUJPOPGUIFQPQVMBS44.(5IJTWFSTJPONBJOUBJOTTJNQMJDJUZPGPQFSBUJPO
XJUITJNVMUBOFPVTEJTQMBZPGTFUQPJOUBOEUFNQFSBUVSF0UIFSOFX JNQSPWFE BOEVOJRVFGFBUVSFTJODMVEF
Key Features
t-BSHF%JHJUBM%JTQMBZ
'PSFBTJFSSFBEBCJMJUZPGUFNQFSBUVSF QPXFSBOEGBVMUT
tSetpoint Pushwheel
'PSTFUUJOHEFTJSFETFUQPJOUUFNQFSBUVSF
"MMPXTBEKVTUNFOUPGTFUQPJOUCFGPSFUVSOJOHQPXFSPO
t"VUP1PXFS%JTQMBZ
4IPXTQPXFSPVUQVUXIJMFJO"650NPEF
*OEJDBUFTBWFSBHFQPXFSSFRVJSFNFOUPOUIFSNPDPVQMFGBJMVSF
4FSWFTBTBEJBHOPTUJDUPPMGPSTPMWJOHIPUSVOOFSTZTUFNQSPCMFNT
Operational Refinements
44.JTUXJDFBT
XJEFBTBCPWFBOEIBT
DJSDVJUCSFBLFSJOTUFBE
PGQPXFSPOPGGTXJUDI
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Control Modules with Digital Display
NOTE:

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
t K Type Thermocouple Support
t Cut Feature
(BJODVUGFBUVSFGPSTNBMMOP[[MFTBOEIFBUFSTXJUIVOHSPVOEFEJOUFSOBMUIFSNPDPVQMFT
Switchable Options
Smart Series
tImproved SmartStart
"NPSFHSBEVBMUFNQFSBUVSFSJTFMFBETUPBNPSFFGGFDUJWFIFBUFSESZPVUQFSJPE
UIFSFCZFYUFOEJOHIFBUFSMJGF
4NBSU4UBSUOPXBWBJMBCMFJO."/6"-NPEF PQUJPOBM
tSelectiveCycle
"WFSZIJHITQFFEQPXFSPVUQVUBQQSPBDI
&OBCMFTBDDVSBUFUFNQFSBUVSFDPOUSPMBOEMPOHFSIFBUFSMJGF
tBumpless Transfer
8IFOBUIFSNPDPVQMFGBJMVSFPDDVST PQFSBUJPOJTBVUPNBUJDBMMZDPOUJOVFEXJUIBMFBSOFEQPXFS
6OJRVFTPGUXBSFBDDVSBUFMZBTTJHOTQFSDFOUQPXFSTFUUJOH
tThird Fuse
"MMPXTGPSBMBSNPVUQVUXIFOUIFMPBEGVTFTBSFCMPXO
1SPUFDUTNPEVMFGSPNBQQMJDBUJPOPGFYDFTTJWFWPMUBHF
tAnti-Arcing Feature
1SPUFDUTDJSDVJUCPBSEGSPNEBNBHFXIFONPEVMFJTFJUIFSJOTFSUFEPSSFNPWFEVOEFSQPXFS
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:
5XPZFBST
FYDMVEJOHUSJBDBOEGVTFT
MODULE
ITEM NUMBER
VOLTAGE
(VAC)
240
120
240
SSM1512
SSM1511
SSM3012
Fuse Requirements
(15 AMP only)

"#$GVTFT #VTTNBOPOMZ

TQBSFGVTFTJODMVEFE
XJUINPEVMF
AMPS
WATTS
15
15
30
3600
1800
7200
NOTE: 4UBOEBSE 7"$

NPEVMFTBSFDPNQBUJCMFXJUINBJOGSBNFTXJSFEGPSFJUIFS
7"$UISFFQIBTF TUBOEBSE
PS7"$TJOHMFQIBTF
4
1
2. Temperature Deviation Lights

*OEJDBUFTEFWJBUJPOGSPNTFUQPJOU0VUFSMJHIUTCMJOLXIFOUFNQFSBUVSFJTNPSF
UIBO' $
GSPNTFUQPJOU
2
3. Auto/Manual/Auto % Power Switch
4FMFDUT"650PS."/6"-DPOUSPMNPEF4IPXTQPXFSXIFOQSFTTFEJOUP
i"650wQPTJUJPO
5
Smart Series
Control Modules with Digital Display
1. Process Temperature Display

*OEJDBUFTQSPDFTTUFNQFSBUVSF UIFSNPDPVQMFGBVMUTBOEPUIFSPQFSBUJPOBMNPEFT
%JTQMBZTQPXFSXIFOTXJUDI
JTJOi"VUPwQPTJUJPO
4. LED Mode Indicators

-FGU-&%JMMVNJOBUFTEVSJOH."/6"-NPEF
3JHIU-&%JMMVNJOBUFTXIFOQPXFSJTTVQQMJFEUPIFBUFS
3JHIU-&%CMJOLTPOBOEPGGEVSJOH4NBSU4UBSU
5. Setpoint Pushwheel
5ISFFEJHJUTXJUDIQSPHSBNTTFUQPJOUJO"650NPEF3JHIUUXPEJHJUTQSPHSBN
QPXFSJO."/6"-NPEF
6. Power On/Off Switch
$POUSPMT"$QPXFSUPNPEVMF
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
139
RoHS/WEEE Compliant: Microprocessor-Based Temperature

Control Modules with Dual Digital Display
DSS1512/11 (15 AMP) & DSS3012 (30 AMP)
COMPATIBLE WITH TAS MODULE
ALARM AND STANDBY HEAT
FUNCTIONS. SEE PAGES 143-144.
5IF%444NBSU4FSJFT.PEVMFIBTEVBMEJHJUBMEJTQMBZTQSPWJEJOHSFBEPVUTPGCPUIQSPDFTTBOE
TFUQPJOUUFNQFSBUVSFTBUBHMBODF$MPTFEMPPQ GV[[ZMPHJD1*%DPOUSPM BOEBVUPUVOJOHPG1*%
QBSBNFUFSTQSPWJEFQSFDJTFDPOUSPMFWFOVOEFSUIFNPTUBEWFSTFQSPDFTTJOHDPOEJUJPOT
*OUIFFWFOUPGBUIFSNPDPVQMFGBJMVSF UIF%44DBOBVUPNBUJDBMMZJOWPLFCVNQMFTTUSBOTGFSUPB
QFSDFOUQPXFSNPEFCBTFEPOUIFMBTUWBMJEQFSDFOUBHFMFBSOFECFGPSFUIFUIFSNPDPVQMFGBJMVSF
*GEFTJSFE NBOVBMCVNQMFTTUSBOTGFSNBZCFTFMFDUFE JOXIJDIDBTFBUIFSNPDPVQMFGBVMUXJMMUVSO
PGGQPXFSUPUIFIFBUFSVOUJMUIFNBOVBMQFSDFOUQPXFSNPEFJTBDUJWBUFECZUIFPQFSBUPS
"VOJRVFGFBUVSFPGUIF%44JTBQPXFSPQUJPO'PSBTXJUDITFMFDUBCMF JOUFSWBMPGPS
1 TFDPOET GVMMQPXFSDBOCFJNNFEJBUFMZEFMJWFSFEUPUIFIFBUFSUPSBQJEMZCSFBLUISPVHIGSP[FO
HBUFTUPBDIJFWFRVJDLFSTUBSUVQT5IFQPXFSNPEFDBOCFEJTFOHBHFEBUBOZUJNFCZ
TJNQMZQSFTTJOHBOZGSPOUQBOFMCVUUPO
2 *OEJDBUPSMJHIUTQSPWJEFRVJDLSFGFSFODFGPSNPEVMFDPOUSPMNPEFT UFNQFSBUVSFEFWJBUJPOBOE
3 CMPXOGVTFT5IFQSPDFTTUFNQFSBUVSFEJTQMBZBMTPQSPWJEFTRVJDLEJBHOPTUJDTPGUIFSNPDPVQMF
10
1. Smart Start Light

*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
9. 100% Power Light
*OEJDBUFTQPXFSNPEF
10. Up Arrow
*ODSFBTFTEFTJSFETFUQPJOUWBMVF
11. Down Arrow
%FDSFBTFTEFTJSFETFUQPJOUWBMVF
12. F1/F2 Lights
*MMVNJOBUFXIFOGVTFJTCMPXO
13. Power On/Off Switch
9
NOTE:

%44JTUXJDFBT
XJEFBTBCPWFIBT
DJSDVJUCSFBLFSJOTUFBE
PG''MJHIUTBOEQPXFS
POPGGTXJUDI
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
11
7
8
Smart Series
4
5
6
GBVMUT VTJOHUIFGPMMPXJOHBCCSFWJBUFEDPEFT

4IJ4IPSUFE5IFSNPDPVQMF

P1J0QFO5IFSNPDPVQMF

CDJ3FWFSTFE5IFSNPDPVQMF
5IF%44NPEVMFBMTPJODMVEFTB4NBSU4UBSUNPEFUPTBGFMZCBLFPVUEBNBHJOHJOUFSOBMIFBUFS
NPJTUVSFBUTZTUFNTUBSUVQBOEUPQSPMPOHIFBUFSMJGF'BTUPSTMPXMPBENPEFTNBZBMTPCF
TFMFDUFE
UPQSPUFDUTNBMMFSIFBUFSTPSDPNQFOTBUFGPSiTMPXwMPBETTVDIBTFYUFSOBMMZIFBUFENBOJGPMET
"OBDDVSBUF EVSBCMFBOEGVMMGFBUVSFENPEVMF UIF%44JTGVMMZDPNQBUJCMFXJUIBMM4NBSU4FSJFT
PS(4FSJFTAMPNBJOGSBNFT
140
Smart Series
Microprocessor-Based Temperature
DSS1512/11 (15 AMP) & DSS3012 (30 AMP)
Performance Specifications
5JNFQSPQPSUJPOJOH4FMFDUJWF$ZDMF
Ambient to 999F (537C)
' $
EFQFOEFOUPOUIFUPUBMUIFSNBMTZTUFN
PGGVMMTDBMFPWFSUIFBNCJFOUSBOHFPGUP' UP$
#FUUFSUIBOPGGVMMTDBMF
TFDPOET
"EKVTUBCMFGSPN NBJOUBJOTPVUQVUQPXFSUPXJUIJOPGTFUQPJOU
-JOFBSWPMUBHFSBNQJOH
NJOVUFT
' $)
"QQMJFTQPXFSUPUIFPVUQVU4PGUXBSFTFMFDUBCMFJOIJCJUPS4 -TFDPOET
r4NBSU4UBSUQSFDFEFTBVUPNPEF
r5IFSNPDPVQMF 5$
CSFBL SFWFSTFEPSTIPSUFOFE5$PWFSSJEFT4NBSU4UBSUBOEBVUPNPEFT
r.BOVBMDPOUSPMPWFSSJEFTBVUPNPEF 5$CSFBLT SFWFSTFEPSTIPSUFOFEUIFSNPDPVQMFT
r0VUQVUJTJOIJCJUFEEVSJOHBMMGBVMUDPOEJUJPOT
Auto and Manual Control Modes:

Temperature Range:
Control Accuracy:
Temperature Stability:
Calibration Accuracy:
Power Response Time:
Manual Control:
Smart Start:
Maximum Smart Start Duration:
Smart Start Override Temperature:
100% Power:
Operational Mode Priority:

Smart Series
Input Specifications
Thermocouple Sensor:
External T/C Residence:
T/C Isolation:
Cold Junction Compensation:
T/C Break, Reversed & Shorted Protection:
Input Impedance:
Input Amplifier Stability:
Common Mode Rejection Ratio:
Power Supply Rejection:
5ZQF+ HSPVOEFEPSVOHSPVOEFE
-FTTUIBO' .
*TPMBUFECZDPOUSPMDJSDVJUQPXFSTVQQMZ
"VUPNBUJD CFUUFSUIBO'' $$

"VUPNBUJDBMMZJOIJCJUTQPXFSUPIFBUFSVOMFTT CVNQMFTTUSBOTGFSJTJOWPLFE
.FHPINT
(SFBUFSUIBO'' $$
.
(SFBUFSUIBOE#
(SFBUFSUIBOE#
Output Specifications
Voltage Power Capability:

Output Drive:
Overload Protection:

Transient Protection:
Power Line Isolation:
".1OPNJOBM TJOHMFQIBTF 7"$BWBJMBCMF BNQFSFT XBUUT!7"$ XBUUT!7"$

".1BNQFSFT XBUUT!7"$
*OUFSOBMTPMJETUBUFUSJBD USJHHFSFECZ[FSP"$DSPTTJOHQVMTFT
".1'VTFTBSFQSPWJEFEPOCPUITJEFTPG"$MJOF
".1'BTUBDUJOHDJSDVJUCSFBLFS
EWEUBOEUSBOTJFOUQVMTFTVQQSFTTJPOJODMVEFE
0QUJDBMMZBOEUSBOTGPSNFSJTPMBUFEGSPN"$MJOFT*TPMBUJPOWPMUBHFJTHSFBUFSUIBOWPMUT
Controls and Indicators

Auto/Manual Selection:
Setpoint Adjustment:
100% Power Selection:
Power On/Off:
Setpoint Display:
Process Display:
100% Power Indication:
Auto Indication:
Manual Indication:
Smart Start Indication:
Shorted T/C Indication:
Opened T/C Indication:
Reversed T/C Indication:
Temperature Deviation Indicators:

Blown Fuse Indicators:
1VTICVUUPOTXJUDIXJUI-&%JOEJDBUPSTBEKBDFOUUPTXJUDI
1VTICVUUPOVQEPXOBSSPXLFZT
1VTICVUUPOTXJUDIXJUI-&%JOEJDBUPSBEKBDFOU
AMPSPDLFSTXJUDI AMP
PSAMPDJSDVJUCSFBLFS BNQ
#PUIBSF6- $4" 7%&approved.
5ISFF TFWFOTFHNFOUEJHJUEJTQMBZ
5ISFF TFWFOTFHNFOUEJHJUEJTQMBZ"MTPEJTQMBZTBMBSNDPEFTBOEGMBTIJOHiwGPSQPXFSPQFSBUJPO
3FE-&%BEKBDFOUUPQPXFSLFZGMBTIFT1SPDFTTEJTQMBZGMBTIFTiw
*MMVNJOBUFTHSFFO-&%BEKBDFOUUP"VUP.BOLFZ
*MMVNJOBUFTZFMMPX-&%BEKBDFOUUP"VUP.BOLFZ
*MMVNJOBUFTHSFFO-&%BCPWFUIFQSPDFTTEJTQMBZ
'MBTIFTi4IJwJOQSPDFTTEJTQMBZ
'MBTIFTiP1JwJOQSPDFTTEJTQMBZ
'MBTIFTiCDJwJOQSPDFTTEJTQMBZ
'JWFTFQBSBUF-&%T '$3FE

'$:FMMPX

(SFFO
OFPOJOEJDBUPST AMPPOMZ
Electrical Power Specifications

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

NPEVMFTBSF

DPNQBUJCMFXJUINBJOGSBNFTXJSFE

GPSFJUIFS7"$UISFFQIBTF

TUBOEBSE
PS7"$TJOHMFQIBTF
FOR C OPERATION: 4XJUDIUP$POGSPOUQBOFM
FUSE REQUIREMENTS (15 AMP ONLY):

"#$'VTFT #VTTNBOPOMZ

NOTE:
TQBSFGVTFTJODMVEFEXJUINPEVMF
WARRANTY: 5XPZFBST FYDMVEJOHUSJBDBOEGVTFT
U.S. 800-626-6653
Smart Series Microprocessor-Based Temperature Control Modules

(240 VAC, standard)
ITEM NUMBER
DSS1512
DSS3012
Canada 800-387-6600
(120 VAC, optional)
AMPS WATTS
15
3600
30
7200
ITEM NUMBER
DSS1511
dme@milacron.com
AMPS WATTS
15
1800
www.milacron.com
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.NPEVMFBMTPJODMVEFTB4NBSU4UBSUNPEFUPTBGFMZCBLFPVUEBNBHJOHJOUFSOBM
IFBUFSNPJTUVSFBUTZTUFNTUBSUVQBOEUPQSPMPOHIFBUFSMJGF'BTUPSTMPXMPBENPEFT
NBZBMTPCFTFMFDUFEUPQSPUFDUTNBMMFSIFBUFSTPSDPNQFOTBUFGPSiTMPXwMPBETTVDIBT
FYUFSOBMMZIFBUFENBOJGPMET"OBDDVSBUF EVSBCMFBOEGVMMGFBUVSFENPEVMF UIF54.JT
GVMMZDPNQBUJCMFXJUIBMM4NBSU4FSJFTPS(4FSJFT".1NBJOGSBNFT
|
TSM15 SmartSeries Controller with Default Settings (Factory Settings)
Zone temperature
Standby level
Boost level
Over temperature range
Under temperature range
Ramp
Auto-Manual
Extended alarms for Manual, Standby and
Boost
260C or 500F
100C or 180F
75C or 135F
10C or 18F
On
On
Off
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)

2 Current mode shows set-point
Front Panel Controls

and Indicators
3 Percentage power applied

4 Current reading
U.S. 800-626-6653
Canada 800-387-6600
sales@dme.net
www.dme.net
-FBL%FUFDUJPODBQBCJMJUJFT SFGFSFODF54.6TFS.BOVBM
Smart Series
142

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.
Smart Series
ERROR MESSAGE
CAUSE
ACTION
ERR!
-JUUMFPSOPUFNQFSBUVSFSJTFIBTCFFOEFUFDUFEJOUIBU
[POF8IFOUIFDPOTPMFTUBSUTUPBQQMZQPXFSJUFYQFDUT
UPTFFBOFRVJWBMFOUIFBUSJTFBUUIFUIFSNPDPVQMF*GUIF
UIFSNPDPVQMFIBTCFFOUSBQQFEBOEQJODIFEFMTFXIFSF
JOUIFUPPMPSDBCMFUIFOJUDBOOPUTFOTFUIFGVMMIFBUSJTFUIBU
PDDVSTBUUIFUJQ*GMFGUVODPSSFDUFE UIFSFJTBEBOHFSUIBUUIF
[POFDPVMEPWFSIFBUBOEEBNBHFUIFUJQ*OTUFBEUIFDJSDVJU
NBJOUBJOTUIFPVUQVUBUXIBUFWFSMFWFMJUSFBDIFEXIFOUIF
NPOJUPSDJSDVJUEFUFDUFEUIFGBVMU
$IFDLUIFSNPDPVQMFXJSJOHJUNBZCFSFWFSTFE)FBUFS
XJSJOHNBZCFGBVMUZPSFMFNFOUNBZCFPQFODJSDVJU
FUSE
5IFPVUQVUGVTFGPSUIBU[POFIBTGBJMFE1MFBTFOPUF
"GVTFDBOPOMZGBJMEVFUPBGBVMUFYUFSOBMUPUIFDPOUSPMMFS
*EFOUJGZBOESFDUJGZUIFGBVMUCFGPSFSFQMBDJOHUIFGVTF
/PUF5IFGVTFEFUFDUJPODJSDVJUSFRVJSFTBDPOUJOVPVTMPXMFWFM
DVSSFOUUISPVHIBIJHIJNQFEBODFCMFFESFTJTUPSUPNBJOUBJOUIF
BMBSNDPOEJUJPO"TBSFTVMUUIFMPBEDJSDVJUJTTUJMMDPOOFDUFEUP
UIFNBJOTWPMUBHFTVQQMZBOEJUJTOPUTBGFUPBUUFNQUUPSFQBJS
PSSFQMBDFUIFGVTFXJUIPVUSTUJTPMBUJOHUIFDJSDVJU*GUIFGVTF
JORVFTUJPOJTNPVOUFEPOBDPOUSPMDBSEUIFOJUJTTBGFUPVOQMVH
UIFCPBSEJOPSEFSUPJTPMBUFUIFDJSDVJUBOESFQMBDFUIFGVTFPO
UIFDBSE
3FQMBDFUIFGVTFXJUIPOFPGUIFTBNFSBUJOHBOEUZQF
JF)JHI3VQUVSF$VSSFOUMPBEGVTF5IFCMPXOGVTFJT
MPDBUFE
POUIFDPOUSPMDBSE
GND
5IFTZTUFNIBTEFUFDUFEBOHSPVOEGBVMU
$IFDLZPVSIFBUFSXJSJOHGPSBMPXJNQFEBODFQBUIUP
UIFHSPVOE
LINE
/PNBJOTTVQQMZTZODISPOJ[BUJPOQVMTFTCFJOHSFDFJWFE5IF
QIBTFTVQQMZJTVTFEJOBDSPTTPWFSEFUFDUJPODJSDVJUUPHFOFS
BUFUJNJOHQVMTFTGPSBDDVSBUFQIBTFDPOUSPMBOESJOHUIFUSJBD
*GUIFQIBTFEFUFDUJPOGBJMTPOPOFPSUXPQIBTFTUIFOUIFSFJT
OPQVMTFUPVTFUPNFBTVSFQIBTFBOHMFBOEUIF-*/&FSSPSNFT
TBHFJTHFOFSBUFE.FBOXIJMF BMMDJSDVJUTPOUIFIFBMUIZQIBTFT
XJMMDPOUJOVFUPXPSLOPSNBMMZ
5IFSFJTBQIBTFEFUFDUJPODJSDVJUPOFBDI5.44FSJFT
DBSEBOEBDPNNPOQIBTFEFUFDUJPODJSDVJUPOBMMPUIFS
DPOUSPMMFSUZQFT"MUIPVHIBGBVMUJOTVDIDJSDVJUTNBZ
DBVTFUIF-*/&FSSPSNFTTBHF TVDIGBVMUJTWFSZSBSFMZ
TFFO5IFNPTUDPNNPOFSSPSJTFJUIFSUIFBCTFODFPG
POFQIBTFPS JGBQMVHIBTCFFOSFXJSFEJODPSSFDUMZ B
TXBQQFEQIBTFBOEOFVUSBM*GB-*/&FSSPSNFTTBHFPD
DVSTUIFOTXJUDIPGGBOEJTPMBUFUIFDPOUSPMMFSUIFODIFDL
TVQQMZXJSJOHGPSQSFTFODFPGBMMUISFFQIBTFT
REV
5IFDBSEIBTEFUFDUFEBOBCOPSNBMJOQVUBUUIF5$UFSNJOBUJPO
UIBUJOEJDBUFTBTIPSUFEPSSFWFSTFEUIFSNPDPVQMF
*GUIF3&7BMBSNQFSTJTUT TXJUDIPGGUIFDPOUSPMMFSBOE
JOWFTUJHBUFUIFPGGFOEJOH[POF
"OPQFODJSDVJUUIFSNPDPVQMFIBTCFFOEFUFDUFEBOEOPBVUP
SFTQPOTFIBTCFFOTFMFDUFEJOUIF5$0QFO&SSPSDPMVNOPGUIF
4FUVQQBHF
'PSJNNFEJBUFSFDPWFSZ DIBOHFUPPQFOMPPQDPOUSPM
.BLFBOPUFPGUIFBCPWFBDUJPOTPUIBUXIFOUIF
DPOUSPMMFSJTGSFFZPVDBODIFDLUPTFFXIFUIFSUIFJOQVU
GVTFPOUIFDPOUSPMDBSEIBTSVQUVSFE*GUIFGVTFJTHPPE
UIFOZPVNBZOFFEUPDIFDLUIFXJSJOHGPSGBVMUTPSFWFO
SFQMBDFUIFUIFSNPDPVQMF
T/C
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
1
t1SPWJEFTBMBSNGPSPWFSPSVOEFSUFNQFSBUVSF PSEJBHOPTUJDFSSPS
t1SPWJEFTWJTVBMBOEBVEJCMFJOEJDBUJPOTPGBOBMBSN
t5IFBVEJCMFBMBSN
DBOCFUVSOFEPOPSPGGXJUITXJUDI

t3FMBZDPOUBDUT
BSFQSPWJEFEUPBMMPXIPPLVQPGSFNPUFFRVJQNFOUTVDIBTBMJHIU
BDPOWFZPSPSBNBDIJOFGVODUJPO
t3FMBZDPOUBDUTBSFVOBGGFDUFECZUIFQPTJUJPOTXJUDI
t"OJOGJOJUFOVNCFSPG[POFTPGDPOUSPMDBOCFNPOJUPSFEBTMPOHBTUIFZBSFDPOUBJOFEXJUIJO
UIFTBNFDPNNVOJDBUJPOTTUZMFNBJOGSBNFBTUIF5"4NPEVMF
System Control Functions
6QUP[POFTDBOCFDPOUSPMMFESFNPUFMZBUPOFUJNF5IFTF[POFTNVTUCFDPOUBJOFEXJUIJO
UIFTBNFDPNNVOJDBUJPOTTUZMFNBJOGSBNFBTUIF5"4NPEVMF
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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
t3PUBSZTXJUDI
QSPWJEFTSFNPUFDPOUSPMPG%44 %44 $44
44. BOE44.
t$POUSPMNPEVMFTDBOBMMCFDPNNBOEFEUPSFTQPOEGSPN/03."-UP*%-& 4UBOECZ)FBU
t*O*%-& UIFNPEVMFTXJMMBEKVTUUPBTFUUJOHPG$ '

&YDFQUJPOT44.BOE44.BEKVTUUPBTFUUJOHPG$ '

t.PWJOHUIFSPUBSZTXJUDICBDLUP/03."-SFTUPSFTBMMNPEVMFTUPUIFJSFTUBCMJTIFETFUQPJOUT
t5IFVTFSDBOTFMFDU*%-&GPSUFNQPSBSZMPXFSJOHPGBMM[POFTUPQSFWFOUNBUFSJBMEFHSBEBUJPO
t5IJTGFBUVSFDBOCFVTFEUPLFFQIFBUFSTXBSNFOPVHIUPQSFWFOUBCTPSQUJPOPGNPJTUVSF
Smart Series
NORMAL / IDLE
144
Smart Series

NOTE: 4UBOEBSE 7"$
NPEVMFTBSFDPNQBUJCMFXJUINBJOGSBNFTXJSFEGPSFJUIFS7"$

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

VOLTS
NOTE:
5"4NPEVMFJTOPUDPNQBUJCMFXJUIPMEFS$44((PS%44((NPEVMFT
TAS Module Compatibility

FUNCTIONS
ALARM IDLE
MODULE
MODULE
BOOST
OFF
BOOST
BOOST
5IFi#0045wTFUUJOHJTUIF/03."-TFUQPJOUQMVT PSGPSFYBNQMF

iGTFUQPJOU'BOE#0045JT UIFO#0045UFNQFSBUVSF'
NORMAL
NORMAL
Remote
Control
Functions
i/03."-wPQFSBUJPOJTBTUIPVHI
UIF5"4NPEVMFJTOPUQSFTFOU
IDLE
i*%-&w 4UBOECZIFBU
SFEVDFTIFBUUP'PS'
IDLE
93C (200F)
or
100C (212F)
i0''wDVUTQPXFSUPUIFIFBUFS
5IFVTFSDBONPOJUPSDPPMEPXO
OFF
AMBIENT
|
Smart Series
OFF
CSS1502/01
CSS3002
SSM15G
SSM15G1
SSM30G
SSM1502/01/12/11
SSM3002/12
DSS1502/01/12/11
DSS3002/12
TSM1512
FUNCTIONS
ALARM IDLE BOOST
TIME
Upgrade Kits For Converting to Communications Mainframes

ITEM NUMBER
MAIN FRAME
ITEM NUMBER
MAIN FRAME
CIK4
4-ZONE
CIK28
28-ZONE
CIK5
5-ZONE
CIK32
32-ZONE
CIK7
7-ZONE
CIK36
36-ZONE
CIK8
8-ZONE
CIK40
40-ZONE
CIK11
11-ZONE
CIK44
44-ZONE
CIK12
12-ZONE
CIK48
48-ZONE
CIK16
16-ZONE
CIK2HP
2-ZONE HIGH POWER
CIK20
20-ZONE
CIK3HP
3-ZONE HIGH POWER
CIK24
24-ZONE
CIK5HP
5-ZONE HIGH POWER
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
145
Replacement Parts and Service Items for DME

Smart Series
Connectors / Connector Kits (5-48 zone, 15 Amp; 2-5 zone, 30 Amp)

REFERENCE
LETTER
DESCRIPTION
ITEM NUMBER
.PME5IFSNPDPVQMF0VUQVU$POOFDUPS
TFFQBHF
.PME1PXFS*OQVU$POOFDUPS
TFFQBHF
.PME&OE,JUGPS;POF5IFSNPDPVQMF$BCMF PS".1
$,5'(
$,5'(
$,5'(
D
E
.PME&OE,JUGPSBMMPS".11PXFS$BCMFT
$,1'#(
.PME&OE,JUGPSBMMPS;POF".11PXFS$BCMFT
$,1'$(
.PME&OE,JUGPSBMM;POF".11PXFS$BCMFT
$,1'$(
'SBNF&OE,JUGPSBMM5IFSNPDPVQMF$BCMFT PS".1
$,5'"(
'SBNF&OE,JUGPSBMMPS".11PXFS$BCMFT
$,1.#(
'SBNF&OE,JUGPSPS;POF".11PXFS$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
$,1'$(
&EHF$BSE$POOFDUPS,JUGPSBMM.BJOGSBNF1$#PBSET PS".1
$,'(
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Replacement Parts for Smart Series Temperature Control Systems
NOTE: 'PSVQQFSJOTJEFDPNNVOJDBUJPOTDPOOFDUPST TFFQSFWJPVTQBHF
146
Smart Series

Smart Series
Mainframe, Cable Components, and Service Tools*

CBD10M
CBD20M
CBD30M
CBD50
CBD70
PIN0114
PIN0214
PIN0120
PIN0220
WHT1919
RPM0048
RPM0038
RPM0044
RPM0046
RPM0059
RPM0060
RPM0061
RPM0062
RPM0063
RPM0064
RPM0065
RPM0066
RPM0067
RPM0068
RPM0069
RPM0070
RPM0071
RPM0072
RPM0073
10 AMP 2 POLE, CIRCUIT BREAKER USED IN MFP1G AND MFP1G1

20 AMP 2 POLE, CIRCUIT BREAKER USED IN MFR2G
30 AMP 2 POLE, CIRCUIT BREAKER USED IN MFFPR2G AND MFHP1G
50 AMP 3 POLE, CIRCUIT BREAKER USED IN 5 THROUGH 12 ZONE MAINFRAMES
70 AMP 3 POLE, CIRCUIT BREAKER USED IN 16 THROUGH 48 ZONE & HIGH POWER MAINFRAMES
SEE PREVIOUS PAGE
14 GAUGE MALE PIN FOR B& F POWER CONNECTORS (PACKAGE OF 30)
SEE PREVIOUS PAGE
14 GAUGE FEMALE SOCKET FOR D& H POWER CONNECTORS (PACKAGE OF 30)
SEE PREVIOUS PAGE
20 GAUGE MALE PIN FOR G THERMOCOUPLE CONNECTOR (PACKAGE OF 30)
SEE PREVIOUS PAGE
20 GAUGE FEMALE PIN FOR E THERMOCOUPLE CONNECTOR (PACKAGE OF 30)
CRIMP TOOL FOR ALL PIN-XXXX LISTED ABOVE
EXTRACTION TOOL FOR ALL PIN-TYPE CONNECTOR PINS
NEON INDICATORS USED ON 240 VAC MAINFRAME CIRCUIT BREAKER PANELS
CARD GUIDES FOR ALL MAINFRAMES
PINS FOR WHITE EDGE CARD CONNECTORS I (PACKAGE OF 20)
SEE PREVIOUS PAGE
PANEL MOUNT BASE & LATCH FOR 5-ZONE THERMOCOUPLE MOLD CONNECTION A
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
MALE INSERT FOR 5 ZONE THERMOCOUPLE MOLD CONNECTION A
SEE PREVIOUS PAGE
MALE INSERT FOR 8-ZONE THERMOCOUPLE MOLD CONNECTION A
SEE PREVIOUS PAGE
MALE INSERT FOR 12-ZONE THERMOCOUPLE MOLD CONNECTION A
SEE PREVIOUS PAGE
FEMALE INSERT FOR 5-ZONE THERMOCOUPLE CABLE CONNECTOR C
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
HOOD FOR 5 ZONE THERMOCOUPLE CABLE CONNECTOR C
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
SEE PREVIOUS PAGE
HOOD FOR 5, 8 & 12 POWER & THERMOCOUPLE CABLE CONNECTIONS D,E & F
SEE PREVIOUS PAGE
MALE INSERT FOR B, F & G (15 AMP CONNECTOR RATING IS EXCLUSIVE TO DME)
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
ABC3
ABC5
ABC10
ABC15
RPM0123
RPM0124
NYL0001
RPM0008
RPM0009
RPM0027
RPM0039
RPM0023
RPM0054
RPM0050
RPM0088
1 AMP 250 VAC FUSE

3 AMP 250 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES
5 AMP 250 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES
10 AMP 250 VAC FUSE - NOTE: REQUIRED FOR 15 AMP MODULES USED IN 10 AMP FRAMES
15 AMP 250 VAC FUSE
15 AMP 250 VAC FUSE - ULTRAFAST
.062 AMP TC FUSE FOR TSM MODULES ONLY
NYLATCH MODULE RETENTION PLUNGER AND GROMMET (10/PKG) - NOTE: AT THE BOTTOM OF EACH MODULE
POWER ROCKER SWITCH FOR ALL MODULES EXCEPT DSS AND CSS1524
TRANSFORMER TYPE DST416 FOR ALL MODULES EXCEPT DSS & TAS
ALUMINUM HANDLE FOR 15 AMP MODULES
30 AMP 2 POLE, CIRCUIT BREAKER FOR MODULES
TRIAC - TYPE Q6040P 40 AMP 600 VOLT FOR USE ON ALL MODULES
TRIAC - TYPE BTA40800B 40 AMP 800 VOLT FOR USE ON ALL MODULES EXCEPT CSS
2200 OHM FLAME PROOF FUSIBLE LINK RESISTOR USED IN THERMOCOUPLE CIRCUIT (10/PK) USED ON ALL MODULES
A/D CONVERTER FOR SSM15G, SSM15G1, SSM30G, SSH1001, SSH-1002 AND ALL CSS MODULES
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
147

Smart Series
|
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
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
OPTION A
(Standard)
208 240 VAC, Three-Phase, 4-Wire Delta

or Y Power Distribution System
Smart Series
Input Power Wiring Diagrams (Option A)
NOTE: 'PSNPMEQPXFSBOEUIFSNPDPVQMFDPOOFDUPSXJSJOHJOGPSNBUJPO TFFQBHFT
"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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series
149
Input Power Wiring Diagrams (Option B)
OPTION B
380 415 VAC, Three-Phase, 5-Wire

Y Power Distribution System
Smart Series
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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Input Power Wiring Diagrams (Option B)
WARNING: *GFYQPSUPGUIJTTZTUFNJTJOUFOEFE NBLFTVSFUIBUXJSJOHJTSFDPOGJHVSFEGPSUIFDPVOUSZXIFSFJUJTUPCFVTFE
CAUTION NOTE:5IFWPMUBHFTGSPNMJOFUPMJOFJOUIJTTZTUFNBSFUPWPMUT4FWFSFEBNBHFUPNPEVMFBOE
NBJOGSBNFDPVMESFTVMUJGUIJTUZQFPG"$JOQVUTZTUFNJTDPOOFDUFEUPBNBJOGSBNFXJSFEBT015*0/"5IJTUZQFPGQPXFS
EJTUSJCVUJPOJTOPUGPVOEPSJTWFSZVODPNNPOJOUIF6OJUFE4UBUFTCVUJTUIFNPTUDPNNPOTZTUFNGPVOEJONBOZPUIFS
DPVOUSJFTXPSMEXJEF
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

240 VAC, Two-Phase, 4-Wire
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
Input Power Wiring Diagrams (Options C and D)
OPTION C
"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-
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Smart Series Alternate Connectors
151
Alternate Cable Configuration

Mold-Masters to DME Smart Series Conversion Cables
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)
Combination Mold Power and Thermocouple Conversion Cables allow

ease of conversion between Mold-Masters and DME systems
Thermocouple
Zones
PITC1210YFE
Cable
Length
Mainframe
Connector
Mold
Connector
DME G
Series
HBE48
(Mold
Master
MPlug.12)
5
(Frame End)
HBE48
(Mold
Master
MPlug.12)
DME G
Series
5
(Mold End)
10
PITC1220YFE
20
12
Splits
12
PITC1210YME
10
PITC1220YME
20
Works with the following connectors:
PIC12G
U.S. 800-626-6653
MTC12G
Canada 800-387-6600
MPlug.12
dme@milacron.com
www.milacron.com
Mold-Masters to DME Smart Series
Mold Power
Zones
Item Number
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
Husky is a trademark of
Husky Injection Molding Systems
MOLD POWER
THERMOCOUPLE
PICO12
TCO12C10 OR 20G
MTCO12
E
F
MPCO12C10 OR 20G
C
D
PTCO12TB
MTCO8
TCO8C10 OR 20G
E
F
PICO8
MPCO8C10 OR 20G
PTCO8TB
MTCO5
TCO5C10 OR 20G
PICO5
MPCO5C10 OR 20G
C
D
PTCO5TB
12-ZONE MOLD THERMOCOUPLE CONNECTOR
12-ZONE THERMOCOUPLE CABLE; 10' OR 20'

O.A.L.
12-ZONE MOLD POWER INPUT CONNECTOR
12-ZONE MOLD POWER CABLE; 10' OR 20' O.A.L.
12-ZONE TERMINAL MOUNTING BOX
12-ZONES OF CONTROL

O.A.L.
8-ZONES OF CONTROL

O.A.L.
5-ZONES OF CONTROL
Mold-Masters to DME Smart Series
152
HUSKY COMPATIBLE CONTROL SYSTEM COMPONENTS
www.milacron.com
dme@milacron.com
www.milacron.com
13
14
15
16
17
18
19
20
21
22
23
24
PICO12
1
2
3
4
5
6
7
8
1
2
3
4
5
MARKED ON
HEATER
HEATER
VOLTS
9
10
11
12
13
14
15
16
PROBE OR
NOZZLE
HEATER
MEASURED
RESISTANCE
OHMS
t 64&0)..&5&350
CHECK EACH HEATER
POWER LEAD. RESISTANCE
TO GROUND SHOULD BE
GREATER THAN 20,000
OHMS.
t $)&$,3&4*45"/$&
BETWEEN HEATER POWER
LEADS. (SEE CALCULATION
BELOW)
BEFORE POWER
IS CONNECTED:
MARKED ON
HEATER
HEATER
WATTS
ZONE
6 ZONE 1
7 ZONE 2
8 ZONE 3
9 ZONE 4
10 ZONE 5
ZONE 6
ZONE 7
ZONE 8
ZONE 9
ZONE 10
ZONE 11
ZONE 12
6 7 8 9 10
1 2 3 4 5
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
13 14 15 16 17 18 19 20 21 22 23 24
2 3 4 5 6 7 8 9 10 11 12
PICO8
EXAMPLE: (240 VOLTS) (240 VOLTS) 820 WATTS # 70 OHMS

NOTE: ALL GROUNDS MUST BE CONNECTED TO MOLD TO INSURE OPERATOR SAFETY.
MARKED ON
HEATER
HEATER
VOLTS
1
2
3
4
5
6
7
8
9
10
11
12
REAR
VIEW
PICO5
1
2
Z
O
N
E
BEFORE POWER IS
CONNECTED:
TYPE J
T/C ONLY
THERMOCOUPLE LEADS
WHITE (-)
BLACK (+)
2 3 4 5 6 7 8 9 10 11 12
10
REAR
VIEW
ZONE BLK WHT BLK WHT BLK WHT

ZONE 1 1
6
1
9
1
13
ZONE 2 2
7
2
10
2
14
ZONE 3 3
8
3
11
3
15
ZONE 4 4
9
4
12
4
16
ZONE 5 5
10
5
13
5
17
ZONE 6
6
14
6
18
ZONE 7
7
15
7
19
ZONE 8
8
16
8
20
ZONE 9
9
21
ZONE 10
10 22
ZONE 11
11 23
ZONE 12
12 24
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
13 14 15 16 17 18 19 20 21 22 23 24
MOLD THERMOCOUPLE CONNECTORS
DISTRIBUTOR TUBE OR MANIFOLD HEATER (ZONE 1)
MTCO12
MTCO8
MOLD POWER
INPUT CONNECTORS
Canada 800-387-6600
U.S. 800-626-6653
MTC05
HEATER POWER LEADS

153
TYPICAL MOLD CONNECTOR WIRING DIAGRAM (REVISION A)
154
Terminal Box Detail & Mold Connectors

EUROPEAN CONFIGURATION
2
E
Terminal Box Detail & Mold Connectors
E
B
C
Callout Number 1 is special

order with a short lead time;
all other items are in stock
B
D
C
|
CALLOUT
NUMBER
1
ITEM NUMBER
TERMINAL
BOX
PTO5TB
CALLOUT
NUMBER
2
DIMENSIONS
ITEM NUMBER
MOLD
CONNECTOR
PICO5
A
1.50"
B
38mm
4.25"
C
108mm
2.44"
D
62mm
4.88"
E
124mm
4.10"
104mm
PTO5TB
MTCO5
1.50"
38mm
4.25"
108mm
2.44"
62mm
4.88"
124mm
4.10"
104mm
PTO8TB
PICO8
1.50"
38mm
4.99"
127mm
2.44"
62mm
5.61"
142mm
4.10"
104mm
PTO8TB
MTCO8
1.50"
38mm
4.99"
127mm
2.44"
62mm
5.61"
142mm
4.10"
104mm
PTO12TB
PICO12
1.50"
38mm
6.05"
154mm
2.44"
62mm
6.68"
170mm
4.10"
104mm
PTO12TB
MTCO12
1.50"
38mm
6.05"
154mm
2.44"
62mm
6.68"
170mm
4.10"
104mm
PTCO5TB
PICO5
1.50"
38mm
8.84"
225mm
2.44"
62mm
9.47"
241mm
4.10"
104mm
MTCO5
1.50"
38mm
8.84"
225mm
2.44"
62mm
9.47"
241mm
4.10"
104mm
PTCO8TB
PICO8
1.50"
38mm
9.91"
252mm
2.44"
62mm
10.53"
267mm
4.10"
104mm
MTCO8
1.50"
38mm
9.91"
252mm
2.44"
62mm
10.53"
267mm
4.10"
104mm
PTCO12TB
PICO12
1.50"
38mm
12.17"
309mm
2.44"
62mm
12.79"
325mm
4.10"
104mm
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
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
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 12-zone stand
Smart Series 8-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
U.S. 800-626-6653
Attach Shorter Cable Ties to Corners
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Valve Gate C ontrols
ENERGY EFFICIENT, RELIABLE

AND COMPACT HYDRAULIC AND
PNEUMATIC CONTROLS
157
Valve Gate Controls
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
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
t Calibrate analog signals for position, pressure and volumetric settings
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)
SVGP
DESCRIPTION
INCLUDES
SVGP2
2 ZONE PNEUMATIC
SVG12 HMI, 1-2 SOLENOID VALVE BANK
SVGP4
4 ZONE PNEUMATIC
SVGP6
6 ZONE PNEUMATIC
SVGP8
8 ZONE PNEUMATIC
SVGP12
12 ZONE PNEUMATIC
SVG12 HMI, 2-6 SOLENOID VALVE BANKS
SVGPC2
2 ZONE COMPACT PNEUMATIC
SVG12C HMI, 1-2 SOLENOID VALVE BANK
SVGPC4
SVGPC6
SVGPC8
SVGPC12
SVG12C HMI, 2-6 SOLENOID VALVE BANKS
SVGPC
If you do not see the number of controlled zones required in the table above please contact us.
Optional Accessories
ITEM
NUMBER
DESCRIPTION
ITSPTROLLEY
STAND
PNEUPP
PNEUMATIC POWER PACK 500 PSI
U.S. 800-626-6653
Canada 800-387-6600
Pneumatic Power pack

Stand
dme@milacron.com
www.milacron.com
DME Valve Gate Controller Products and Solutions
or Optional 480V three phase
ITEM
NUMBER
Valve Gate Controls
t (2) digital and analog triggers for 2-shot applications
Valve Gate
textControls
text
158
158
DME Pneumatic Sequential

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

t
t
t
t
t
t
t
Digital input sequence start trigger

Digital input triggers programmable sequence triggers
(2) Analog inputs 0-10 volts
Analog input 4-20ma
Remote enable signal from IMM
Fault relay output (dry contact) to IMM
Dry contact or 24VDC input triggering
Controller includes 15ft (4.8m) cables

U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
159
Valve Gate Controls
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)
t Available as standalone controller or semi-integrated into the TSP or TSP Plus
temperature controller
ITEM
NUMBER
DESCRIPTION
SVGH62
2 ZONE HYDRAULIC
SVGH64
4 ZONE HYDRAULIC
SVGH66
6 ZONE HYDRAULIC
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
SVGH122
2 ZONE HYDRAULIC
SVG12 HMI, POWER PACK, 1-2 SOLENOID VALVE BANK, STAND
SVGH124
4 ZONE HYDRAULIC
SVGH126
6 ZONE HYDRAULIC
SVGH128
8 ZONE HYDRAULIC
POWER PACK
PSI
CONSISTS OF
3L-600 PSI
3L-1200 PSI
3L-600 PSI Power pack
SVGH1212
12 ZONE HYDRAULIC
SVGH1216
16 ZONE HYDRAULIC
SVGH1224
24 ZONE HYDRAULIC
SVGH162
2 ZONE HYDRAULIC
SVGH164
4 ZONE HYDRAULIC
SVGH166
6 ZONE HYDRAULIC
SVGH168
8 ZONE HYDRAULIC
SVGH1612
12 ZONE HYDRAULIC
3L-1600 PSI

SVGH1616
16 ZONE HYDRAULIC
SVGH1624
24 ZONE HYDRAULIC
If you do not see the number of controlled zones required in the table above please contact us.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
3L-1200 PSI / 3L-1600 PSI

Power pack
or Optional 480V three phase
text
Valve Gate
textControls
160
160
pageValve
content
DME Sequential
Gate Controller
KEY TECHNICAL FEATURES AT A GLANCE

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

t
t
t
t
t
t
t
Digital input sequence start trigger

Digital input triggers programmable sequence triggers
(2) Analog inputs 0-10 volts
Analog input 4-20ma
Remote enable signal from IMM
Fault relay output (dry contact) to IMM
Dry contact or 24VDC input triggering
Controller includes 15ft (4.8m) cables

U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
161
Valve Gate Controls
VCAP Air Valve Assemblies and 4-Zone Timer

VCAP multi-station air valve assemblies
5IF7$"1TFSJFTPGGFSTTUBUJPO
TUBUJPO
TUBUJPO

TUBUJPO
BOETUBUJPO
WBMWFBTTFNCMJFT5IFTJOHMFTPMFOPJE
WBMWFTBSFTQSJOHSFUVSOFEBOEEFTJHOFEUPSVOGSPN7%$5IFBJS
TVQQMZ NBYJNVNSBUFEQSFTTVSF14*
DBOCFMVCSJDBUFEPSOPOMVCSJDBUFE
oESZBJSJTQSFGFSSFECVUUIFWBMWFJTEFTJHOFEUPUPMFSBUFTPNFNPJTUVSF
2VJDLDPOOFDUTBSFQSPWJEFEPOBMMBJSPVUQVUTUPBDDFQUTUBOEBSEUVCJOH
5IFEFFOFSHJ[FEPVUQVUT VTFEGPSDMPTJOHWBMWFHBUFT GFBUVSFDIFDLWBMWFT
UPFOTVSFUIBUVOVTFEWBMWFTEPOPUMFBLBJS
DESCRIPTION
4-STATION AIR VALVE ASSEMBLY
Valve Gate Controls
ITEM NUMBER
VCAP0400
VCAP0600
VCAP0800
VCAP1000
VCAP1200
Note: Each valve assembly includes a valve cable.
5IF7$5#7BMWF(BUF$POUSPMMFSJTEFTJHOFEUPQSPWJEFUJNFSCBTFEDPOUSPM
PGVQUPGPVSWPMU%$WBMWFTVTFEUPBDUVBUFQOFVNBUJDWBMWFHBUFDZMJOEFSTBT
XFMMBTTPNFIZESBVMJDWBMWFT BOEGFBUVSFTBVTFSGSJFOEMZBVUPSFTFUGFBUVSF*UT
DPNQBDUTJ[FNBLFTJUFYUSFNFMZQPSUBCMFBOESFRVJSFTNJOJNBMTQBDF"TJOHMF
%#DBCMFDPOOFDUTUIFDPOUSPMMFSUPVQUPGPVSSFNPUFMZMPDBUFEWBMWFT
NJOJNJ[JOHXJSJOHBOEBJSDPOOFDUJPOT
ITEM NUMBER
VCTB4000
VCPT0100
DESCRIPTION
4-ZONE PNEUMATIC
HYDRAULIC CONTROLLER
100-FT. LENGTH OF
PNEUMATIC TUBING
Highly accurate DME

solid state timers
feature resolution to
Note: Trigger signal cable included with controller.
1/100 of a second, far

exceeding the industry
standard of 1/10 of
a second.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
VCAP Air Valve Assemblies and 4-Zone Timer
Compact 4-zone pneumatic or hydraulic control unit
Valve Gate Controls
162
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.
6OJUQMVHTEJSFDUMZJOUP%.&4NBSU4FSJFT.BJOGSBNFT
5SJHHFSJOQVUTJHOBMDBOCFHBOHFEUPPQFSBUFNPSFUIBO
POFUJNFSXIFONVMUJQMFVOJUTBSFVTFE 7%$JOQVUPOMZ
5FTUCVUUPO HSFFOMJHIUJOEJDBUFTQPXFSPVU
*OQVUTJHOBMBOEPVUQVUQPXFSDBOCFVTFEGSPNUJNFS
GSPOUQBOFMDPOOFDUPSTPS%.&NBJOGSBNFDBCMFT
:FMMPXMJHIUJOEJDBUFTUSJHHFSTJHOBMCFJOHBQQMJFE
PSUJNFSJOPQFSBUJPO
5IFSNPDPVQMFDBCMFTFSWFTBTUSJHHFSTJHOBMQPXFS
DBCMFTFSWFTBT7%$QPXFSTVQQMZUPBOZ7%$
TPMFOPJEWBMWF
5SJHHFSTJHOBMIBTUXPBWBJMBCMFTPVSDFToESZTFUPG
DPOUBDUTPS7%$JOQVU
DME Single Zone Timer
DME Single Zone Timers (TCM03024D)
Valve Gate Controls
are highly accurate, solid state timers

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.
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Control Systems
163
Technical Support
Customer Power Requirement Worksheet Option A Delta 3-Phase Power 240 VAC
*UJTUIFDVTUPNFSTSFTQPOTJCJMJUZUPNBLFTVSFIJT)PU3VOOFS.PME"QQMJDBUJPOXJMMOPUFYDFFEUIFQPXFSMJNJUBUJPOTPGUIF
%.&)PU3VOOFS$POUSPM4ZTUFN.BJO$JSDVJU#SFBLFS&WFOUIPVHIFBDITMPUNBZCFSBUFEBUBNQT BMMTMPUT$"//05
OFDFTTBSJMZEFMJWFSGVMMQPXFSGSPNBMM[POFTTJNVMUBOFPVTMZ
Record Product Breaker

Size Phase Wattage Not
To Exceed
Record Product Breaker

Size Phase Wattage Not
To Exceed
Record Product
Breaker Size Phase
Wattage Not To Exceed
Breaker Wattage Size Table For Delta 240 VAC 3-Phase Power
BREAKER RATING AMPS
MAXIMUM PHASE WATTS

EACH PHASE A,B,C
CANNOT EXCEED THIS VALUE
MAXIMUM PHASE AMPS

EACH PHASE A,B,C
CANNOT EXCEED THIS VALUE
10 AMP
1,386 WATTS
5.77 AMPS
20 AMP
2,771 WATTS
11.55 AMPS
30 AMP
4,157 WATTS
17.32 AMPS
40 AMP
5,542 WATTS
23.09 AMPS
50 AMP
6,928 WATTS
28.87 AMPS
63 AMP
8,729 WATTS
36.27 AMPS
70 AMP
9,699 WATTS
40.41 AMPS
100 AMP
13,856 WATTS
57.74 AMPS
'PS1IBTF%FMUB1PXFS505"-8"5544RVBSF3PPU
Y7PMUT"$Y".14
."9*.6.1)"4&8"554505"-8"554
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
Technical Support
PHASE C POWER
ZONE #
WATTAGE
3
6
9
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
TOTAL PHASE C WATTS
PHASE B POWER
ZONE #
WATTAGE
2
5
8
11
14
17
20
23
26
29
32
35
38
41
44
47
50
53
56
59
TOTAL PHASE B WATTS
Control Systems
PHASE A POWER
ZONE #
WATTAGE
1
4
7
10
13
16
19
22
25
28
31
34
37
40
43
46
49
52
55
58
TOTAL PHASE A WATTS
Control Systems
164
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.
Control
Control
Systems
Systems
| Technical
| blankSupport
%
.&$PNQBOZ
4UFQIFOTPO)JHIXBZ
.BEJTPO)FJHIUT .*
"UUFOUJPO3FQBJST
All other temperature controls needing repairs send to:
%.&3FQBJST
4UBUF3PVUF4PVUI
"VTUJOCVSH 0)
Canadian Customers:
%.&$PNQBOZ
/PSUIXFTU%S
.JTTJTTBVHB 0/5-7+
"UUFOUJPO3FQBJST

$BMMJGZPVOFFEBEEJUJPOBMIFMQ
1MFBTFFODMPTFDPOUBDUJOGPSNBUJPOBOEBEFTDSJQUJPOPGXIBUQSPCMFNTZPVIBWFCFFOFYQFSJFODJOHXJUIUIFQSPEVDU
5IJTQSPDFEVSFJODMVEFTJUFNTTUJMMVOEFSXBSSBOUZ IPXFWFSGVTFTBOEUSJBDTBSFOPUDPWFSFE
Return for Credit

$BMM%.&64"BUPS%.&$BOBEBBUUPMMGSFF
U.S. 800-626-6653
Canada 800-387-6600
dme@milacron.com
www.milacron.com
DME Mold Technology Catalogs
DME: Your Complete Mold Technologies Provider
Check Out All of the DME Mold Technology Catalogs

And Youll See Why Were an Essential Resource to Thousands of Customers Worldwide!
Equipment and Supplies

From high-speed cutting tools
and finishing and polishing
systems to a vast array of
maintenance, repair and
operation-related products,
the Equipment and
Supplies Catalog is an
invaluable resource for mold
technology professionals.
Industrial Supplies
Featuring the best product
offerings of Northern Supply,
Nickerson and OHS, DME
Industrial Supplies now has
thousands more of the
high-quality, economical
MRO products youve
come to expect from an
industry leader.
DME: Your Complete Mold Technologies Provider
Mold Components
With the largest selection of
mold components available
around the globe, the Mold
Components Catalog has
the products that will help
you meet the unprecedented
demands you face for
speed, cost reduction
and performance.
MUD Quick-Change
Systems
Reduce downtime by as
much as 75 percent with an
innovative approach to fast
production changeovers.
Master Unit Die is the leader
in quick-change systems and
the MUD Catalog offers many
systems that will maximize
your production volume.
DME Mold Technology Catalogs
Mold Bases & Plates

Choose from the worlds widest
selection of mold bases from
uniquely featured, off-the-shelf
solutions to full-featured,
custom-configured offerings.
An array of standard and
specially machined mold
plate sizes gives you
unlimited options.
DME Company USA

29111 Stephenson Highway
Madison Heights, MI 48071
800-626-6653 (toll-free)
248-398-6000
dme@milacron.com
DME Canada
6510 Northwest Drive
Mississauga, ONT
Canada L4V 1J6
800-387-6600 (toll-free)
905-677-6370
dme_canada@milacron.com
DME Mexico
Circuito el Marques Norte, No. 55
Parque Industrial El Marqus
El Marqus, Quertaro, CP 76246
52 442 713 5666
dme_mexico@milacron.com
www.milacron.com
2016 Milacron All rights reserved. Printed in the U.S.A.

Hot Runner Control Systems

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Hot Runner Control Systems

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DME

Hot Runner Systems

Temperature Control Systems

TSP (Touch Screen Panel)......................................110-112

Thermal Gate Hot Runner Systems

Hot Runner Systems

Hot Sprue Bushings

Hot Runner Services

Valve Gate Controller Products &

SVG Pneumatic Control Systems...........................161-161

Obsolete System Replacement Parts

Modular Components Deliver High Performance......102

Alternate Cable Configuration........................................151-152

Blank Panels, Fuses & Crimp Connectors............................. 128

Sales and Ordering Information ............................................... 6

Mainframe Connector Wiring ........................................ 127-128

Replacement Parts (Temp Control) ................................ 145-147

Input Power Wiring Diagrams........................................148-149

Obsolete Hot Runner Replacement Parts........................92-101

Hot Runner Systems

Hot One Components & Accessories ................................ 24-42

Pre-Wired Combination Terminal Mounting Boxes .............. 135

Hot Runner Systems

Hot Runner Systems

To take advantage of any or all of these services, or if

Part prints or system design prints may be sent in the

248-544-5707 (U.S.) fax

905-677-5280 (Canada) fax

DME offers you a wide range of services from

Analyze the best system to fit your needs

Assist in system design

Perform computerized system analysis and resin

Marry your system to the mold base, plates and

Provide quotations for and perform all of the special

Assemble and wire the system

Check mechanical fit of all components and perform

Assist with system start-up and maintenance

Field Sales and Customer Service

All of which gives you ... more time to concentrate on

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

Hot Runner Systems

Terms and Conditions of Sale

(b) The claim of infringement is not based, directly or indirectly,

Returned Goods: No goods are returnable without prior approval,

Hot Runner Systems

Sales and Ordering Information

DME Company, 29111 Stephenson Highway, Madison Heights, Michigan 48071-2330

FAX: You may fax your order to:

DME Customer Service

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 Systems

Hot Runner Warranty

Stellar Hot Runner Hot Halves

Plastic leakage, due to manufacturing defect, within hot

DME Hot One and Stellar Manifold and Components

One (1) year

DME Electrical Parts

One (1) year

DME Mold Controls

Two (2) years

DME Hot One Hot Halves

Hot Runner Systems

DME Hot Runner