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Hot Runner and Controllers Product Handbook
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Hot Runner and Controllers Product Handbook
Product catalog summary
General Hot Runner Information
- Ultra Advantage: Features include reduced gate and stem wear, guaranteed leakproof operation, and ease of maintenance with replaceable components.
- Nozzle Sizes: Various sizes are available, with specific dimensions for different models like Ultra 1000, Ultra 750, and others.
- Melt Flow Index/Viscosity: Provides typical ranges for different resins, indicating their viscosity levels.
Valve Gate Nozzle Stacks
- Key Advantages: Includes options for plunger and taper shut-offs, ease of maintenance, and UltraSeal technology for leakproof operation.
- Gate Quality Guidelines: Factors influencing gate quality include tip/gate variables, manifold variables, and processing variables.
- Valve Stem Actuation Options: Different actuation options like PX, SX, LX, and EX are available, each with specific features and suitable nozzle sizes.
- Product Matrix: Details various gating styles and their applications, including Ultra Helix and other models.
Valve Gate Nozzle Stacks and Pitch Spacing
The document outlines specifications for valve gate nozzle stacks, focusing on pitch spacing and nozzle configurations. Key points include:
The document outlines specifications for valve gate nozzle stacks, focusing on pitch spacing and nozzle configurations. Key points include:
- Minimum pitch spacing is determined by melt channel sizing, with specific part and resin requirements potentially necessitating larger spacing.
- Minimum distances from nozzle drop centers to manifold plate edges are specified, with reduced distances requiring consultation with Husky.
- Nozzles can be grouped in clusters of up to 8, except for Ultra 1000, and systems with more than 16-drop layouts need engineering review.
- Various nozzle sizes and valve stem actuation options are detailed, with specific guidelines for minimum pitch layouts.
Ultra Helix Valve Gate Technology
Ultra Helix Valve Gates offer advanced technology for superior gate quality and longevity. Features include:
Ultra Helix Valve Gates offer advanced technology for superior gate quality and longevity. Features include:
- Valve stem alignment technology to reduce wear and extend gate life.
- Precision gate integrated in the tip for superior gate quality.
- Highly wear-resistant materials and minimized heat loss to the mold.
Application Guidelines
Guidelines for different Ultra Helix models (250, 350, 500, 750, 1000) are provided, detailing:
Guidelines for different Ultra Helix models (250, 350, 500, 750, 1000) are provided, detailing:
- Material compatibility and application recommendations, with specific notes on resin types and viscosity.
- Maximum throughput rates and recommended air pressures for optimal operation.
- Special considerations for abrasive and corrosive materials, as well as color change applications.
Overview: The document is a technical handbook for Hot Runner systems, specifically focusing on valve gate nozzle stacks and UltraSync technology. It provides detailed specifications, procedures, and recommendations for various components and configurations.
Specifications: The handbook outlines specifications for different nozzle series such as Ultra 350, 500, 750, and 1000, including dimensions, pressure ratings, and temperature limits. It also details the materials compatible with these systems, such as PC, PMMA, and PP, among others.
Procedures: Maintenance procedures are specified, including preventative maintenance at 500K cycles and seal replacements every one million cycles. The document also provides guidelines for disassembly and inspection of components.
Standards and Recommendations: Recommendations for air circuit setups are provided, including pressure requirements and solenoid specifications. The document advises on the use of quick exhaust valves and appropriate air hose dimensions to optimize performance.
Product Configurations: The handbook distinguishes between Configure to Order (CTO) and Engineering to Order (ETO) offerings, highlighting the benefits and limitations of each. CTO offers shorter lead times and standard components, while ETO supports custom applications.
UltraSync Technology: UltraSync systems offer synchronized valve stem movement with options for electric, pneumatic, and hydraulic actuation. Benefits include improved consistency, energy savings, and extended component life. The document details the integration with Altanium controllers for enhanced control and monitoring.
Key Features: The document emphasizes features such as constant stem force, close pitch availability, and clean room compatibility. It also highlights the benefits of integrated temperature and servo control for UltraSync-E systems.
Data and Tables: The handbook includes detailed tables with dimensions and specifications for various nozzle sizes and configurations, providing critical data for system setup and operation.
Overview
The document provides a comprehensive guide on the Individual Servo Valve Gate (ISVG) system, focusing on its features, benefits, and integration with the Altanium Controller. The ISVG system offers complete valve stem motion control to enhance molded part quality and consistency, featuring electric servo actuation, synchronized movement, and profiled motion for each valve stem.
Features
The ISVG system supports low cavitation with up to 8 drops and various gating styles. It can handle part fill pressures up to 179.2 MPa and mold temperatures up to 100°C, with a maximum melt temperature of 340°C. The system allows for precise valve stem position adjustments and offers a compact design to minimize shut height.
Technology Comparison
The ISVG system is compared with the UltraSync-E system, highlighting features like repeatable shot-to-shot consistency, constant stem force, and valve stem velocity profiling. The ISVG system supports clean room environments and offers energy savings and extended component life.
Benefits
The ISVG system extends gate and stem longevity, reduces downtime, and minimizes mechanical stress on molds. It provides precise and repeatable valve stem positioning, synchronized actuation, and independent gate opening and closing. The system supports multi-gate molding and allows for valve stem protrusion adjustability.
ISVG with Altanium Controller
The ISVG system can be controlled using the Matrix5 ISVG controller, available in standalone or integrated configurations. The controller offers features like synchronized or sequential mode operation, historical data logging, and integrated temperature control. It also includes safety features and user-configurable inputs and outputs.
Controller Valve Stem Operation Screens
The document details various controller screens for operating the ISVG system, including setup, cycle, open profile, close profile, and sequence screens. These screens allow for configuring and monitoring valve stem operations, setting limits, and viewing motion profiles.
Hot Tip Nozzle Stacks
The document also covers hot tip nozzle stacks, highlighting key advantages like leakproof operation, wide operating temperature ranges, and ease of maintenance. It provides guidelines for gate quality and a product matrix for different gating styles and applications.
The document provides a comprehensive guide on the Individual Servo Valve Gate (ISVG) system, focusing on its features, benefits, and integration with the Altanium Controller. The ISVG system offers complete valve stem motion control to enhance molded part quality and consistency, featuring electric servo actuation, synchronized movement, and profiled motion for each valve stem.
Features
The ISVG system supports low cavitation with up to 8 drops and various gating styles. It can handle part fill pressures up to 179.2 MPa and mold temperatures up to 100°C, with a maximum melt temperature of 340°C. The system allows for precise valve stem position adjustments and offers a compact design to minimize shut height.
Technology Comparison
The ISVG system is compared with the UltraSync-E system, highlighting features like repeatable shot-to-shot consistency, constant stem force, and valve stem velocity profiling. The ISVG system supports clean room environments and offers energy savings and extended component life.
Benefits
The ISVG system extends gate and stem longevity, reduces downtime, and minimizes mechanical stress on molds. It provides precise and repeatable valve stem positioning, synchronized actuation, and independent gate opening and closing. The system supports multi-gate molding and allows for valve stem protrusion adjustability.
ISVG with Altanium Controller
The ISVG system can be controlled using the Matrix5 ISVG controller, available in standalone or integrated configurations. The controller offers features like synchronized or sequential mode operation, historical data logging, and integrated temperature control. It also includes safety features and user-configurable inputs and outputs.
Controller Valve Stem Operation Screens
The document details various controller screens for operating the ISVG system, including setup, cycle, open profile, close profile, and sequence screens. These screens allow for configuring and monitoring valve stem operations, setting limits, and viewing motion profiles.
Hot Tip Nozzle Stacks
The document also covers hot tip nozzle stacks, highlighting key advantages like leakproof operation, wide operating temperature ranges, and ease of maintenance. It provides guidelines for gate quality and a product matrix for different gating styles and applications.
Specifications and Features:
- The nozzle pitch has been increased to 50mm from the standard 44.5mm, and the HR shut height can increase by up to 16mm. The L-dimension can be up to 60mm, with preferred values at 30mm or 40mm.
- Benefits include up to 30% energy savings, minimal impact on mold design, and similar processing windows and heat-up times compared to standard applications.
- Key features include a 14mm height back-up pad, 7mm bottom manifold clearance, low conduction nozzle insulator, larger nozzle bore, modified nozzle housing, and increased clearance on gate insert.
- The nozzle pitch has been increased to 50mm from the standard 44.5mm, and the HR shut height can increase by up to 16mm. The L-dimension can be up to 60mm, with preferred values at 30mm or 40mm.
- Benefits include up to 30% energy savings, minimal impact on mold design, and similar processing windows and heat-up times compared to standard applications.
- Key features include a 14mm height back-up pad, 7mm bottom manifold clearance, low conduction nozzle insulator, larger nozzle bore, modified nozzle housing, and increased clearance on gate insert.
Hot Tip Nozzle Stacks:
- Ideal for high-speed packaging applications with cycle times as low as 3 seconds, injection pressure up to 2413 bar, and throughputs up to 300 g/sec.
- Features robust design, easy maintenance, and various gating options.
- Ideal for high-speed packaging applications with cycle times as low as 3 seconds, injection pressure up to 2413 bar, and throughputs up to 300 g/sec.
- Features robust design, easy maintenance, and various gating options.
Ultra SideGate Overview:
- Target applications include small, long parts, medical market components, and technical market components.
- Offers flexibility with 1, 2, or 4 tips per nozzle, design flexibility in cooling placement, and high gate quality.
- Order guidelines include material compatibility and throughput per gate chart, with specific gate diameter and cooling requirements.
- Target applications include small, long parts, medical market components, and technical market components.
- Offers flexibility with 1, 2, or 4 tips per nozzle, design flexibility in cooling placement, and high gate quality.
- Order guidelines include material compatibility and throughput per gate chart, with specific gate diameter and cooling requirements.
Ultra SideGate Features:
- Tip independent from the nozzle housing, simple integration, and better part quality with less scrap and maintenance cost.
- Features include ceramic insulation, low conduction seal ring, high conduction tip body, anti-tilting fingers, wear-resistant ring, and spring seal.
- Tip independent from the nozzle housing, simple integration, and better part quality with less scrap and maintenance cost.
- Features include ceramic insulation, low conduction seal ring, high conduction tip body, anti-tilting fingers, wear-resistant ring, and spring seal.
PRONTO Overview:
- Offers faster delivery, easy ordering, and no compromise in quality with optimized melt channels.
- Features include optimized processing, flexible pitch, configurable plates, and multi-material options.
- Offers faster delivery, easy ordering, and no compromise in quality with optimized melt channels.
- Features include optimized processing, flexible pitch, configurable plates, and multi-material options.
Design for PRONTO:
- A 5-step process for eligibility includes nozzle length, sprue clearance, pitch spacing, plate sizes, and configurable system options.
- Specific requirements for pitch spacing and plate sizing are outlined to ensure compatibility with standard designs and components.
- A 5-step process for eligibility includes nozzle length, sprue clearance, pitch spacing, plate sizes, and configurable system options.
- Specific requirements for pitch spacing and plate sizing are outlined to ensure compatibility with standard designs and components.
Overview: The document is a technical handbook for Hot Runner systems, specifically focusing on the PRONTO design and Stack Hot Runners. It provides detailed specifications, configurable options, and FAQs related to the PRONTO system, as well as considerations for thermal and valve gate systems in stack hot runners.
PRONTO Design:
- Configurable Options: Includes clamping options with benefits like easy specification and predictable design, electrical options with top locations and standard connectors, and guide pins and interface options available in metric or imperial sizes.
- Utility Locations: Options for water and air fittings from various manufacturers like DME, Festo, Hasco, Parker, and Staubli.
- Custom Cutouts: Installation options for back-up, latch, and bolting cutouts with a manufacturing tolerance of +/- 0.2 mm.
PRONTO FAQs:
- Allowable Items: Customized plate cutouts, sequential valve gate systems, and different nozzle lengths are permissible, subject to engineering review.
- Non-Fitting Items: Special shut-off geometry, contoured gates, and offset injection locations are not compatible with PRONTO but may be available through custom systems.
Stack Hot Runners:
- Overview: Husky offers 2, 3, and 4 level stack manifold systems to increase output per machine. The document details the integration of hot runners into molds.
- Sprue Bars: Standard and split sprue bars are discussed, including their purpose, installation, and pressure limits. The split sprue bar allows for free access to the molding surface and is available in inline and offset configurations.
- Thermal and Valve Gate Considerations: Details on available systems, minimum shutheights, and options for offset stack valve gates are provided.
Key Features and Recommendations:
- Anti-Drool Bushing: Designed to minimize resin drool, with options for standard and ball check configurations.
- General Molder Considerations: Recommendations for operating split sprue bars, including stocking custom items, controlling valve stems, and adjusting mold protection.
Tables and Data: The document includes tables with dimensions for heat shield installation, sprue bar pressure limits, and material compatibility for split sprue bars. Key data points include dimensions in metric and imperial units, pressure limits, and material recommendations.
Overview: The document is a technical handbook for Husky's Hot Runner systems, focusing on maintenance, installation, and refurbishment services. It provides detailed guidelines for preventive maintenance, system specifications, and refurbishment processes.
Preventive Maintenance: The document outlines maintenance intervals for various components of the Hot Runner system, such as the Split Sprue Bar and Nozzle Tip. Key actions include cleaning, visual inspections, and replacement of parts like piston seals every 2 million cycles or 12 months. Husky offers refurbishment services every 4 million cycles or 37 months.
System Specifications: The handbook details the UNIFY and Bolted Manifold systems, highlighting features like easy installation, leak-proof technology, and maintenance-friendly designs. Specifications include nozzle sizes, gating styles, and actuation methods, with dimensions provided for various configurations.
Installation Reference: Detailed installation guidelines are provided for both UNIFY and Bolted Manifold systems, including dimensions and actuation strokes for different nozzle sizes and gating styles.
Flow Simulation Services: Husky offers flow simulation consulting to optimize the injection molding process, addressing issues like filling, packing, cooling, and warpage prediction. Services are categorized into basic (MPA) and advanced (MPI) analyses.
Refurbishment Services: The document describes Husky's refurbishment services, which include cleaning, inspection, and component replacement. The Platinum refurbishment option offers additional benefits like a fixed delivery date, discounted pricing, and a renewed 3-year leak-free warranty.
Warranty and Additional Services: Husky provides a 3-year leak-proof warranty for Hot Tip and Valve Gated Hot Runners, contingent on component replacement during initial inspection. A 6-month warranty is offered on replacement parts.
Maintenance Tasks Overview:
Regular maintenance tasks for valve gate systems are outlined with specific intervals: every 6 months, 1 year, and 3-4 years. Key tasks include cleaning and inspecting various components such as nozzle tip retainers, sprue bushings, and valve gate pistons. Electrical components should be checked against schematics, and manifold backing plates should be cleaned to prevent plastic leakage. Water fittings should be inspected for corrosion, and manifold heaters should be checked for insulation integrity.
Regular maintenance tasks for valve gate systems are outlined with specific intervals: every 6 months, 1 year, and 3-4 years. Key tasks include cleaning and inspecting various components such as nozzle tip retainers, sprue bushings, and valve gate pistons. Electrical components should be checked against schematics, and manifold backing plates should be cleaned to prevent plastic leakage. Water fittings should be inspected for corrosion, and manifold heaters should be checked for insulation integrity.
Controller Overview:
The document provides an overview of Altanium controllers, which are designed for hot runner temperature control. These controllers are available in different models (Neo5, Delta5, Matrix5) supporting various zone configurations. They feature color touchscreens and are optimized for different cavity applications. The controllers come with a 5-year warranty and are equipped with interchangeable control cards.
The document provides an overview of Altanium controllers, which are designed for hot runner temperature control. These controllers are available in different models (Neo5, Delta5, Matrix5) supporting various zone configurations. They feature color touchscreens and are optimized for different cavity applications. The controllers come with a 5-year warranty and are equipped with interchangeable control cards.
Key Advantages of Altanium Controllers:
Altanium controllers utilize Active Reasoning Technology (ART) to enhance temperature control accuracy and repeatability. ART offers over 15 million control combinations, ensuring precise thermal response management. The controllers also feature phase angle and zero-cross power modulation to optimize power delivery and extend heater life. Additional benefits include plastic leak detection, automated mold diagnostics, and heater failure detection, all contributing to reduced downtime and improved process stability.
Altanium controllers utilize Active Reasoning Technology (ART) to enhance temperature control accuracy and repeatability. ART offers over 15 million control combinations, ensuring precise thermal response management. The controllers also feature phase angle and zero-cross power modulation to optimize power delivery and extend heater life. Additional benefits include plastic leak detection, automated mold diagnostics, and heater failure detection, all contributing to reduced downtime and improved process stability.
FTO (Finish to Order) Program:
The FTO program offers a 2-week lead time for controller configurations, with specific regional coverage. The program includes various mainframe, power input, connector, card, and cable choices, allowing for customized configurations.
The FTO program offers a 2-week lead time for controller configurations, with specific regional coverage. The program includes various mainframe, power input, connector, card, and cable choices, allowing for customized configurations.
Dimensions and Interface Features:
The document provides detailed dimensions for Neo5 models and compares interface features across Neo5, Delta5, and Matrix5 controllers. Each model supports a different maximum number of zones and screen sizes, with touchscreen technology allowing for manual boost and standby modes.
The document provides detailed dimensions for Neo5 models and compares interface features across Neo5, Delta5, and Matrix5 controllers. Each model supports a different maximum number of zones and screen sizes, with touchscreen technology allowing for manual boost and standby modes.
Control Features: The document outlines various control features available in the Neo5, Delta5, and Matrix5 systems. These include Soft Start for even heating, Active Reasoning Technology for temperature control, and staging for startup and shutdown. Other features include multi-cycle wet-heater bake-out, zero cross/phase angle control, auto/manual regulation, and power limit settings.
Interface Features: The systems offer an operator interface with features like auto power limiting, at-temperature delay timer, zone recovery features, and security features such as role-based security profiles and lock zone parameters. Calibration features include thermocouple calibration and multi-zone trimming.
Card Features: The systems have an integrated all-in-one design with features like an external heat sink, safety relay, and support for various thermocouple types. They also offer fast power modulation and short circuit detection.
Monitoring Features: Monitoring capabilities include text and bar graph views, multi-group view, mold picture view, and real-time zone charting. Additional features include current and voltage measurement, heater wattage and resistance display, and earth leakage measurement.
Auditing Features: The systems provide blown fuse detection, open/pinched/reversed T/C detection, ground fault detection, and data logging. They also offer real-time zone charting and power deviation monitoring.
Connectivity and Communication Features: The systems support online help, multi-language support, PDF and image storage, and networking capabilities. They also offer remote standby input and wireless network connection.
Diagnostic Features: Diagnostic capabilities include mold diagnostics routine, thermodynamic mold analysis, X-talk, and the ability to detect and rewire a miswired mold. Mold test comparisons and export mold test data features are also available.
Overview: The document provides a comprehensive guide on the features and functionalities of the Altanium hot runner and mold control systems, specifically focusing on the Neo5, Delta5, and Matrix5 models. It outlines diagnostic features, optional features, digital I/O options, hardware overview, and advanced features.
Diagnostic Features: The system includes a circuit test for detecting faults such as leakage, power to thermocouple, short circuit, open circuit, and wrong heater. These features are crucial for minimizing damage risks to the controller or hot runner system. Circuit overload detection is also included to alert operators if a heater exceeds the zone capacity.
Optional Features: Various optional features are available, including integrated digital I/O, remote load, part counting, link option, dashboard option, and UltraSync-E Gen2 options for different cavity configurations. These options enhance the system's flexibility and integration capabilities.
Interface Feature Comparison: The document compares the Neo5, Delta5, and Matrix5 models, highlighting differences in features such as power output detection, troubleshooting guides, and various interface options like Modbus, Shotscope NX, and VNC Server.
Digital I/O Options: The system supports various digital input and output signals for remote standby, boost, start, stop, and other functions. These signals facilitate automated control and monitoring of the hot runner system.
Hardware Overview: The Delta5 and Matrix5 models offer advantages such as larger screen sizes, faster boot times, increased setpoint limits, and improved heater failure detection. They also feature high-performance CPUs, SSDs, and fanless industrial PCs for reliability and efficiency.
Advanced Features: Altanium provides a highly integrated control platform for temperature, servo, and valve gate control. It supports data exchange interfaces like automatic file transfer and OPC UA Server for seamless integration with process control systems.
Overview: The document provides detailed information on production monitoring systems that utilize third-party client applications supporting the OPC UA data exchange standard. It focuses on interfaces based on the Euromap 82.2 standard, allowing data exchange in Industry 4.0 solutions.
Interfaces:
- Euromap 82.2 Injection Molding Machine Interface: A paid option for Delta5 and Matrix5 operator interfaces, enabling interaction with injection molding machines supporting Euromap 82.2 for hot runner controllers.
- SPI Injection Molding Machine Interface: Another paid option for Delta5 and Matrix5, interfacing with machines supporting the SPI interface, primarily for Priamus Fill & Cool and Kistler Como systems.
- Shotscope NX Interface: Available for Delta5 and Matrix5, this interface connects with the Husky Shotscope NX system for process and production monitoring.
- TeamViewer Interface: Standard on all Delta5 and Matrix5 interfaces, allowing remote troubleshooting by Husky service personnel.
- Virtual Network Computing (VNC) Server: A paid option for remote control of Altanium screens, intended for use with a clear line of sight.
Network Connections:
- Wired Network Connection: Standard on Neo5, Delta5, and Matrix5 interfaces, required for several data exchange options.
- Wireless Network Connection: Supported by Delta5 and Matrix5, requiring a Netgear A6200 Wi-Fi USB Adapter.
Data Exchange Capabilities: The document includes a table summarizing the data collection, reading, writing, and remote support capabilities of various interfaces across Neo5, Delta5, and Matrix5.
H-Series Card Configurations:
- Details on zone configurations, models, and compatibility with ICC2 cards.
- Startup tests for detecting heater circuit faults, including leakage, power to thermocouple, short circuit, open circuit, and wrong heater issues.
H-Series Card Key Improvements:
- Enhanced troubleshooting and fault mitigation capabilities.
- Improved current and voltage measurement circuits.
- Upgraded processor and communication systems.
H-Series Card Feature Comparison: A comparison of features and benefits between HL and H-Series cards, highlighting improvements in diagnostics, safety, and energy efficiency.
Cables: The document outlines standard cable packages for power and thermocouple connections, including configurations for Husky, DME, and Harting standards.
Connectors and Cable Specifications
The document provides detailed specifications for various types of connectors and cables used in hot runner systems. It includes pin-out configurations for different zones and types of cables such as power cables, thermocouple cables, and interflex cables. The connectors are primarily from the Harting series, with specific models like Han D, Han E, and Han A being mentioned. The cables are available in various lengths, typically ranging from 4.5 to 9 meters.
Standard Cable Packages
The document outlines standard cable packages offered by Husky, including power and thermocouple cables with specific connector configurations. These packages are designed for compatibility with Husky systems and are available in multiple lengths. The document also mentions non-standard cable packages that require custom configurations and may have longer lead times.
Altanium Servo Control System
The Altanium Servo Control system is highlighted as a solution for electrification in hot runner systems, offering benefits over hydraulic or pneumatic systems. Key advantages include greater precision, environmental friendliness, energy efficiency, and reduced maintenance. The system supports various functions such as valve stems, core pulls, and ejector plates.
System Architecture and Features
The Altanium Servo Control system is based on Matrix5 technology, consolidating all functions into a single operator interface. It includes servo drives, linear and rotary axes, and a machine interface for routing I/O and safety signals. The system is scalable and can be integrated with hot runner control.
Screen Overview and User Interface
The document describes the user interface of the Altanium Servo Control system, including features like digital I/O configuration, jogging modes, and multi-step motion profiles. It provides detailed information on setting up axes, defining motion parameters, and configuring alarms and warnings. The system allows for user-defined permissions and supports manual and automatic operation modes.
The document provides detailed specifications for various types of connectors and cables used in hot runner systems. It includes pin-out configurations for different zones and types of cables such as power cables, thermocouple cables, and interflex cables. The connectors are primarily from the Harting series, with specific models like Han D, Han E, and Han A being mentioned. The cables are available in various lengths, typically ranging from 4.5 to 9 meters.
Standard Cable Packages
The document outlines standard cable packages offered by Husky, including power and thermocouple cables with specific connector configurations. These packages are designed for compatibility with Husky systems and are available in multiple lengths. The document also mentions non-standard cable packages that require custom configurations and may have longer lead times.
Altanium Servo Control System
The Altanium Servo Control system is highlighted as a solution for electrification in hot runner systems, offering benefits over hydraulic or pneumatic systems. Key advantages include greater precision, environmental friendliness, energy efficiency, and reduced maintenance. The system supports various functions such as valve stems, core pulls, and ejector plates.
System Architecture and Features
The Altanium Servo Control system is based on Matrix5 technology, consolidating all functions into a single operator interface. It includes servo drives, linear and rotary axes, and a machine interface for routing I/O and safety signals. The system is scalable and can be integrated with hot runner control.
Screen Overview and User Interface
The document describes the user interface of the Altanium Servo Control system, including features like digital I/O configuration, jogging modes, and multi-step motion profiles. It provides detailed information on setting up axes, defining motion parameters, and configuring alarms and warnings. The system allows for user-defined permissions and supports manual and automatic operation modes.
Altanium Servo Control Overview
Specifications and Features:
The Altanium Servo Control system is designed for precise control of servo motors and actuators in injection molding applications. Key features include signal inversion, jogging using index positions, and sequencing of axis/steps with start triggers and hold force applications. The system supports motion profiles with target positions, speed, acceleration/deceleration, and force limits per step. Motion curves display speed and force per indexed motion step, and measured values such as position, move time, and peak force are stored for process history.
Servo I/O Screen:
This screen provides access to all safety and digital I/O channels, allowing users to add labels, invert channels, and configure signals using Boolean logic. Each channel is labeled for easy identification in the electrical schematic.
Motors and Actuators:
The system supports various servo motor configurations, including linear actuators with integrated or bolt-on servo motors. Gearboxes are used to alter torque and speed between the servo motor and the load. Compatible feedback types include resolvers, absolute encoders, and incremental encoders, each with specific advantages and requirements.
Preferred Suppliers:
Husky's preferred suppliers for motors and actuators include Baumueller and Exlar, known for their high-performance servo motors and linear actuators. The system is also compatible with other brands, determined by feedback type compatibility.
Application Assessment:
For new mold designs or retrofitting existing molds, specific information is required for budgetary quotes, including the number of axes, running voltage, motion type, axis function, and more.
Signal Interface:
The signal interface connects the Altanium Servo Controller to the injection molding machine and mold, supporting various signals based on the enclosure size.
Altanium Valve Gate Sequencer (VGS):
The VGS provides pneumatic and hydraulic sequential control for up to 32 valve gates, ideal for multi-gated parts in automotive and consumer electronics. It offers precision control over weld line positioning and supports various configurations and signal interfaces.
Hardware Layout:
VGS control configurations are available in low and high circuit options, with operator interfaces like Delta5 or Matrix5. The system supports multiple signal types, including digital and analog inputs and outputs, for comprehensive control and feedback.
Specifications and Features:
The Altanium Servo Control system is designed for precise control of servo motors and actuators in injection molding applications. Key features include signal inversion, jogging using index positions, and sequencing of axis/steps with start triggers and hold force applications. The system supports motion profiles with target positions, speed, acceleration/deceleration, and force limits per step. Motion curves display speed and force per indexed motion step, and measured values such as position, move time, and peak force are stored for process history.
Servo I/O Screen:
This screen provides access to all safety and digital I/O channels, allowing users to add labels, invert channels, and configure signals using Boolean logic. Each channel is labeled for easy identification in the electrical schematic.
Motors and Actuators:
The system supports various servo motor configurations, including linear actuators with integrated or bolt-on servo motors. Gearboxes are used to alter torque and speed between the servo motor and the load. Compatible feedback types include resolvers, absolute encoders, and incremental encoders, each with specific advantages and requirements.
Preferred Suppliers:
Husky's preferred suppliers for motors and actuators include Baumueller and Exlar, known for their high-performance servo motors and linear actuators. The system is also compatible with other brands, determined by feedback type compatibility.
Application Assessment:
For new mold designs or retrofitting existing molds, specific information is required for budgetary quotes, including the number of axes, running voltage, motion type, axis function, and more.
Signal Interface:
The signal interface connects the Altanium Servo Controller to the injection molding machine and mold, supporting various signals based on the enclosure size.
Altanium Valve Gate Sequencer (VGS):
The VGS provides pneumatic and hydraulic sequential control for up to 32 valve gates, ideal for multi-gated parts in automotive and consumer electronics. It offers precision control over weld line positioning and supports various configurations and signal interfaces.
Hardware Layout:
VGS control configurations are available in low and high circuit options, with operator interfaces like Delta5 or Matrix5. The system supports multiple signal types, including digital and analog inputs and outputs, for comprehensive control and feedback.
Specifications:
The document outlines the specifications for various cables and options available for the Altanium Valve Gate Sequencer (VGS) used in hot runner systems. It includes details on cable types, lengths, and their purposes, such as connecting digital inputs and outputs to injection molding machines (IMM) and connecting 24VDC signals to air valves.
Procedures:
The document provides guidance on configuring the VGS with different circuit configurations, including solenoid outputs and position transducers. It specifies the standard and optional configurations for connecting to Husky air kits and linear position transducers.
Available Options:
Several options are available for the VGS, including Linear Position Transducer Kits, Low Circuit Air Kits, High Circuit Air Kits, and Hydraulic Power Units. Each option includes necessary cables and connectors for compatibility with valve stack control.
Norms and Recommendations:
The document emphasizes the importance of using compatible cables and connectors for optimal performance. It also highlights Husky's commitment to protecting its technical innovations through patents.
Key Data from Tables:
The tables provide detailed information on cable types, lengths, and their specific uses, as well as descriptions of available options for the VGS. This includes the number of circuits supported and the components included in each kit.
Critical Information:
It is crucial to select the appropriate cable and configuration for the specific application to ensure proper functionality. The document also notes that longer lengths for linear position transducers are available upon request.
The document outlines the specifications for various cables and options available for the Altanium Valve Gate Sequencer (VGS) used in hot runner systems. It includes details on cable types, lengths, and their purposes, such as connecting digital inputs and outputs to injection molding machines (IMM) and connecting 24VDC signals to air valves.
Procedures:
The document provides guidance on configuring the VGS with different circuit configurations, including solenoid outputs and position transducers. It specifies the standard and optional configurations for connecting to Husky air kits and linear position transducers.
Available Options:
Several options are available for the VGS, including Linear Position Transducer Kits, Low Circuit Air Kits, High Circuit Air Kits, and Hydraulic Power Units. Each option includes necessary cables and connectors for compatibility with valve stack control.
Norms and Recommendations:
The document emphasizes the importance of using compatible cables and connectors for optimal performance. It also highlights Husky's commitment to protecting its technical innovations through patents.
Key Data from Tables:
The tables provide detailed information on cable types, lengths, and their specific uses, as well as descriptions of available options for the VGS. This includes the number of circuits supported and the components included in each kit.
Critical Information:
It is crucial to select the appropriate cable and configuration for the specific application to ensure proper functionality. The document also notes that longer lengths for linear position transducers are available upon request.
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Hot Runner and Controllers Product Handbook Version 18.1
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Table of Contents Section 1 General Hot Runner Information Section 2 Valve Gate Nozzle Stacks Section 3 UltraSync Section 4 Individual Servo Valve Gate (ISVG) Section 5 Hot Tip Nozzle Stacks Section 6 Ultra SideGate Section 7 PRONTO Section 8 Stack Hot Runners Section 9 UNIFY Section 10 Bolted Manifold System Section 11 Services Section 12 General Controller Information Section 13 Operator Interface Section 14 H-Series Card Section 15 Cables Section 16 Altanium Servo Control Section 17 Valve Gate Sequencer
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General Hot Runner Information Ultra Advantage Ultra Helix • Reduced gate and stem wear • Stem pre-aligned before gate • Superior gate quality with precise stem alignment • Cylindrical shut-off • Industry leading gate longevity • Continuous valve stem guidance UltraSeal • Guaranteed leakproof operation • Less plate deflection • Preload nozzle to manifold Ease of Maintenance • Nozzle tips, thermocouples and heaters are replaceable in the press • Single O-ring operates in a cooled backing plate for reduced maintenance Wear Resistant Tips General Hot Runner Information • Improved longevity when...
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General Hot Runner Information Hot Runner Product Handbook v 18.1
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Nozzle Sizes L-Dim L-Dim Range BL-Dim Range Valve Gate Valve Gate Ultra 750 & Ultra Helix 750 (VG only) Ultra 500 & Ultra Helix 500 (VG only) Ultra 350 & Ultra Helix 350 (VG only) Ultra 250 & Ultra Helix 250 (VG Only) General Hot Runner Information Nozzle Size
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Melt Flow Index / Viscosity Resin Medium Viscosity HDPE LDPE High Viscosity General Hot Runner Information Bars represent typical Melt Flow Index ranges * Resins with no numbers shown are not typically characterized with MFI values. Hot Runner Product Handbook v 18.1
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Valve Gate Nozzle Stacks Key Advantages • O-ring replaceable without pulling valve stems • Double Delta O-ring in cooled backing plate doubles seal life • Tips, nozzle heaters & T/Cs replaceable in the press UltraSeal • 3 year guaranteed leakproof operation • Pre-loads nozzle to manifold • Minimizes plate deflection / bowing UltraGuide/Ultra Helix • • • • Valve stem pre-aligned before gate Reduced gate / stem wear Thermally conductive component for fast start-up Cylindrical (Plunger) shut-off for improved gate quality Valve Gate Nozzle Stacks Valve Gate Stem Shut-off Options • 0˚ shut-off • Ultra...
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Gate Quality Guidelines Factors Influencing Gate Quality Gate detail tolerances Shut-off Style Gate wear Tip / Gate Gate cooling Shut-off style Stem position / length Gate diameter / land Flow balance Thermal balance Variables Melt channel sizing Stem open/close timing Pneumatic pressure Injection speed Processing Variables Melt temperature Mold temperature Cooling time Decompression Valve Gate Nozzle Stacks Hold time Hot Runner Product Handbook v 18.1
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Valve Stem Actuation Options Key points Nozzle Sizes Available Double Delta O-ring design for ease of maintenance Small diameter piston for tight pitch spacing down to 25.4mm (1") Extended maintenance interval design to combat weepage prone resins Double Delta O-ring design for ease of maintenance Up to 200psi (13.8bar) air pressure may be required for proper operation of SX valve gated systems Insufficient air pressure provided to SX piston can lead to stems seizing, sticking, and/or posting on the molded part Ultra 350 Ultra 500 Ultra Helix 350 Ultra Helix 500 Double Delta O-ring design for...
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Valve Stem Actuation Option (continued) Actuation All standard valve gating styles Actuation drive designs o Electric (Servo Motor) UltraSync-E o Hydraulic - UltraSync-H o Pneumatic - UltraSync-P UltraSync Plate Actuation * UltraSync-H not available with Ultra Helix 250 Valve Gate Nozzle Stacks 2-4 Gating styles available - VG, VX, Ultra Helix Plunger only O-rings, cylinder caps, pistons and stems accessible in the press without removing backing plate Limiting factor for tight pitch applications Individual drop airplate or multi-drop airplates are available Ultra 350 Ultra 500 Ultra 750 Ultra...
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Product Matrix - Helix Ultra Helix 500 Excellent gate quality with precise stem alignment. Excellent gate quality with gate hole included in tip Standard Product Valve Gate Nozzle Stacks Gating Style Application Overview Hot Runner Product Handboo
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Product Matrix - Other Application Gating Style VG General purpose valve gate. Suitable for most resins General purpose valve gate for retrofitting into 750 Series VG gate details General purpose valve gate with gate shutoff within the nozzle tip. Typically applied on abrasive applications. Offers simplified gate detail Extended valve gate for improved gate access Double extended valve gate for improved gate access Valve Gate Nozzle Stacks (Double Extended) VG-HP (High Pressure) Single piece valve gate nozzle tip and housing for high pressure applications. (Only for Ultra 500) Typically used...
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Product Matrix - Other Ultra 500 Extended VX for increased gate access and/ or customization of the contact land. Typically applied on Automotive applications. Offers simplified gate detail Extended VX with extra stock tip for contouring Valve gate with gate shutoff within the nozzle tip. For high pressure applications. Typically used for Telecom. Offers simplified gate detail Extended VX with extra stock for increased gate access and tip contouring. Typically applied on Automotive applications (High Pressure) Valve Gate Nozzle Stacks Application Overview Gating Style VX-X XS (Extended Extra...
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Ultra Helix Gate Detail Dimensions Gate Detail Dimensions (mm [in]) Size Gate Detail Valve Gate Nozzle Stacks
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Ultra Helix Gate Detail Dimensions Gate Detail Dimensions (mm [in]) Tip Style Gate Detail Valve Gate Nozzle Stacks * Effective interfacing diameter on manifold plates is 35.0 [1.377"] Ultra Helix VG Tip Diameter Gate Dia
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Valve Gate Detail Dimensions Gate Detail Dimensions (mm [in]) Size Gate Detail Valve Gate Nozzle Stacks Hot Runner Product Handbook v 18.1
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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.