blue series low profile pneumatic guns -...

Blue Series� LowProfile Pneumatic

GunsCustomer Product Manual

Part 1074086A03Issued 9/08

NORDSON CORPORATION • DULUTH, GEORGIA • USAwww.nordson.com

For convenient reference of replacementparts, please place label(s) located in

pocket of back cover on parent machine.

Part 1074086A03 � 2008 Nordson Corporation

For CE Declaration, refer to melter documentation.

Nordson Corporation welcomes requests for information, comments, and inquiries about its products.General information about Nordson can be found on the Internet using the following address:

http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2006.No part of this document may be photocopied, reproduced, or translated to another language without the prior

written consent of Nordson Corporation. The information contained in this publication is subject to change withoutnotice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat,CleanSleeve, CleanSpray, ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate,

DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat,e.dot, EFD, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt,

FoamMix, HDLV, Heli-flow, Horizon, Hot Shot, iControl, iDry, iFlow, isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, LEAN CELL,Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium,

Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod,Porous Coat, PowderGrid, Powderware, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter,Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback,

Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK,Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, u−TAH, Vantage, VersaBlue, Versa-Coat, Versa-Screen,

Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice,Blue Series, Bowtie, Bravura, Check Mate, ClassicBlue, Classic IX, Controlled Fiberization, Control Weave, ContourCoat,CPX, cScan+, Cyclo-Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn,EasyPW, Eclipse, e.dot+, Emerald, Encore, E-Nordson, Equi=Bead, FillEasy, Fill Sentry, Fluxplus, Get Green With Blue,

GreenUV, G-Net, G-Site, iON, Iso-Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue,MiniEdge, Minimeter, MonoCure, Multifil, Myritex, Nano, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI,PicoDot, Pinnacle, Powder Pilot, Powercure, Precise Coat, Process Sentry, Pulse Spray, Quad Cure, Ready Coat,RediCoat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Signature, Smart, SolidBlue, Spectral,Spectronic, SpeedKing, Spray Works, Summit, SureFoam, SureMix, SureSeal, SureWrap, Swirl Coat, TinyCure,

Trade Plus, ThruWave, TrueCoat, Ultra FoamMix, UltraMax, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail,Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their ownpurposes, could lead to violation of the owners’ rights.

Table of Contents i

Part 1074086A03� 2008 Nordson Corporation

Table of Contents

Safety 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Alert Symbols 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Safety Information 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Shutdown 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving System Hydraulic Pressure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . De-energizing the System 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disabling the Guns 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Safety Precautions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Selection 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Identification 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Devices and Spare Parts 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Guidelines 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Supplied Materials 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic and Pneumatic Connections 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Valves 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount the Gun 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect an Air Supply 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Triggering Device 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Hose 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush the Gun 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For all guns except ClassicBlue zero and reduced cavity guns 21 . . . . . . . . For ClassicBlue zero and reduced cavity guns 21 . . . . . . . . . . . . . . . . . . . . . .

Operation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun Module Adjustment 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust a ClassicBlue Zero Cavity Module 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust an Air-Open-Air-Closed Module 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Under 30 bar (450 psi) Hydraulic Pressure 24 . . . . . . . . . . . . . . . Compensating for Low Gun Air Pressure (AOSC Guns) 24 . . . . . . . . . . . . . Return a SolidBlue or SureBead Module to the Factory Setting 25 . . . . . . . .

Table of Contentsii


Troubleshooting 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Table 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedures (DPs) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DP1. Check a Solenoid Valve 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DP2. Check for a Clogged Nozzle or Module 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . DP3. Check Module Operation (AOSC Guns) 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . DP4. Check a Heater 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DP5. Check an RTD 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean Nozzles 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean Nozzles 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect the Gun Wiring 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace a Heater or RTD 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access the RTD or Heater 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace the RTD or Heater 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To replace the RTD 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To replace the heater 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace a Module 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii


Parts 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Illustrated Parts Lists 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClassicBlue Low Profile (LP) Guns 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun-Specific Parts 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Modules 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ClassicBlue Modules 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SolidBlue and SureBead Modules 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Rebuild Kits 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClassicBlue Rebuild Kits 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SolidBlue Rebuild Kits 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SureBead Rebuild Kits 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid Valves 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturn Ring Identification 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Large Cv Saturn Solenoid Part Numbers 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Small Cv Saturn Solenoid Part Numbers 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturn Solenoid Spare Components Part Numbers 51 . . . . . . . . . . . . . . . . . . . . . .

Cordsets 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostats 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Cartridges 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ClassicBlue Low Profile Heater Cartridge Selection 53 . . . . . . . . . . . . . . . . . . . . . SolidBlue Low Profile Heater Cartridge Selection 54 . . . . . . . . . . . . . . . . . . . . . . . .

Saturn Nozzles 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturn Nozzles for SureBead Guns 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Saturn Nozzles 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Nozzles 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturn In-line Filters and Accessories 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun-to-Hose Connectors 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulating Cuffs 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extension Cables 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Accessories 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun Specifications 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cordset Wiring Diagram 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


1Blue Series� Low Profile (LP) Pneumatic Guns

� 2008 Nordson Corporation Part 1074086A03

Blue Series� Low ProfilePneumatic Guns

Safety Read this section before using the equipment. This section contains recommendations andpractices applicable to the safe installation, operation, and maintenance (hereafter referredto as “use”) of the product described in this document (hereafter referred to as“equipment”). Additional safety information, in the form of task-specific safety alertmessages, appears as appropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, and hazardavoidance procedures provided in this document can result in personal injury,including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout this document toalert the reader to personal safety hazards or to identify conditions that may result indamage to equipment or property. Comply with all safety information that follows the signalword.

WARNING! Indicates a potentially hazardous situation that, if not avoided, canresult in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided, canresult in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Equipment Safety Information

This equipment safety information is applicable to the following types of Nordsonequipment:

� hot melt and cold adhesive application equipment and all related accessories

� pattern controllers, timers, detection and verification systems, and all other optionalprocess control devices

Blue Series� Low Profile (LP) Pneumatic Guns2


Equipment Shutdown

To safely complete many of the procedures described in this document, the equipment mustfirst be shut down. The level of shut down required varies by the type of equipment in useand the procedure being completed. If required, shut down instructions are specified at thestart of the procedure. The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulic connection orseal. Refer to the melter-specific product manual for instructions on relieving systemhydraulic pressure.

De-energizing the System

Isolate the system (melter, hoses, guns, and optional devices) from all power sourcesbefore accessing any unprotected high-voltage wiring or connection point.1. Turn off the equipment and all auxiliary devices connected to the equipment (system).

2. To prevent the equipment from being accidentally energized, lock and tag the disconnectswitch(es) or circuit breaker(s) that provide input electrical power to the equipment andoptional devices.

NOTE: Government regulations and industry standards dictate specific requirementsfor the isolation of hazardous energy sources. Refer to the appropriate regulation orstandard.

Disabling the Guns

All electrical or mechanical devices that provide an activation signal to the guns, gunsolenoid valve(s), or the melter pump must be disabled before work can be performed on oraround a gun that is connected to a pressurized system.1. Turn off or disconnect the gun triggering device (pattern controller, timer, PLC, etc.).

2. Disconnect the input signal wiring to the gun solenoid valve(s).

3. Reduce the air pressure to the gun solenoid valve(s) to zero; then relieve the residual airpressure between the regulator and the gun.



General Safety Warnings and Cautions

Table 1 contains the general safety warnings and cautions that apply to Nordson hot meltand cold adhesive equipment. Review the table and carefully read all of the warnings orcautions that apply to the type of equipment described in this manual.

Equipment types are designated in Table 1 as follows:HM = Hot melt (melters, hoses, guns, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, and guns)

Table 1 General Safety Warnings and Cautions

EquipmentType

Warnings and Cautions

HM

WARNING: Hazardous vapors! Before processing anypolyurethane reactive (PUR) hot melt or solvent-basedmaterial through a compatible Nordson melter, read andcomply with the material’s MSDS. Ensure that the material’sprocessing temperature and flashpoints will not be exceededand that all requirements for safe handling, ventilation, first aid,and personal protective equipment are met. Failure to complywith MSDS requirements can cause personal injury, includingdeath.

HM

WARNING: Reactive material! Never clean any aluminumcomponent or flush Nordson equipment with halogenatedhydrocarbon fluids. Nordson melters and guns containaluminum components that may react violently withhalogenated hydrocarbons. The use of halogenatedhydrocarbon compounds in Nordson equipment can causepersonal injury, including death.

HM, CA

WARNING: System pressurized! Relieve system hydraulicpressure before breaking any hydraulic connection or seal.Failure to relieve the system hydraulic pressure can result inthe uncontrolled release of hot melt or cold adhesive, causingpersonal injury.

HM

WARNING: Molten material! Wear eye or face protection,clothing that protects exposed skin, and heat-protective gloveswhen servicing equipment that contains molten hot melt. Evenwhen solidified, hot melt can still cause burns. Failure to wearappropriate personal protective equipment can result inpersonal injury.

Continued...



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)

EquipmentType Warnings and Cautions

HM, PC

WARNING: Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt guns. Beforeworking on or near an operating gun, disable the gun’striggering device and remove the air supply to the gun’ssolenoid valve(s). Failure to disable the gun’s triggering deviceand remove the supply of air to the solenoid valve(s) canresult in personal injury.

HM, CA, PC

WARNING: Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker,the equipment may still be connected to energized auxiliarydevices. De-energize and electrically isolate all auxiliarydevices before servicing the equipment. Failure to properlyisolate electrical power to auxiliary equipment before servicingthe equipment can result in personal injury, including death.

HM, CA, PC

WARNING: Risk of fire or explosion! Nordson adhesiveequipment is not rated for use in explosive environments andshould not be used with solvent-based adhesives that cancreate an explosive atmosphere when processed. Refer to theMSDS for the adhesive to determine its processingcharacteristics and limitations. The use of incompatiblesolvent-based adhesives or the improper processing ofsolvent-based adhesives can result in personal injury,including death.

HM, CA, PC

WARNING: Allow only personnel with appropriate training andexperience to operate or service the equipment. The use ofuntrained or inexperienced personnel to operate or service theequipment can result in injury, including death, to themselvesand others and can damage to the equipment.

Continued...



EquipmentType

Warnings and Cautions

HM

CAUTION: Hot surfaces! Avoid contact with the hot metalsurfaces of guns, hoses, and certain components of themelter. If contact can not be avoided, wear heat-protectivegloves and clothing when working around heated equipment.Failure to avoid contact with hot metal surfaces can result inpersonal injury.

HM

CAUTION: Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting toprocess PUR in equipment not specifically designed for thispurpose can damage the equipment and cause prematurereaction of the hot melt. If you are unsure of the equipment’sability to process PUR, contact your Nordson representativefor assistance.

HM, CA

CAUTION: Before using any cleaning or flushing compoundon or in the equipment, read and comply with themanufacturer’s instructions and the MSDS supplied with thecompound. Some cleaning compounds can reactunpredictably with hot melt or cold adhesive, resulting indamage to the equipment.

HM

CAUTION: Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipateplasticizer. Certain hot melt materials can react with Type Rfluid and form a solid gum that can clog the equipment. Beforeusing the equipment, confirm that the hot melt is compatiblewith Type R fluid.

Other Safety Precautions � Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, or leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.



First Aid

If molten hot melt comes in contact with your skin:1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melt has cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hot melt to themedical personnel providing treatment.

Safety Labels and Tags

Figure 1 illustrates the location of the product safety labels and tags affixed to theequipment. Table 2 provides an illustration of the hazard identification symbols that appearon each safety label and tag, the meaning of the symbol, or the exact wording of any safetymessage.

1

2

3 5

4

Figure 1: Safety labels and tags



Table 2 Safety Labels and Tags

Item Part Description

1. 178475 WARNING: Hot Surface! Before touching the gun body,allow the gun to cool, or wear heat-protective gloves.Failure to allow the gun body to cool or to wearheat-protective gloves may cause personal injury.

2. 600137 WARNING: Disconnect power and remove systempressure before disassembly or maintenance. Failure tofollow these instructions may result in serious personalinjury.

3. 243352 WARNING: Fire, injury, or equipment damage canresult if cleanout materials do not meet the followingrequirements:

A. Minimum flashpoint to be 550�F (288�C).

B. Liquid and vapor to be non-toxic at use temperature inequipment.

C.Chemical reactions with adhesive and equipmentmaterials must not be violently heat producing.

D.Cleanout material must not corrode or otherwiseweaken equipment materials.

4. 600103 CAUTION: This gun is RTD (resistance temperaturedetector) controlled. Prior to operation and beforechanging adhesive, consult instruction manual forchanging operating temperature. Failure to followinstructions may result in personal injury or propertydamage.

5. 243352 CAUTION: This equipment is factory tested withNordson type R fluid containing Polyester Adipateplasticizer. Certain adhesives may reactwith the type R fluid residue to form solid gum, whichcan be difficult to remove.To avoid equipment damage,check with adhesive supplier regarding compatibilityand cleanout procedure before putting adhesive into thesystem.



Description Blue Series low profile pneumatic hot melt guns (ClassicBlue�, SolidBlue� andSureBead®) have an EasyOn� module mounting design that provides machined surfaceson both the gun body and the module.

EasyOn technology provides� Guided, one-way fit

� Easier, safer installation, especially on gun bodies located deep within machines

� Backward compatibility (modules fit existing Nordson gun bodies).

Blue Series guns use new Saturn® solenoid valves and Saturn nozzles.

Blue Series guns are characterized by the type of module installed. Figure 3 shows the keycomponents of a Blue Series low profile gun. Table 3 describes the different modules usedwith the guns.

NOTE: Blue Series guns are available in multiple-module and water-wash designs.Refer to ClassicBlue Low Profile (LP) Guns under Parts for the available LP gunconfigurations.



Figure 2: Blue Series gun with EasyOn design

1

2

3

5

4

67

Figure 3: Blue Series gun components (ClassicBlue module shown)

1. Cordset

2. Mounting bracket

3. Module

4. Nozzle (sold separately)

5. Manifold

6. Hose connector

7. Location of port for air supplyconnection

10 Blue Series� Low Profile (LP) Pneumatic Guns


Mo

du

le S

elec

tio

n

Tabl

e 3

Blu

e S

erie

s G

un M

odul

es

Mo

du

le T

ype

Ch

arac

teri

stic

sD

escr

ipti

on

Cla

ssic

Blu

e�

Cla

ssic

Blu

e st

anda

rd m

odul

e,ad

just

able

(al

low

s ch

ange

s in

bea

dpl

acem

ent)

�A

ir-op

en, s

prin

g-cl

ose

(AO

SC

)op

erat

ion

�A

ccom

mod

ates

Sat

urn

sing

le-o

rific

e an

d rig

ht-a

ngle

nozz

les

Cla

ssic

Blu

e gu

ns a

re th

e in

dust

ry s

tand

ard

for

disp

ensi

ng c

onve

ntio

nal h

ot m

elt a

dhes

ives

. The

ball

and

seat

des

ign

assu

res

clea

n cu

toff

at th

eno

zzle

. Cla

ssic

Blu

e gu

ns a

re s

uita

ble

for

low

-to-

med

ium

spe

ed a

pplic

atio

ns.

Cla

ssic

Blu

erig

ht-a

ngle

�C

lass

icB

lue,

rig

ht-a

ngle

mod

ule,

adju

stab

le (

allo

ws

chan

ges

in b

ead

plac

emen

t)

�A

ir-op

en, s

prin

g-cl

ose

(AO

SC

)op

erat

ion

�In

clud

es a

n in

tegr

ated

rig

ht-a

ngle

nozz

le

Cla

ssic

Blu

e rig

ht-a

ngle

gun

s pr

ovid

e 90

-deg

ree

appl

icat

ion

flexi

bilit

y fo

r lo

w-t

o-m

ediu

m s

peed

appl

icat

ions

.

Cla

ssic

Blu

ere

duce

dca

vity

�C

lass

icB

lue

redu

ced

cavi

ty m

odul

e,ad

just

able

(al

low

s ch

ange

s in

bea

dpl

acem

ent)

�A

ir-op

en, s

prin

g-cl

ose

(AO

SC

)op

erat

ion

�A

vaila

ble

in fo

ur o

rific

e si

zes

Cla

ssic

Blu

e re

duce

d ca

vity

gun

s ha

ve a

n in

tegr

ated

nozz

le a

nd n

eedl

e as

sem

bly

that

res

ults

inse

lf-cl

eani

ng a

ctio

n an

d sh

arp

cuto

ff. W

hen

used

inlo

w to

med

ium

spe

ed a

pplic

atio

ns, r

educ

ed c

avity

guns

pro

vide

clo

g-fr

ee/m

inim

um d

rip o

pera

tion,

unifo

rm b

eads

, and

con

sist

ent f

low

ove

r a

wid

era

nge

of te

mpe

ratu

res.

Con

tinue

d...

Blue Series� Low Profile (LP) Pneumatic Guns 11


Gu

n T

ype

Ch

arac

teri

stic

sD

escr

ipti

on

Cla

ssic

Blu

eze

ro c

avity

(ZC

) an

dze

ro c

avity

case

sea

ling

(ZC

S)

�C

lass

icB

lue

zero

cav

ity m

odul

ew

ith m

icro

-adj

uste

r

�A

ir-op

en, s

prin

g-cl

ose

(AO

SC

)op

erat

ion

�A

vaila

ble

in s

ix o

rific

e si

zes

Use

Cla

ssic

Blu

e ze

ro c

avity

gun

s in

crit

ical

appl

icat

ions

that

req

uire

con

sist

ent

no-c

log/

no-d

rip o

pera

tion,

pre

cise

bea

dpl

acem

ent,

and

extr

usio

n co

ntro

l. T

hecl

ose-

tole

ranc

e, m

atch

edno

zzle

-and

-nee

dle

asse

mbl

y el

imin

ates

the

form

atio

n of

min

ute

adhe

sive

poc

kets

that

can

lead

to n

ozzl

e cl

oggi

ng, d

rool

, and

adhe

sive

str

ingi

ng. T

he m

ovem

ent o

f the

need

le w

ithin

the

nozz

le c

reat

es a

self-

clea

ning

act

ion,

min

imiz

ing

bloc

kage

san

d re

duci

ng m

aint

enan

ce. A

pplic

atio

ns fo

rth

ese

guns

incl

ude

high

-spe

ed c

arto

ning

,ca

se s

ealin

g, c

ap li

ning

, non

wov

ens

side

seam

ing

and

elas

tic a

ttach

men

t, bo

ndin

g,an

d ga

sket

ing.

Zer

o ca

vity

gun

s fe

atur

e a

pate

nted

mic

ro-a

djus

t mod

ule.

A m

icro

met

erad

just

men

t scr

ew a

t the

top

of th

e m

odul

eca

n re

duce

adh

esiv

e flo

w b

y up

to 3

0pe

rcen

t. A

dditi

onal

ly, m

inor

var

iatio

ns in

bead

pos

ition

can

be

achi

eved

via

a lo

adad

just

men

t mec

hani

sm. T

hese

adj

ustm

ents

are

espe

cial

ly b

enef

icia

l in

high

-spe

ed,

mul

ti-m

odul

e gu

n ap

plic

atio

ns.

Cla

ssic

Blu

eze

ro c

avity

exte

nded

nozz

le(Z

CE

)

Con

tinue

d...



Mo

du

le S

elec

tio

n (

cont

d)

Tabl

e 3

Blu

e S

erie

s G

un M

odul

es (

cont

d)

Gu

n T

ype

Fea

ture

sA

pp

licat

ion

Sol

idB

lue

S�

Sol

idB

lue

S s

tand

ard

mod

ule,

sprin

g-te

nsio

n ad

just

able

(no

tst

roke

-adj

usta

ble)

�A

ir-op

en, s

prin

g-cl

ose

(AO

SC

)op

erat

ion

�A

ccom

mod

ates

Sat

urn

sing

le-o

rific

e an

d rig

ht-a

ngle

nozz

les

Sol

idB

lue

S g

uns

prov

ide

long

er li

fe th

anC

lass

icB

lue

guns

and

del

iver

exc

eptio

nal a

dhes

ive

cut-

off/

min

imum

-drip

ope

ratio

n fo

r m

ediu

m-t

o-hi

ghsp

eed

appl

icat

ions

.

Sol

idB

lue

A�

Sol

idB

lue

A s

tand

ard

mod

ule,

non-

adju

stab

le

�A

ir-op

en, a

ir-cl

ose

(AO

AC

)op

erat

ion

�F

acto

ry in

stal

led

Sat

urn

sole

noid

valv

e

�A

ccom

mod

ates

Sat

urn

sing

le-o

rific

e an

d rig

ht-a

ngle

nozz

les

Sol

idB

lue

A g

uns

prov

ide

bette

r cu

toff

than

Sol

idB

lue

S g

uns

(bec

ause

of t

he a

ir-op

en, a

ir-cl

ose

oper

atio

n), p

rovi

de e

xten

ded

serv

ice

life

beyo

ndC

lass

icB

lue

guns

, and

del

iver

exc

eptio

nal a

ccur

acy

for

dem

andi

ng a

pplic

atio

ns. S

olid

Blu

e A

gun

s ar

ere

com

men

ded

for

use

with

adh

esiv

es th

at h

ave

avi

scos

ity g

reat

er th

an 1

,250

cps

and

cyc

le r

ates

belo

w 1

5 m

s.

Con

tinue

d...



Tabl

e 3

Blu

e S

erie

s G

un M

odul

es (

cont

d)

Gu

n T

ype

Fea

ture

sA

pp

licat

ion

Sur

eBea

d S

�H

igh

qual

ity p

atte

rns

with

virt

ually

clog

-fre

e op

erat

ion,

eve

n w

hen

usin

g“d

iffic

ult t

o m

achi

ne”

low

and

med

ium

visc

osity

adh

esiv

es

�M

axim

um b

ead

depo

sitio

n ca

pabi

lity

�A

ir-op

en, s

prin

g-cl

ose

(Sur

eBea

d S

)or

air-

open

, air-

clos

e (S

ureB

ead

A)

oper

atio

n

�C

olor

ed r

ing

on th

e re

mov

able

noz

zle

easi

ly id

entif

y or

ifice

siz

e

�N

ozzl

es a

re in

terc

hang

eabl

e—ch

ange

orifi

ce s

izes

with

out r

emov

ing

the

mod

ule

from

the

gun

�N

ozzl

e tip

is m

aint

aine

d re

sulti

ng in

clea

nly

appl

ied

bead

s an

d be

tter

prod

uct s

eals

Sur

eBea

d m

odul

ar h

ot m

elt g

uns

are

desi

gned

for

easy

flus

hing

by

rem

ovin

g th

e no

zzle

from

the

mod

ule.

Noz

zles

use

d w

ith a

Sur

eBea

d gu

n ar

ede

sign

ed to

per

form

sim

ilar

in fu

nctio

n to

red

uced

cavi

ty a

nd z

ero

cavi

ty n

ozzl

es. S

ureB

ead

guns

are

desi

gned

to d

ispe

nse

pack

agin

g gr

ade

adhe

sive

s.

Sur

eBea

d A



Mo

du

le Id

enti

fica

tio

n

The

face

pla

tes

of S

olid

Blu

e an

d S

ureB

ead

mod

ules

are

col

or c

oded

for

easy

gun

and

mod

ule

iden

tific

atio

n. F

igur

e 4

show

s th

e fa

ce p

late

opt

ions

.U

se th

is in

form

atio

n fo

r se

rvic

e an

d re

plac

emen

t nee

ds.

Inte

nd

ed U

se

Blu

e S

erie

s gu

ns a

re d

esig

ned

to b

e rig

idly

mou

nted

, pne

umat

ical

lyop

erat

ed, a

nd tr

igge

red

by a

n el

ectr

ical

ly c

ontr

olle

d so

leno

id v

alve

. Blu

eS

erie

s gu

ns a

re d

esig

ned

for

use

with

Nor

dson

mel

ters

and

hos

es.

Au

xilia

ry D

evic

es a

nd

Sp

are

Par

ts

Blu

e S

erie

s gu

ns s

houl

d on

ly b

e co

nnec

ted

to a

ppro

ved

auxi

liary

dev

ices

.U

se o

nly

new

Nor

dson

rep

lace

men

t par

ts o

r ap

prov

ed fa

ctor

y re

furb

ishe

dpa

rts.

Fig

ure

4: S

olid

Blu

e an

d S

ureB

ead

Iden

tific

atio

n

Blu

e =

Air-

Clo

se

Bla

ck =

Spr

ing-

Clo

se

Gra

y =

Sol

idB

lue

(bal

l and

sea

t)

Tan

= S

ureB

ead

(nee

dle

and

seat

)



Installation The following items must be ordered separately:� extension cables, if needed (such as when a gun has two cordsets and only one hose

will be used)

� solenoid valves for guns that are not configured with solenoid valves

� nozzles, if applicable

Refer to Parts at the end of this manual for some extension cable part numbers. Refer tothe Nordson Adhesive and Sealants Equipment Guide or contact a Nordson representative.

Installation Guidelines

Customer Supplied Materials � Power supply

� 3-conductor signal cable

Mounting � Mount the gun so that the nozzle is no more than 13 mm (1/2 in.) from the substrate.

� Provide room to access the rear or sides of the gun manifold to service and maintain thegun.

� Rigidly support the gun and isolate it from external vibration.

� Thermally insulate the gun from the support (insulator provided).

Hydraulic and Pneumatic Connections � Use only one fitting to connect a hose to a hose connector on the gun.

� Insulate the hose-to-gun joint. Refer to Parts for insulation cuff information.

� Use only clean, dry, non-lubricated air.

� The plant air supply and regulator must provide a minimum of 3.4 bar (50 psig) to the gunsolenoid valve.

Solenoid Valves � Third-party solenoid valves must be able to be manually triggered at the gun.



Mo

un

t th

e G

un

1.

Rel

ieve

sys

tem

pre

ssur

e be

fore

inst

allin

g or

rep

laci

ng a

gun

. Ref

er to

Saf

ety.

See

Fig

ures

5 a

nd 6

to m

ount

a g

un a

nd c

onne

ct a

hos

e.

13 m

m (

1 /2

in.)

Fig

ure

5: L

ocat

ion

of th

e m

ount

ing

bar

for

inst

allin

g an

LP

gun



Fig

ure

6: C

onne

ctin

g a

hose

to a

n LP

gun



Co

nn

ect

an A

ir S

up

ply

See

Fig

ure

7. C

onne

ct a

mod

ule-

actu

atin

g ai

r su

pply

to th

e ai

r su

pply

por

t on

the

back

of t

he g

un m

anifo

ld a

nd th

en c

onne

ct th

e ai

r su

pply

toth

e so

leno

id v

alve

s th

at w

ill c

ontr

ol m

odul

e ac

tuat

ion.

Sol

enoi

d va

lves

mus

t be

conn

ecte

d to

an

air

supp

ly a

nd to

a tr

igge

ring

devi

ce, s

uch

as a

pat

tern

con

trol

ler

or ti

mer

. Sol

enoi

ds w

ork

with

AO

AC

or

AO

SC

gun

s. If

sol

enoi

d va

lves

wer

e no

t spe

cifie

d w

hen

the

gun

was

ord

ered

, the

y m

ust b

e cu

stom

er-in

stal

led.

CA

UT

ION

! R

isk

of s

olen

oid

valv

e fa

ilure

. Sol

enoi

d va

lves

mus

t be

rate

d fo

r th

e ou

tput

vol

tage

of t

he tr

igge

ring

devi

ce (

patte

rnco

ntro

ller,

timer

, PLC

, etc

.) a

nd fo

r us

e in

hig

h-te

mpe

ratu

re a

pplic

atio

ns. R

efer

to In

stal

latio

n G

uide

lines

.

1/8

NP

T

Fig

ure

7: L

ocat

ion

of th

e ai

r su

pply

por

t for

con

nect

ing

a m

odul

e-ac

tuat

ing

air

supp

ly

Blue Series Pneumatic Guns 19


Connect the Triggering Device

Use one of the following power supplies (for CE, UL or CUL compliance):� In North America, use a National Electrical Code (NEC) Class 2 or equivalent power

supply.

� In Europe, use a Protective Extra Low Voltage (PELV) or Safety Extra Low Voltage(SELV) power supply. This supply must provide 24 VDC, have an output limited to 8 A,and must not be capable of providing more than 240 VAC under any fault condition. Thesupply must be certified for use in the country of installation.

1. See Figure 8. Loosen the terminal block screw, and then remove the terminal block. Savethe gasket and screw.

2 31

Figure 8: Solenoid Valve Terminal Block

1. Terminal block screw

2. Terminal block

3. Gasket

CAUTION! Do not pry the terminal block out of the housing. Doing so can damagethe electrical connection pins.

2. See Figure 9. Gently press against the edge of one of the terminal block retaining prongsto remove the terminal block from the housing.

Figure 9: Remove the Terminal Block from the Housing

1 2

Blue Series Pneumatic Guns20


Connect the Hose

CAUTION! Solenoid valves must be rated for the outputvoltage of the triggering device. Make sure the ratingsmatch.

3. Thread a customer-supplied 0.75−0.34 mm2

(18−22 AWG) three-conductor cable through thehousing strain relief.

4. Connect the positive and negative wires of theconductor cable to terminals 1 and 2 (polarity does notmatter), and the ground wire to the ground terminal.

5. Snap the terminal block back into its housing.

6. Align the gasket on the terminal block housing, plug the terminal block into the solenoidvalve, and then secure the terminal block with the screw.

7. Connect the three-conductor cable to the triggering device. Refer to the instructions thatcame with the triggering device.

8. Connect a clean, dry, non-lubricated air supply to Port 3 of the AOSC solenoid, or to Port 1of the AOAC solenoid. The ports on the solenoid valve are numbered for easy reference.

Connect the Hose

NOTE: Refer to the user’s guide shipped with the hose for detailed hose installationguidelines.

1. See Figure 10. Connect the hose swivel fitting to the gun hose connector or in-line filter.Use two wrenches to tighten the hose fitting.

2. Connect the gun cordset to the hose.

3. Connect the hose and hose cordset to the melter.

4. Insulate the hose-to-gun connector.

Figure 10: Connect the Hose (SolidBlue gun without an in-line filter shown)



Flush the Gun

Before the gun is placed into operation, it must be flushed.

CAUTION! This equipment is factory tested with Nordson Type R fluid containingpolyester adipate plasticizer. Certain adhesives may react with the Type R fluidresidue to form a solid gum that can be difficult to remove. Consult with youradhesive supplier to determine the compatibility of your adhesive with Type R fluid.

WARNING! Risk of personal injury or equipment damage. Do not remove thenozzle from SureBead guns until it is time to start the system and flush the guns.The sharp needle on these guns is exposed whenever the nozzle is removed.

1. Disconnect or turn off the solenoid valve triggering device.

2. Heat the system to the operating temperature and pressure. Refer to the melter productmanual and the adhesive instructions as needed.

3. Place a catch pan under the guns.

4. Flush the guns as appropriate for the type of gun:

For all guns except ClassicBlue zero and reduced cavity gunsA. Ensure that all nozzles are removed.

B. Manually trigger the solenoid valve(s).

C.Dispense hot melt until it is clear and free of foreign material.

For ClassicBlue zero and reduced cavity gunsA. Relieve system hydraulic pressure and disable the gun. Refer to Safety.

B. Remove the gun module.

C.Re-pressurize the system; then place the gun into operation.

D.Dispense hot melt from the port(s) in the manifold, increasing the pump output in smallincrements.

E. Stop dispensing when the hot melt is clear and free of foreign material.

5. Check for leaks between the gun, hose, and melter.



Operation

WARNING! SolidBlue S and SureBead S gun modules are adjustable. Adjustingthe gun modules for low air pressure operation without making a correspondingreduction in system hydraulic pressure may cause the gun modules to remainopen. Refer to Gun Module Adjustment to properly adjust the operating airpressure for these modules if the guns must be operated at a low air pressure.

WARNING! SolidBlue A and SureBead A gun modules operate as air-open,air-close valves. The loss or elimination of air pressure to the gun solenoid valvewithout a corresponding reduction in system hydraulic pressure may cause the gunmodules to remain open.

Gun Module Adjustment

Modules are set at the factory for operation prior to shipping. Modules should only be ad-justed if absolutely necessary for application performance. Stroke adjustments can be madeon zero cavity ClassicBlue guns, and spring tension adjustments can be made on SolidBlueS and SureBead S guns. Most applications require no adjustments.

NOTE: Adjusting the spring tension on SolidBlue S and SureBead S guns does notadjust stroke length.

Adjust a ClassicBlue Zero Cavity Module

ClassicBlue zero cavity guns are equipped with a micro-adjuster that allows the nozzle flowrate to be decreased up to 30 percent from the maximum flow rate set at the factory.

WARNING! System pressurized! Relieve system pressure before attempting toadjust the gun. If the micro-adjuster is unscrewed too far, hot melt can be releasedunder pressure. Failure to relieve system pressure can result in personal injury.

1. Relieve system hydraulic pressure and disable the gun. Refer to Safety.

2. See Figure 11. Loosen the locking nut.

12

3

Figure 11: Micro-adjuster on a ClassicBlue Zero Cavity Module

1. Loading screw

2. Locking nut

3. Flow-rate adjusting nut



3. Hold the loading screw in place and turn the flow-rate adjusting nut as follows:

� To decrease the flow rate, turn clockwise.

� To increase the flow rate, turn the counterclockwise.

NOTE: Each quarter-turn of the adjusting nut (clockwise) reduces the stroke of themodule by 0.0254 mm (0.001 in.).

4. Tighten the locking nut.

5. Check the flow rate. Repeat until the desired flow rate is achieved.

Adjust an Air-Open-Air-Closed Module

SolidBlue A and SureBead A guns normally operate at air pressure ranges between3.4−5.5 bar (50−80 psi) and at hydraulic pressure ranges between 30−90 bar (450−1,300psi). However, if an application requires operating at a hydraulic pressure below 30 bar (450psi), adjust the gun air pressure or the gun module. Use these procedures as needed to ad-just SolidBlue A and SureBead A guns for low-pressure operation.



Operating Under 30 bar (450 psi) Hydraulic Pressure

Increase the gun air pressure to operate at a hydraulic pressure as low as 14 bar (200 psi).Refer to Table 4. If 3.4 bar (50 psi) cannot be achieved, go to Compensating for Low Gun AirPressure (AOSC Guns).

Table 4 Increasing Gun Air Pressure to Operate at Low Hydraulic Pressure

To operate at this hydraulic pressure...The minimum gun air pressure

required is...

30−90 bar (450−1,300 psi)* 3.4 bar (50 psi)*

20−90 bar (300−1,300 psi) 4.1 bar (60 psi)

14−90 bar (200−1,300 psi) 4.8 bar (70 psi)

*This is the factory setting.

Compensating for Low Gun Air Pressure (AOSC Guns)

If an application requires gun operation at an air pressure below 3.4 bar (50 psi) and at ahydraulic pressure below 30 bar (450 psi), reduce the gun module spring tension.

NOTE: The needle stroke on SolidBlue and SureBeadmodules cannot be adjusted. Only the module springtension can be adjusted.

WARNING! Risk of burns. Reducing the gun module spring tension also reducesthe maximum hydraulic pressure at which the module will self-relieve or free-flow. Ifthe maximum hydraulic pressure is exceeded, the gun module will remain openand dispense adhesive uncontrollably.

To reduce the gun module spring tension, loosen the locking nut and turn the adjustmentscrew counterclockwise in 1/2-turn increments. Each 1/2 turn reduces the hydraulic pressurecapability by 7 bar (100 psi). Refer to Table 5.



Table 5 Adjusting a SolidBlue and SureBead Module to Operate at Low Gun Air Pressure and Low Hydraulic Pressure

Adjustment ScrewPosition

Maximum Gun AirPressure Available

Minimum HydraulicPressure

Factory setting

3.4 bar (50 psi)

30 bar (450 psi)

Approximately 1/2 turncounterclockwise fromfactory setting

24 bar (350 psi)

Approximately 1 turncounterclockwise fromfactory setting

17 bar (250 psi)

Return a SolidBlue or SureBead Module to the Factory Setting 1. Disable the gun. Refer to Safety.

2. See Figure 11. Loosen the module locking nut.

3. Turn the adjustment screw clockwise only until it bottoms out. Do not over-tighten thescrew.

4. Turn the adjusting screw counterclockwise two revolutions.

5. Hold the adjustment screw in place and tighten the lock nut.

Troubleshooting

WARNING! Risk of personal injury. This equipment contains pressurized hot meltmaterial and high voltage circuits. Read the Safety information provided in thisdocument before completing any troubleshooting procedure. Failure to observesafety messages and hazard-avoidance procedures can result in personal injury,including death.

Troubleshooting Table

The following table lists the gun problems that are most likely to occur, the possible causes ofeach problem, and steps for corrective action. Where applicable, cross-references are madeto expanded diagnostic procedures (DPs) provided later in this section or to other sections ofthis manual.



Pro

ble

mP

oss

ible

Cau

seC

orr

ecti

ve A

ctio

n

1.N

o a

dh

esiv

e o

utp

ut

fro

m a

ny

mo

du

le(s

)A

dhes

ive

leve

l low

Add

adh

esiv

e.

No

inpu

t pow

erV

erify

that

all

disc

onne

ct s

witc

hes

and/

or c

ircui

tbr

eake

rs a

re o

n an

d op

erab

le.

Sys

tem

not

at o

pera

ting

tem

pera

ture

Ver

ify th

at th

e R

EA

DY

ligh

t is

on a

t the

mel

ter

and

that

the

hot m

elt i

s m

olte

n.

Mel

ter,

hose

or

gun

tem

pera

ture

setti

ng to

o lo

w.

Adj

ust.

Ref

er to

the

spec

ific

mel

ter

man

ual.

Air

pres

sure

to g

un to

o lo

w.

Adj

ust.

NO

TE

: M

inim

um 3

.4 b

ar (

50 p

si)

requ

ired.

4.5

bar

(65

psi)

is r

ecom

men

ded.

Ver

ify a

dequ

ate

pres

sure

from

pla

nt a

ir su

pply

.V

erify

that

the

air

pres

sure

reg

ulat

or is

oper

atin

g co

rrec

tly.

Low

or

no h

ydra

ulic

pre

ssur

eR

efer

to th

e hy

drau

lic s

yste

m tr

oubl

esho

otin

gse

ctio

n of

the

mel

ter

man

ual.

Fai

led

sole

noid

Sol

enoi

d m

uffle

r cl

ogge

d. R

epla

ce.

Cle

an o

r re

plac

e so

leno

id. R

efer

to D

P.1,

Che

ck a

Sol

enoi

d V

alve

.

Con

tinue

d...



Co

rrec

tive

Act

ion

Po

ssib

le C

ause

Pro

ble

m

1.N

o a

dh

esiv

e o

utp

ut

fro

m a

ny

mo

du

le(s

)(co

ntd

)C

logg

ed h

ose

Cle

an o

r re

plac

e.

Clo

gged

noz

zle

Cle

an o

r re

plac

e. R

efer

to D

P.2,

Che

ck fo

r a

Clo

gged

Noz

zle

or M

odul

e.

Clo

gged

or

faile

d m

odul

eC

lean

, rep

air

or r

epla

ce. R

efer

to D

P.2,

Che

ckfo

r a

Clo

gged

Noz

zle

or M

odul

e.

Dirt

y or

faul

ty tr

igge

ring

devi

ceS

ervi

ce o

r re

plac

e. R

efer

to th

e m

anua

l tha

tac

com

pani

ed th

e tr

igge

ring

devi

ce.

Fau

lty e

ncod

erC

alib

rate

or

repl

ace.

2.N

o a

dh

esiv

e fr

om

so

me

mo

du

les

(mu

lti-

mo

du

le g

un

s o

nly

)C

logg

ed n

ozzl

eC

lean

or

repl

ace.

Ref

er to

DP.

2, C

heck

for

aC

logg

ed N

ozzl

e or

Mod

ule.

Clo

gged

or

faile

d m

odul

eC

lean

, rep

air

or r

epla

ce. R

efer

to D

P3,

Che

ckM

odul

e O

pera

tion.

Indi

vidu

al m

odul

es n

ot p

rope

rlyad

just

ed.

Adj

ust.

Ref

er to

Gun

Mod

ule

Adj

ustm

ent.

3.U

nco

ntr

olle

d a

dh

esiv

e fl

ow

fro

m m

od

ule

Hyd

raul

ic p

ress

ure

too

high

Adj

ust.

Ref

er to

the

mel

ter

man

ual.

Gun

air

pres

sure

lost

(A

OA

Cm

odul

es o

nly)

Sto

p th

e m

elte

r pu

mp

and

rest

ore

air

pres

sure

.

Mod

ule

faile

d w

ith n

eedl

e in

open

pos

ition

Cle

an, r

epai

r or

rep

lace

. Ref

er to

DP

3, C

heck

Mod

ule

Ope

ratio

n.

Con

tinue

d...



Co

rrec

tive

Act

ion

Po

ssib

le C

ause

Pro

ble

m

3.U

ncon

trol

led

adh

esiv

e flo

w fr

omm

odul

e(co

ntd)

Insu

ffici

ent s

prin

g te

nsio

n(A

OS

C m

odul

es o

nly)

Incr

ease

spr

ing

tens

ion.

Ref

er to

Gun

Mod

ule

Adj

ustm

ent.

Sol

enoi

d fa

iled

or p

orte

din

corr

ectly

Ver

ify th

at th

e so

leno

id is

por

ted

prop

erly

.R

epla

ce th

e so

leno

id if

nec

essa

ry. R

efer

toD

P.1,

Che

ck a

Sol

enoi

d V

alve

.

4.G

un

ove

rhea

ts o

r u

nd

erh

eats

Fai

led

heat

erR

epla

ce. R

efer

to D

P.4,

Che

ck a

Hea

ter.

Fai

led

RT

DR

epla

ce th

e co

rdse

t. R

efer

to D

P.5,

Che

ck a

nR

TD

.

No

pow

erV

erify

that

all

disc

onne

ct s

witc

hes

and/

or c

ircui

tbr

eake

rs a

re o

n an

d op

erab

le.

Impr

oper

tem

pera

ture

set

ting

Adj

ust t

empe

ratu

re. R

efer

to th

e m

elte

rm

anua

l.

Mal

func

tion

in th

e m

elte

r he

ater

cont

rol c

ircui

tR

efer

to th

e m

elte

r m

anua

l to

diag

nose

sho

rtci

rcui

t pro

blem

s.



Diagnostic Procedures (DPs)

The following diagnostic procedures (DPs) are referenced in the Troubleshooting Table.

DP1. Check a Solenoid Valve1. Place the system into operation.

2. Trigger the gun using the timer or pattern controller:

� Adhesive flows—normal indication. Return to the Troubleshooting Table.

� No adhesive flow—go to step 3.

3. Manually trigger the gun at the solenoid valve:

� Adhesive flows—normal indication. Return to the Troubleshooting Table.

� No adhesive flow—go to step 4.

4. Check the solenoid valve coil for continuity:

� Continuity okay—normal indication. Return to the Troubleshooting Table.

� No continuity—failed solenoid valve. Replace the solenoid valve.

NOTE: Verify that the solenoid valve being used has a rated service temperatureabove 85 �C (185 �F).



DP2. Check for a Clogged Nozzle or Module

NOTE: This procedure cannot be used for ClassicBlue right-angle, zero cavity, orreduced cavity guns.

1. Disable the gun. Refer to Safety.

2. See Figure 12. Remove the nozzle.

WARNING! Risk of personal injury or equipment damage. The sharp needle onSureBead guns is exposed whenever the nozzle is removed.

Figure 12: Removing a nozzle

3. Place the gun back into operation.

4. Trigger the gun:

� Adhesive flows—normal indication. Clean the nozzle. Refer to Maintenance.

� No adhesive flow—the module is clogged. Replace the module. Refer to Repair.



DP3. Check Module Operation (AOSC Guns)

NOTE: This procedure assumes that thetriggering device and solenoid valve arefunctioning normally.

1. See Figure 13. Insert a small Allen wrench orsimilar probe into the top of the module.

2. Manually trigger the gun at the solenoid valve:

� Probe moves up and down—normal indication.Return to the Troubleshooting Table.

� Probe does not move—possible failed module.Replace the module. Refer to Repair.

Figure 13: Checking module operation

DP4. Check a Heater1. Disable the gun. Refer to Safety.

2. Unplug the gun cordset from the hose.

3. See Figure 14. Test for continuity across the heater circuit (pins 1 and 2):

� Continuity okay—normal indication. Return to the Troubleshooting Table.

� No continuity—the heater is defective. Replace the heater. Refer to Repair.

1

2

3 4

5

6

1

2

3

5

HEATER

HEATER

RTD

RTD

GND

4

1 2

3 4

5

Figure 14: Gun cordset pins (as viewed from hose end)



DP5. Check an RTD 1. Disable the gun. Refer to Safety.

2. Unplug the gun cordset from the hose.

3. Allow the gun to reach room temperature or use a pyrometer to determine thetemperature of the gun.

4. See Figure 14. When the gun temperature is known, measure the resistance across theRTD circuit (pins 3 and 5).

5. See Figure 15 to determine the expected resistance of the RTD at the knowntemperature. Compare the expected and measured resistance values:

� Measured resistance is within the expected range—normal indication. Return to theTroubleshooting Table.

� Measured resistance is not within the expected range—the RTD is defective. Replacethe RTD. Refer to Repair.

Resistancein Ohms

Temperature in F

Temperature in CNickel RTD

Figure 15: RTD resistance vs. temperature



Maintenance Table 6 provides the recommended schedule for gun maintenance. Detailed procedures forweekly and semi-annual maintenance tasks are provided in the remainder of this section.

Table 6 Gun Maintenance Schedule

Frequency Task Notes

Daily Remove hot melt and char from the exterior ofthe gun assembly.

Weekly Clean the gun nozzle(s). A, B

Semi-annually Inspect the gun wiring.

NOTE A: Use a nozzle cleaning kit.B: Application-specific nozzle performance history may indicate the need for

more or less frequent nozzle cleaning.

Clean Nozzles

Gun nozzles may become clogged when char, a by-product of overheating the hot melt,becomes lodged in the nozzle. The use of an in-line filter will significantly reduce nozzleclogging.1. Heat the gun to operating temperature.

2. Disable the gun. Refer to Safety.

3. Remove nozzles as shown in Table 7.

WARNING: Risk of personal injury or equipment damage. The sharp needle onSureBead guns is exposed whenever the nozzle is removed.



Cle

an N

ozz

les

Tabl

e 7

Noz

zle

Rem

oval

and

Inst

alla

tion

Pro

cedu

res

No

zzle

Typ

eR

emo

val P

roce

du

reIn

stal

lati

on

Pro

ced

ure

Sta

ndar

d nu

t-ty

pe n

ozzl

es (

incl

udin

gS

atur

n rig

ht-a

ngle

and

Sur

eBea

d no

zzle

s)U

se a

wre

nch

to lo

osen

the

nozz

le, t

hen

rem

ove

the

nozz

le b

y ha

nd (

wea

r sa

fety

glov

es).

Thr

ead

the

nozz

le o

nto

the

mod

ule

thre

ads

by h

and;

then

use

a to

rque

wre

nch

totig

hten

the

nozz

le to

4.5

N�m

(40

in.-

lb).

Inte

grat

ed C

lass

icB

lue

right

-ang

le m

odul

eno

zzle

sTu

rn th

e no

zzle

ada

pter

(3)

unt

il th

e no

zzle

(2)

is a

cces

sibl

e, th

en u

se a

nut

driv

er (

1)or

sm

all s

ocke

t to

care

fully

unt

hrea

d th

eno

zzle

from

the

adap

ter.

1 2 3

Inse

rt th

e no

zzle

into

the

nut d

river

or

smal

lso

cket

and

then

car

eful

ly th

read

the

nozz

lein

to th

e no

zzle

ada

pter

. Tig

hten

the

nozz

leto

0.4

6 N�m

(4

in.-

lb).

Do

not o

ver-

tight

enth

e no

zzle

. Tur

n th

e no

zzle

ada

pter

unt

ilth

e no

zzle

poi

nts

tow

ard

the

prod

uct.

Con

tinue

d...



No

zzle

Typ

eR

emo

val P

roce

du

reIn

stal

lati

on

Pro

ced

ure

Cla

ssic

Blu

e ze

ro c

avity

mod

ule

nozz

le1.

Scr

ibe

or o

ther

wis

e pl

ace

a di

stin

ctiv

em

ark

on th

e si

de o

f the

noz

zle.

Use

the

sam

e m

ark

on th

e gu

n m

anifo

ld to

iden

tify

the

corr

ect r

epla

cem

ent l

ocat

ion

for

the

nozz

le.

2.R

emov

e th

e no

zzle

by

rem

ovin

g th

e fo

ursc

rew

s th

at s

ecur

e it

to th

e m

odul

e.

3.R

emov

e an

d di

scar

d th

e no

zzle

O-r

ing.

1.Lu

bric

ate

and

inst

all a

new

noz

zle

O-r

ing.

2.In

stal

l the

noz

zle

on th

e m

odul

e, v

erify

ing

that

the

need

le g

uide

is s

till i

nsid

e th

eno

zzle

and

that

the

nozz

le is

pro

perly

alig

ned

with

the

need

le ti

p an

d w

ith th

esc

ribe

mad

e ea

rlier

.

3.S

ecur

e th

e no

zzle

with

the

scre

ws

rem

oved

pre

viou

sly.



Cle

an N

ozz

les

(co

ntd

)N

ozz

le T

ype

Rem

ova

l Pro

ced

ure

Inst

alla

tio

n P

roce

du

re

Cla

ssic

Blu

e re

duce

d ca

vity

mod

ule

1.S

crib

e or

oth

erw

ise

plac

e a

dist

inct

ive

mar

k on

the

side

of t

he n

ozzl

e. U

se th

esa

me

mar

k on

the

gun

man

ifold

toid

entif

y th

e co

rrec

t rep

lace

men

t loc

atio

nfo

r th

e no

zzle

.

2.R

emov

e th

e no

zzle

by

rem

ovin

g th

e fo

ursc

rew

s th

at s

ecur

e it

to th

e m

odul

e.

3.R

emov

e an

d di

scar

d th

e no

zzle

O-r

ing.

1.Lu

bric

ate

and

inst

all a

new

noz

zle

O-r

ing.

2.In

stal

l the

noz

zle

on th

e m

odul

e, v

erify

ing

that

the

need

le g

uide

is s

till i

nsid

e th

eno

zzle

and

that

the

nozz

le is

pro

perly

alig

ned

with

the

need

le ti

p an

d w

ith th

esc

ribe

mad

e ea

rlier

.

3.S

ecur

e th

e no

zzle

with

the

scre

ws

rem

oved

pre

viou

sly.



WARNING! Risk of fire. Do not heat Nordson Type R fluid above 245 �C (475�F). Use only an industrial grade, regulated, electrical heating device that isdesigned to heat industrial fluids. Personal injury or property damage can result ifType R cleaning fluid is heated with an open flame or in an unregulated heatingdevice.

1. Soak the nozzles in Nordson Type R cleaning fluidthat has been heated above the melting point ofthe hot melt.

2. Remove the nozzles from the cleaning fluid.

CAUTION! Use the correct size precision pinprobe to clean Nordson nozzles. The use ofnon-precision or incorrectly sized probes maydamage the nozzle. The Nordson nozzle cleaningkit (part 901915) contains a variety of probe sizes.

3. See Figure 16. At the outlet of each nozzle, inserta correctly sized cleaning probe.

4. With a clean cloth, firmly grip the cleaning probe,then pull the probe out of the nozzle, wiping theprobe clean.

5. Reinstall the nozzles. Refer to Table 7.

Figure 16: Cleaning a nozzlewith a probe (typical)

Inspect the Gun Wiring 1. De-energize the system. Refer to Safety.

2. Remove the manifold cover.

3. Check the internal gun wiring for signs of damage and the terminal block connections fortightness.

4. Reinstall the manifold cover. Ensure that the gasket on water-wash guns is in goodcondition and properly positioned, as shown in Figure 17.



Replace a Heater or RTD

2

1

Figure 17: Correct position of the gasket on water-wash guns

1. Manifold cover 2. Gasket

Repair Troubleshooting activities may identify needed repairs. This section provides procedures forreplacing a gun RTD, heater, or module.

NOTE: Refer to Parts later in this manual for replacement part information.

Replace a Heater or RTD

RTDs are hardwired through the gun cordset. If an RTD fails, replace the entire guncordset. Heaters are terminated inside the manifold and can be replaced individually.

The following procedure describes the replacement of an RTD by replacing the entirecordset. Instructions for replacing a heater are also included.

Access the RTD or Heater 1. De-energize the system and disable the gun. Refer to Safety.

2. See Figure 18. Unplug the gun cordset from the hose.

3. (Optional) Relieve system hydraulic pressure. Refer to Safety.

4. (Optional) Using two wrenches, disconnect the hose from the gun.

NOTE: Steps 3 and 4 are not necessary if the gun is easily accessible and can beserviced without the need to disconnect the hose.

5. See Figure 17.. Remove the manifold cover and, if applicable, the gasket.



Figure 18: Disconnecting a hose

Replace the RTD or Heater

See Figure 19.

1. Remove the RTD or heater from the manifold.

2. Disconnect the cordset leads from the terminal block. If the heater is being replaced,disconnect the heater leads from terminal block.

3. Do one of the following:

To replace the RTDA. Disconnect the ground lead from the manifold and remove the cordset.

B. Install a new cordset and insert the RTD in the manifold.

C.Reconnect the ground lead to the manifold.

To replace the heaterA. If necessary, trim the leads of the new heater to match the leads of the old heater.

B. Insert the heater in the manifold.

C. Insert each heater lead into the terminal block and tighten the terminal block screws.

D. Insert the heater leads from the cordset into the terminal block and tighten the terminalblock screws.



To replace the heater(contd)

CAUTION! Ensure that the gasket on water-wash guns is in good condition andproperly positioned before reinstalling the manifold cover.

4. Install the manifold cover.

NOTE: Make sure the manifold cover does not pinch down on the wire leads for theheater, RTD or ground wire.

5. Connect the hose to the gun.

6. Plug the gun cordset into the hose.

7. Restore the system to normal operation.

.

.

.

.

.

1

5

4

3

6

7

RTD

HEATER

HEATER

4

62

Figure 19: Replace a heater (ClassicBlue gun shown)

1. Cordset

2. Cordset heater leads

3. RTD

4. Ground wire, washer, and screw

5. Heater

6. Terminal block

7. Gasket, waterwash gun (shownfor reference)



Replace a Module 1. De-energize the system and disable the gun. Refer to Safety.

CAUTION! Do not allow adhesive to enter the module air passages. Adhesivethat enters the air passages will obstruct the flow of air and damage the module.

See Figure 20.

3.3 Nwm(30 in.-lb)

O-lube

Never-Seez

Figure 20: Replace a gun module

2. Restore the system to normal operation.



Parts

Using the Illustrated Parts Lists

To order parts, call the Nordson Customer Service Center or your local Nordsonrepresentative. Use these five-column parts lists, and the accompanying illustrations, todescribe and locate parts correctly. The following chart provides guidance for reading theparts lists.

The number in the Item column corresponds to the circled item number in the parts list illustration. Adash in this column indicates that the item is an assembly.

The number in the Part column is the Nordson part number you can use to order thepart. A series of dashes indicates that the part is not saleable. In this case, you mustorder either the assembly in which the part is used or a service kit that includes the part.

The Description column describes the part and sometimes includes dimensionsor specifications.

The Note column contains letters that refer to notes at the bottom of theparts list. These notes provide important information about the part.

The Quantity column tells you how many of the part isused to manufacture the assembly shown in the parts listillustration. A dash or AR in this column indicates thatthe amount of the item required in the assembly is notquantifiable.

Item Part Description Qty Note– 0000000 Assembly A –

1 000000 � Part of assembly A 2 A

2 - - - - - - � � Part of item 1 1

NS 0000000 � � � Part of item 2

NOTE A:NS: Not Shown



ClassicBlue Low Profile (LP) Guns

Part Number Description1054947 2-module, .88 centers, CA

1054948 2-module, .88 centers, IA

1054949 2-module, 1.97 centers, CA

1054950 2-module, .88 centers, CA, right angle

1054998 2-module, .88 centers, CA, .012 in. zero cavity

1055000 2-module, .88 centers, CA, 200V

1055001 2-module, .88 centers, CA, waterwash



1055007 2-module, .88 centers, IA

1055008 2-module, 1.97 centers, CA, right angle


1055014 2-module, 1.50 centers, CA, thermostat, QD

1051868 3-module gun, .88 centers, CA


1051932 4-module, .88 centers, CA, waterwash


1051935 4-module, .88 centers, CA


1051940 4-module, .88 centers, CA, thermostat, QD

1051941 4-module, .88 centers, CA, thermostat

1051943 4-module, .88 centers, 2-2A

1054944 4-module, .88−2.62−.88 centers, CA


1054946 6-module, .88 centers, 1-4-1 air





Gun-Specific Parts

1917

18

6

1

2

22

21

20

24

23

15 16

7 8

141312

1110

272625

3 4

1/8 NPTAIR INPUT

3 56

12

1615

RTD

HEATER

HEATER

Figure 21: Two-module ClassicBlue LP gun parts



Table 8 Two-Module ClassicBlue LP Gun Parts List

Item Part Description Qty Note

1 — Manifold 1 A

2 — Module 2 A, B

3 — Heater 2 A, C

4 — Release agent, high-temperature —

5 — Eyelet, 0.069/0.089 OD x 0.187 in. long 2

6 939586 Connector, plastic, 2-station 1

7 — Plug, pipe, socket, flush, 1/16 1

8 — Sealant, paste, PTFE —

9 — Item no. not used —

10 — Connector, hose 1 A, D

11 — Lubricant, Never-Seez, 8oz can —

12 — Cordset 1 A, C

13 — Washer, lock, external, 3/8 1


15 — Screw, fillister, 5-40 x 0.250 in. 1

16 — Washer, lock, split, #5 1

17 — Cover 1 A


19 — Screw, pan, 8-32 x 0.375 in. 4

20 — Bracket, mounting 1

21 — Insulator, mounting 1


23 — Screw, hex, 10-32 x 0.625 in. 2

24 — Washer, lock, split, #10 2

25 — Nut, hex, regular, 1/2-13 2

26 — Washer, flat, 0.531 x 1.000 x 0.063 in. 2

27 — Washer, lock, split, 1/2 2

NS 272385 Kit, Installation — E

NOTE A: The part number of this item varies depending on the configuration of the gun.B: Refer to Replacement Modules for ordering information.C: Refer to Cordsets for ordering information.D: Refer to Gun-to-Hose Connectors for ordering information.E: This kit is no longer shipped with guns—it must be ordered separately.

NS: Not Shown



Replacement Modules

Replacement modules include screws to mount the modules and the O-rings that sealbetween the module and the manifold.

ClassicBlue Modules Part Description

1054951 Module blank, ClassicBlue

1048115 ClassicBlue

1051794 ClassicBlue RC08


1051792 ClassicBlue RC12, Kalrez



1051746 ClassicBlue RA

1054375 ClassicBlue ZC08







1054379 ClassicBlue ZCS12

1080675 ClassicBlue ZE008







SolidBlue and SureBead Modules

SureBead modules include nozzles. The color indicated next to the orifice size indicatesthe color code of the Saturn nozzle of the SureBead modules.

Part Description

1054951 Module blank, SolidBlue/SureBead

1052925 SolidBlue S

1052927 SolidBlue A

1052928 SureBead S, .008 (purple)

1052929 SureBead S, .012 (green)

1052931 SureBead S, .016 (orange)

1052932 SureBead S, .020 (beige)

1056127 SureBead S, .032 (gold)

1056128 SureBead S, .040 (turquoise)

1052934 SureBead A, .008 (purple)

1052935 SureBead A, .012 (green)

1052936 SureBead A, .016 (orange)

1052937 SureBead A, .020 (beige)

1056129 SureBead A, .032 (gold)

1056130 SureBead A, .040 (turquoise)



Module Rebuild Kits

ClassicBlue Rebuild Kits

Part Description Note1055414 Module rebuild kit, ClassicBlue A

1055411 Module rebuild kit, ClassicBlue B

1055416 Module rebuild kit, ClassicBlue, ZC40 A

1055417 Module rebuild kit, ClassicBlue, ZC32 A

NOTE A: Rebuilds one moduleB: Rebuilds ten modules

SolidBlue Rebuild Kits

Part Description Note1057974 Module rebuild kit, SolidBlue S A

1057973 Module rebuild kit, SolidBlue S B

1057970 Module rebuild kit, SolidBlue A A

1057969 Module rebuild kit, SolidBlue A B


SureBead Rebuild Kits

Part Description Note1057966 Module rebuild kit, SureBead S A

1057965 Module rebuild kit, SureBead S B

1057962 Module rebuild kit, SureBead A A

1057961 Module rebuild kit, SureBead A B




Solenoid Valves

Saturn Solenoid valves have color coded rings to assist in selecting the correct replacementsolenoid valve. See Figure 22. The first ring indicates voltage, the second ring indicates airflow (Cv). Solenoid valves are either 3-way (AOSC) or 4-way (AOAC).

First ring

Second ring Second ring

First ring

Figure 22: Saturn 3-way and 4-way Solenoid Valves

Saturn Ring Identification First Ring Color Voltage

Yellow 24 VDC

Green 12 VDC

Blue 24 VAC

Brown 48 VAC

Red 100 VAC

Beige 120 VAC

Gold 200 VAC

Grey 240 VAC

Second Ring Color Air Flow (Cv)

Blue 1.0

Green 1.5

White 0.18



Large Cv Saturn Solenoid Part Numbers Part Description

1053894 4-way, AO/AC, 24VDC, Q.D. plug with LED light (yellow, blue)

1055480 4-way, AO/AC, 24VDC, Q.D. plug without LED light (yellow, blue)

1055483 4-way, AO/AC, 24VDC, MOV, Q.D. plug with LED light (yellow, blue)

10690204 way, AO/AC, 24 VDC, Q.D. plug without LED light, reverse function(yellow, green)

1074634 4 way, AO/AC, 240 VAC, Q.D. plug without LED light (grey, green)

1056119 3-way, AO/SC, 24VDC, Q.D. plug with LED light (yellow, green)

1055481 3-way, AO/SC, 24VDC, Q.D. plug without LED light (yellow, green)

1056273 3-way, AO/SC, 100VAC, Q.D. plug without LED light (red, green)

1056120 3-way, AO/SC, 120VAC, Q.D. plug without LED light (beige, green)

1056274 3-way, AO/SC, 200VAC, Q.D. plug without LED light (gold, green)

1056121 3-way, AO/SC, 240VAC, Q.D. plug without LED light (grey, green)

1062017 3-way, AO/SC, 24VDC, MOV, Q.D. plug with LED light (yellow, green)

NOTE: 3-way solenoids are used for air-open/spring closed (AO/SC) guns such asClassic Blue Series, SolidBlue S and SureBead S.

NOTE: All Saturn solenoid valves can be used in waterwash applications.

NOTE: Large CV Saturn solenoid valves contain 1/8 x 1/4 in. pipe bushings, mufflers,and universal inlet fitting.

Small Cv Saturn Solenoid Part Numbers Part Description

1069250 4−way, AO/AC, 24VDC, Q.D. plug with LED light (yellow, white)

1069209 4−way, AO/AC, 24VDC, Q.D. plug without LED light (yellow, white)

1069257 4−way, AO/AC, 120VAC, Q.D. plug without LED light (beige, white)

1069258 4−way, AO/AC, 240VAC, Q.D. plug without LED light (grey, white)

1069208 3−way, AO/SC, 24VDC, Q.D. plug with LED light (yellow, white)

1069207 3−way, AO/SC, 24VDC, Q.D. plug without LED light (yellow, white)

1069206 3−way, AO/SC, 12VDC, Q.D. plug without LED light (green, white)

1069251 3−way, AO/SC, 24VAC, Q.D. plug without LED light (blue, white)

1069252 3−way, AO/SC, 48VAC, Q.D. plug without LED light (brown, white)

1069253 3−way, AO/SC, 100VAC, Q.D. plug without LED light (red, white)

1069254 3−way, AO/SC, 120VAC, Q.D. plug without LED light (beige, white)

1069255 3−way, AO/SC, 200VAC, Q.D. plug without LED light (gold, white)

1069256 3−way, AO/SC, 240VAC, Q.D. plug without LED light (grey, white)



Saturn Solenoid Spare Components Part Numbers Part Description

Connectors

1058522 Standard Black No LED

1058523 Clear with LED

1058524 Clear LED 120 VAC

1058525 Clear with LED MOV

Mufflers

1058058 Muffler 1/8 in. NPT

1058059 Muffler 1/4 in. NPT

NOTE: 3-way solenoids are used for air-open/spring closed (AO/SC) guns such asClassic Blue Series, SolidBlue S and SureBead S.

NOTE: All Saturn solenoid valves can be used in waterwash applications.

NOTE: Large CV Saturn solenoid valves contain 1/8 x 1/4 in. pipe bushings, mufflers,and universal inlet fitting.

NOTE: Small CV Saturn solenoid valves contain mufflers and universal inlet fitting.



Cordsets

Cordsets include RTDs. RTDs cannot be ordered individually.

Part Description223826 Cordset, single module

274685 Cordset, multi-module

223804 Cordset, single module, water wash

276770 Cordset, multi-module, water wash

276957 Cordset, all guns, bulkmelter connection

264829 Conversion kit, Meltex gun to Nordson melter, ClassicBlue/SolidBlue S

226750 Conversion kit, gun to ITW Dynatec hose, ClassicBlue/SolidBlue S

309071 Conversion kit, gun to ITW Dynacontrol hose, ClassicBlue/SolidBlue S

146907 Cordset, gun-unit, 3100/3400 PAL

152127 Cordset, Meltex, sq t couple,5 wire

224908 Cordset, SB (Slauterback)

321699 Cordset, DYP (Dyna Pro)

321701 Cordset, DYC (Dyna Mini)

321717 Cordset, RB (Robatech)

1060388 Cordset, armored, H20/H200

1077909 Cordset, t-stat

1081196 Cordset, Meltex with pt100

Thermostats Part Description

937044 200 �F Thermostat











Heater Cartridges

Refer to the gun part number to select the appropriate heater cartridge. All guns requiretwo cartridges for complete replacement.

ClassicBlue Low Profile Heater Cartridge Selection

Gun Part Hearer Cartridge

1051868 938151

1051931 938152

1051932 938152

1051933 938151

1051935 938152

1051936 938152

1051940 938165

1051941 938165

1051943 938159

1054944 103802

1054945 938101

1054946 938101

1054947 938149

1054949 938149

1054950 938149

1054998 938149

1055000 938150

1055001 938149

1055002 938149

1055006 938149

1055007 938149

1055008 938149

1055013 938131

1055014 938131

1055596 938138

1055597 938128



SolidBlue Low Profile Heater Cartridge Selection

Gun Part Hearer Cartridge

1057393 938149

1057394 938149

1057395 938152

1057397 938149

1057398 938149

1057399 938150

1057400 938149

1057401 938149

1057402 938149

1057403 938131

1057404 938152

1057405 938151

1057406 815976

1057407 103082

1057408 938101

1057411 938101

1062345 1062347

1062346 938139



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Saturn In-line Filters and Accessories

Refer to Table 9 to select the appropriate filter mesh size based on the orifice diameter ofthe nozzle being used. Refer to Table 10 for Saturn filter part numbers.

Figure 30: Saturn in-line filter

Table 9 Recommended Filter Mesh Size

If the Nozzle Orifice Diameter is... ...use a filter with a...

50 Mesh (.30 mm) Screen

(Red ring)

100 Mesh (.15 mm) Screen(Gold ring)

200 Mesh (.07 mm) Screen(Purple ring)



Saturn In-line Filters and Accessories (contd)

Table 10 Saturn Filters and Filter Elements

Description Part

Straight filter, 0.15 mm (0.0059 in.), 50 mesh 1007033



90� filter, 0.15 mm (0.0059 in.), 50 mesh 1007230

90� filter, 0.15 mm (0.0059 in.), 100 mesh 1007231

90� filter, 0.7 mm (0.0029 in.), 200 mesh 1007232

45� filter, 0.15 mm (0.0059 in.), 50 mesh 1007233

45� filter, 0.15 mm (0.0059 in.), 100 mesh 1007234

45� filter, 0.07 mm (0.0029 in.), 200 mesh 1007235

The following table lists the Saturn in-line filter replacement part numbers.

Table 11 Replacement Filter Cartridges

Table 12 In-line Filter Accessories

Component Part Number Description

1056296Saturn In-line filter insulatorkit



Gun-to-Hose Connectors

See Figure 31. Gun-to-hose connectors are installed between the gun and hose to easehose routing and to help prevent bending or pinching of the hose.

2 31

4

Figure 31: Gun-to-hose fittings

Item Part Description Note

1 972657 Connector, hose, with O-ring,straight

A

2 274179 Connector, hose, with O-ring, 45�

3 274180 Connector, hose, with O-ring, 90�

4 945032 � O-ring, Viton, 3/8 in. tube B

NOTE A: All guns are shipped with this straight hose connector preinstalled on the gun.B: This is the replacement O-ring for all hose connectors.

Insulating Cuffs

Insulating cuffs are used to insulate hose-to-gun joints.

Part Description

273634 Cuff, insulating, 64 mm (2.5 in.)





Extension Cables

Extension cables are used when a gun has two cordsets and only one hose will be used.

Part Description

108946 Cable, extension, gun to melter, 4.9 m (16 ft)

728023 Cable, extension, water-wash gun to melter, 5.5 m (18 ft)

728093 Cable, extension, water-wash gun to AquaGuard melter, 6.1 m (20ft)

124992 Cable, extension, gun to bulk melter, 4.3 m (14 ft)

Maintenance Accessories Part Description

132426 Hose/gun diagnostic device

900223 Lubricant, O-ring, 4 oz (for lubricating O-rings)

900344 Never-Seez, 8 oz can

900223 Never-Seez, 1 oz

900290 Neat’s foot oil

901915 Nozzle cleaning kit

331871 Tool, removal/installation, integrated right-angle modulenozzles

231262 Kit, quick-disconnect fitting, 1/4 NPT (solenoids)

2702755 Type R fluid, 1 gal

902514 Protective gloves



Technical Data The following technical data is provided for your reference as needed.

Gun Specifications

ItemSpecification

NoteClassicBlue (all) SolidBlue SureBead A

Operatinghydraulicpressure

103 bar (1,500 psi) maximum

Operating airpressure

2.8−4.8 bar(40−70 psi)

3.1−5.5 bar (45−80 psi) A

Operatingspeed

Exceeds 3,500 cycles per minute

Electricalservice

240 VAC, 50/60 Hz200 VAC, 50/60 Hz optional (for low-voltage areas)

Operatingtemperature

204 �C (400 �F) maximum

NOTE A: Recommended range. Dry, regulated, unlubricated air required for gunoperation.

Torque Specifications Item Torque Specification

Module mounting screws 3.4 N�m (30 in.-lb)

Bead nozzles 4.5 N�m (40 in.-lb)

Integrated right-angle module nozzles 0.46 N�m (4 in.-lb)

Cordset Wiring Diagram

Refer to the gun-specific drawing provided with this manual.

Dimensions

Refer to the gun-specific drawing provided with this manual.

blue series low profile pneumatic guns -...

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