blue series pneumatic applicators -...

Blue Series

Pneumatic Applicators

Customer Product ManualPart 1054960_07

Issued 12/15

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

This document contains important safetyinformation Be sure to read and follow allsafety information in this document and anyother related documentation.

Part 1054960_07 � 2015 Nordson Corporation

For CE Declaration, refer to equipment documentation.

Nordson Corporation welcomes requests for information, comments, and inquiries about itsproducts. 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 date2004. 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 inthis publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, CanWorks, Century,CF, CleanSleeve, CleanSpray, ColorMax, Color‐on‐Demand, Control�Coat, Coolwave, Cross‐Cut, cScan+, Dage,

Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura‐Screen, Durasystem, Easy�Coat,Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI ‐ stylized, Excel 2000,

Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, 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, Micromedics, MicroSet,Millennium, Mini Squirt, Mountaingate, Nordson, Optimum, Package of Values, Pattern View, PermaFlo, PicoDot,

Porous�Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo,ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select�Charge,Select�Coat, Select Cure, Signature, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, SureBead,Sure Coat, Sure‐Max, Sure Wrap, Tracking�Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UpTime,u‐TAH, Vantage, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, Watermark, and

When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste,ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue,Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave, ContourCoat, CPX, cSelect, Cyclo‐Kinetic,

DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site,IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge,

Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke, Partnership+Plus, PatternJet,PatternPro, PCI, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue,

PURJet, Ready Coat, RediCoat, Royal Blue, Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil,SolidBlue, Spectral, SpeedKing, Spray Works, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH,

ThruWave, Trade�Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa,Vista, Web Cure, YESTECH, 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 1054960_07� 2015 Nordson Corporation

Table of Contents

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .User Qualifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Safety Warnings and Cautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Module Selection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Module Identification 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Devices and Spare Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Best Choice Applicator Configuration Code 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Guidelines 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Supplied Materials 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic and Pneumatic Connections 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solenoid Valves 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount the Applicator 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Solenoid Valve 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect the Triggering Device 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Triggering Device to an SP Solenoid Valve 27. . . . . . . . . . . . . . . . . .Connect the Hose 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush the Applicator 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Module Adjustment 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust a ClassicBlue Zero Cavity Module 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust an Air‐Open‐Air‐Closed Module 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Under 30 bar (450 psi) Hydraulic Pressure 32. . . . . . . . . . . . . . . . . . . .

Table of Contentsii


Troubleshooting 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Table 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Table 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Table (contd) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diagnostic Procedures (DPs) 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DP1. Check a Solenoid Valve 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DP2. Check for a Clogged Nozzle or Module 38. . . . . . . . . . . . . . . . . . . . . . . . . . . .DP3. Check Module Operation (AOSC Applicators) 39. . . . . . . . . . . . . . . . . . . . . .DP4. Check a Heater 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DP5. Check a RTD 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean Nozzles 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean Nozzles 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect the Applicator Wiring 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace a Heater or RTD 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access the RTD or Heater 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace the RTD or Heater 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace a Module 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents ii


Parts 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts Lists 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator‐Specific Parts 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Module, Spring Close, Top Feed 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single Module, Spring Close, Rear Feed 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single Module, Air Close 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multi Module, Spring Close 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multi Module, Air Close 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Module Kits 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ClassicBlue Modules 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SolidBlue and SureBead Modules 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Rebuild Kits 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ClassicBlue Rebuild Kits 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SolidBlue Rebuild Kits 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SureBead Rebuild Kits 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid Valves 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn Ring Identification 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Large Cv Saturn Solenoid Part Numbers 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn Platinum Solenoids 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn Applicator Jackets 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Small Cv Saturn Solenoid Part Numbers 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn Solenoid Spare Components Part Numbers 67. . . . . . . . . . . . . . . . . . . . . .Remote Mount Kits 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cordsets 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermostats 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater Selection Tables for Multi Module Applicators 70. . . . . . . . . . . . . . . . . . . . . .

200 VAC Cartridge 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 VAC Cartridge 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Saturn Nozzles 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn Nozzles for SureBead Applicators 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Saturn Nozzles 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Nozzles 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saturn In‐line Filters and Accessories 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator‐to‐Hose Connectors 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulating Cuffs 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extension Cables 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Accessories 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Specifications 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Specifications 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cordset Wiring Diagram 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1Blue Series Pneumatic Applicators

� 2015 Nordson Corporation Part 1054960_07

Blue Series PneumaticApplicators

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 alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, and hazard

avoidance 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 in damageto equipment or property. Comply with all safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided, can

result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided, can

result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentially

hazardous situation that, if not avoided, can result in damage to equipment or

property.

Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuring that allinstructions and regulatory requirements for use of the equipment are met, and for qualifyingall potential users.

Blue Series Pneumatic Applicators2


Safety Information

� Research and evaluate safety information from all applicable sources, including theowner‐specific safety policy, best industry practices, governing regulations, materialmanufacturer's product information, and this document.

� Make safety information available to equipment users in accordance with governingregulations. Contact the authority having jurisdiction for information.

� Maintain safety information, including the safety labels affixed to the equipment, inreadable condition.

Instructions, Requirements, and Standards

� Ensure that the equipment is used in accordance with the information provided in thisdocument, governing codes and regulations, and best industry practices.

� If applicable, receive approval from your facility's engineering or safety department, orother similar function within your organization, before installing or operating the equipmentfor the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are being followed.

� Re‐evaluate safety practices and procedures whenever changes are made to the processor equipment.

User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed by governingregulations and best industry practices

� are familiar with the equipment owner's safety and accident prevention policies andprocedures

� receive, equipment‐ and task‐specific training from another qualified individual

NOTE: Nordson can provide equipment‐specific installation, operation, andmaintenance training. Contact your Nordson representative for information

� possess industry‐ and trade‐specific skills and a level of experience appropriate to theirjob function

� are physically capable of performing their job function and are not under the influence ofany substance that degrades their mental capacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in the manner described inthis document. The information provided here is not meant to include all possible safetypractices, but represents the best safety practices for equipment of similar hazard potentialused in similar industries.



Intended Use of the Equipment

� Use the equipment only for the purposes described and within the limits specified in thisdocument.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordsonrepresentative if you have any questions on material compatibility or the use ofnon‐standard auxiliary devices.

Instructions and Safety Messages

� Read and follow the instructions provided in this document and other referenceddocuments.

� Familiarize yourself with the location and meaning of the safety warning labels and tagsaffixed to the equipment. Refer to Safety Labels and Tags at the end of this section.

� If you are unsure of how to use the equipment, contact your Nordson representative forassistance.

Installation Practices

� Install the equipment in accordance with the instructions provided in this document and inthe documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will be used and that theprocessing characteristics of the material will not create a hazardous environment. Referto the Safety Data Sheet (SDS) for the material.

� If the required installation configuration does not match the installation instructions,contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for clearancebetween the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all independentlypowered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code enforcement agency forspecific requirements.

� Ensure that fuses of the correct type and rating are installed in fused equipment.

� Contact the authority having jurisdiction to determine the requirement for installationpermits or inspections.

Operating Practices

� Familiarize yourself with the location and operation of all safety devices and indicators.

� Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is ingood working order and that the required environmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task. Refer to EquipmentSafety Information or the material manufacturer's instructions and SDS for PPErequirements.

� Do not use equipment that is malfunctioning or shows signs of a potential malfunction.



Maintenance and Repair Practices

� Perform scheduled maintenance activities at the intervals described in this document.

� Relieve system hydraulic and pneumatic pressure before servicing the equipment.

� De‐energize the equipment and all auxiliary devices before servicing the equipment.

� Use only new factory‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the SDS supplied withequipment cleaning compounds.

NOTE: SDSs for cleaning compounds that are sold by Nordson are available atwww.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing the equipment back intooperation.

� Dispose of waste cleaning compounds and residual process materials according togoverning regulations. Refer to the applicable SDS or contact the authority havingjurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damaged labels.

Equipment Safety Information

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

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

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

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 the start of the procedure. The levels ofshut 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, applicators, 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 applicators

All electrical or mechanical devices that provide an activation signal to the applicators,applicator solenoid valve(s), or the melter pump must be disabled before work can beperformed on or around a applicator that is connected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.).

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

3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve theresidual air pressure between the regulator and the applicator.

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, applicators, etc.)

PC = Process control

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



Table 1 General Safety Warnings and Cautions

EquipmentType

Warnings and Cautions

HM

WARNING! Hazardous vapors! Before processing anypolyurethane reactive (PUR) hot melt or solvent‐based materialthrough a compatible Nordson melter, read and comply withthe material's SDS. Ensure that the material's processingtemperature and flashpoints will not be exceeded and that allrequirements for safe handling, ventilation, first aid, andpersonal protective equipment are met. Failure to comply withSDS requirements can cause personal injury, including death.

HM

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

HM, CAWARNING! 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.



EquipmentType


HM, PC

WARNING! Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt applicators.Before working on or near an operating applicator, disable theapplicator's triggering device and remove the air supply to theapplicator's solenoid valve(s). Failure to disable the applicator'striggering device and remove the supply of air to the solenoidvalve(s) can result 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 theSDS 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, includingdeath.

HM, CA, PCWARNING! 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.



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)

EquipmentType


HMCAUTION! Hot surfaces! Avoid contact with the hot metalsurfaces of applicators, 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 representative forassistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound onor in the equipment, read and comply with the manufacturer'sinstructions and the SDS supplied with the compound. Somecleaning compounds can react unpredictably with hot melt orcold adhesive, resulting in damage 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 handapplicator at yourself or others.

� Suspend dispensing handapplicators 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 SDS for the hot melt to the medicalpersonnel providing treatment.

Safety Labels and Tags

Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment.Table 2 provides an illustration of the hazard identification symbols that appear on eachsafety label and tag, the meaning of the symbol, or the exact wording of any safety message.

1

3

4 6

5

2

Figure 1: Safety labels and tags

Table 2 Safety Labels and Tags



Item Part Description

1. N/A WARNING: Hot Surface! Before touching the applicatorbody, allow the applicator to cool, or wearheat-protective gloves. Failure to allow the applicatorbody to cool or to wear heat-protective gloves maycause personal injury.

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

3. 600137 WARNING: Disconnect power and remove systempressure before disassembly or maintenance. Failure tofollow these instructions may result in serious personalinjury.

4. 243352 WARNING: Fire, injury, or equipment damage can resultif 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.

5. 600103 CAUTION: This applicator is RTD (resistancetemperature detector) controlled. Prior to operation andbefore changing adhesive, consult instruction manual forchanging operating temperature. Failure to followinstructions may result in personal injury or propertydamage.

6. 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, which canbe difficult to remove.To avoid equipment damage,check with adhesive supplier regarding compatibility andcleanout procedure before putting adhesive into thesystem.



Description

Blue Series pneumatic hot melt applicators (ClassicBlue�, SolidBlue� and SureBead)have an EasyOn� module mounting design that provides machined surfaces on both theapplicator body and the module.

EasyOn technology provides

� Guided, one‐way fit

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

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

The Best Choice� configurator determines the right applicator for an application. Refer toBest Choice applicator Configuration Code later in this section to determine the configurationof a applicator based on its configuration code.

Blue Series applicators use new Saturn solenoid valves and Saturn nozzles.

Blue Series applicators are characterized by the type of module installed. Figure�2 shows thekey components of a Blue Series applicator. Table 3 describes the different modules usedwith the applicators.

NOTE: Blue Series applicators are available in multiple‐module and water‐washdesigns.

1

2

3

54

6

7

Figure 2: Blue Series applicator Components (SolidBlue A Shown)

1. Cordset

2. Mounting bracket

3. Module

4. Nozzle (sold separately)

5. Manifold

6. Hose connector

7. Solenoid valve

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Module Selection

Table 3 Blue Series Applicator Modules

Module Type Characteristics Description

ClassicBlueright‐angle

� ClassicBlue, right‐angle module,adjustable (allows changes in beadplacement)

� Air‐open, spring‐close (AOSC)operation

� Includes an integrated right‐anglenozzle

ClassicBlue right‐angle applicators provide90‐degree application flexibility for low‐to‐mediumspeed applications.

ClassicBluereduced

cavity

� ClassicBlue reduced cavity module,adjustable (allows changes in beadplacement)


� Available in four orifice sizes

ClassicBlue reduced cavity applicators have anintegrated nozzle and needle assembly that results inself‐cleaning action and sharp cutoff. When used inlow to medium speed applications, reduced cavityapplicators provide clog‐free/minimum dripoperation, uniform beads, and consistent flow over awide range of temperatures.

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Module Type Characteristics Description

ClassicBluezero cavity(ZC) and

zero cavitycase sealing

(ZCS)

� ClassicBlue zero cavity module withmicro‐adjuster


� Available in six orifice sizes

Use ClassicBlue zero cavity applicators incritical applications that require consistentno‐clog/no‐drip operation, precise beadplacement, and extrusion control. Theclose‐tolerance, matchednozzle‐and‐needle assembly eliminates theformation of minute adhesive pockets thatcan lead to nozzle clogging, drool, andadhesive stringing. The movement of theneedle within the nozzle creates aself‐cleaning action, minimizing blockagesand reducing maintenance. Applications forthese applicators include high‐speedcartoning, case sealing, cap lining,nonwovens side seaming and elasticattachment, bonding, and gasketing.

Zero cavity applicators feature a patentedmicro‐adjust module. A micrometeradjustment screw at the top of the modulecan reduce adhesive flow by up to 30percent. Additionally, minor variations inbead position can be achieved via a loadadjustment mechanism. These adjustmentsare especially beneficial in high‐speed,multi‐module applicator applications.

ClassicBluezero cavityextended

nozzle(ZCE)

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Module Selection (contd)

Table 3 Blue Series Applicator Modules (contd)

Module Type Features Application

SolidBlue S � SolidBlue S standard module,spring‐tension adjustable (notstroke‐adjustable)


� Accommodates Saturnsingle‐orifice and right‐anglenozzles

SolidBlue S applicators provide longer life thanClassicBlue applicators and deliver exceptionaladhesive cut‐off/ minimum‐drip operation formedium‐to‐high speed applications.

SolidBlue A � SolidBlue A standard module,non‐adjustable

� Air‐open, air‐close (AOAC)operation

� Factory installed Saturn solenoidvalve

� Accommodates Saturnsingle‐orifice and right‐anglenozzles

SolidBlue A applicators provide better cutoff thanSolidBlue S applicators (because of the air‐open,air‐close operation), provide extended service lifebeyond ClassicBlue applicators, and deliverexceptional accuracy for demanding applications.SolidBlue A applicators are recommended for usewith adhesives that have a viscosity greater than1,250 cps and cycle rates below 15 ms.

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Table 3 Blue Series Applicator Modules (contd)

Module Type Features Application

SureBead S � High quality patterns with virtuallyclog‐free operation, even when using“difficult to machine” low and mediumviscosity adhesives

� Maximum bead deposition capability

� Air‐open, spring‐close (SureBead S) orair‐open, air‐close (SureBead A)operation

� Colored ring on the removable nozzleeasily identify orifice size

� Nozzles are interchangeable - changeorifice sizes without removing themodule from the applicator

� Nozzle tip is maintained resulting incleanly applied beads and betterproduct seals

SureBead modular hot melt applicators are designedfor easy flushing by removing the nozzle from themodule. Nozzles used with a SureBead applicatorare designed to perform similar in function toreduced cavity and zero cavity nozzles. SureBeadapplicators are designed to dispense packaginggrade adhesives.

SureBead A

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Module Identification

The face plates of SolidBlue and SureBead modules are color codedfor easy applicator and module identification. Figure 3 shows the faceplate options. Use this information for service and replacement needs.

Intended Use

Blue Series applicators are designed to be rigidly mounted,pneumatically operated, and triggered by an electrically controlledsolenoid valve. Blue Series applicators are designed for use withNordson melters and hoses.

Auxiliary Devices and Spare Parts

Blue Series applicators should only be connected to approved auxiliarydevices. Use only new Nordson replacement parts or approved factoryrefurbished parts.

Figure 3: SolidBlue and SureBead Identification

Blue = Air‐Close

Black = Spring‐Close

Gray = SolidBlue(ball and seat)

Tan = SureBead(needle and seat)

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Best Choice Applicator Configuration Code

To determine the configuration of a applicator, obtain its configuration code and refer to Table 4.

Table 4 Explanation of Applicator Configuration Code Positions

CodePosition

Description Code Value

SLBS STD A CA 022 T 3A0A E9 304 LB

} } } } } } } } } } }

1 2 3 4 5 6 7 8 9 10 11

Configuration Code

1 Module type CBRC = ClassicBlue Reduced CavityCBZC = ClassicBlue Zero CavityCBRA = ClassicBlue Right AngleSURS = SureBead S (air‐open‐spring‐close) (AOSC)SURA = SureBead A (air‐open‐air‐close) (AOAC)SLBS = SolidBlue S (AOSC)SLBA = SolidBlue A (AOAC)

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Best Choice Applicator Configuration Code (contd)

Table 4 Explanation of Applicator Configuration Code Positions (contd)

CodePosition


2 Orifice size STD = no orifice diameter008 = .008 in. orifice012 = .012 in. orifice016 = .016 in. orifice020 = .020 in. Orifice032 = .032 in. Orifice040 = .040 in. orifice

3 Number of modules 1-26

4 Voltage A = 240 VB = 200 V

5 Air type CA = common airIA = independent airPA = programmed airTF = top feed

6 Module spacing Three digit value (number of modules minus one)

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CodePosition


7 Cordset T = 3000/Blue SeriesB = BulkmelterW = Water washP = DYP (Dyna Pro) <305 mmN = DYC (Dyna Mini) <305 mmR = RB (Robatech) <305 mmS = SB (Slauterback) <305 mmJ = MXT (Meltex TC) <305 mmK = MXR (Meltex Platinum) <305 mm1 = 200F Tstat <305 mm2 = 225F Tstat <305 mm3 = 250F Tstat <305 mm4 = 275F Tstat <305 mm5 = 300F Tstat <305 mm6 = 325F Tstat <305 mm7 = 350F Tstat <305 mm8 = 375F Tstat <305 mm9 = 400F Tstat <305 mmY = PAL 1 (Palette Stabilization - RTD) <305 mmA = PAL 2 (Palette Stabilization - CL IX) 200F Tstat <305 mmC = PAL 2 (Palette Stabilization - CL IX) 225F Tstat <305 mmD = PAL 2 (Palette Stabilization - CL IX) 250F Tstat <305 mmE = PAL 2 (Palette Stabilization - CL IX) 275F Tstat <305 mmF = PAL 2 (Palette Stabilization - CL IX) 300F Tstat <305 mmG = PAL 2 (Palette Stabilization - CL IX) 325F Tstat <305 mmH = PAL 2 (Palette Stabilization - CL IX) 350F Tstat <305 mmL = PAL 2 (Palette Stabilization - CL IX) 375F Tstat <305 mmX = PAL 2 (Palette Stabilization - CL IX) 400F Tstat <305 mmM = Melton <305 mmV = Valco <305 mm

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Best Choice Applicator Configuration Code (contd)


CodePosition

Description Code Values

8 Cordset position LB = left backRB = right backLS = left sideRS = right sideBB = both backBA = BackTF = top feed

9 Solenoid First character: # of air ports

3 = 3 ports (AOSC) 4 = 4 ports (AOAC)

Second Character: Voltage

A = 24 VDCB = 100 VACC= 120 VACD = 200 VACE = 240 VAC

Third Character: LED Option

0 = std (black)1 = LED (white)

Fourth Character: Solenoid Size

A = Large Saturn CV (1/4 in. NPT)B = Small Saturn Cv (1/8 in. NPT)C = Saturn Platinum - multi‐module onlyS = Saturn Platinum - single module only (1/4 in. NPT)Y = Large Saturn - not mounted to applicatorZ = Small Saturn - not mounted to applicator

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CodePosition

Description Code Values

10 Hydraulic connector First Character: Filter mesh sizeE = 50‐meshF = 100‐meshG = 200‐meshSecond Character: Fitting type0 = straight1 = No fitting4 = 45‐degree9 = 90‐degree

11 Number of hydraulicports

135



Installation

The following items must be ordered separately:

� extension cables, if needed (such as when a applicator has two cordsets and only onehose will be used)

� solenoid valves for applicators 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 to theNordson Adhesive and Sealants Equipment Guide or contact a Nordson representative.

Installation Guidelines

Customer Supplied Materials

� Power supply

� 3‐conductor signal cable

Mounting

� Mount the applicator 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 applicator manifold to service and maintainthe applicator.

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

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

Hydraulic and Pneumatic Connections

� Use only one fitting to connect a hose to a hose connector on the applicator.

� Insulate the hose‐to‐applicator joint. Refer to Parts for 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 theapplicator solenoid valve.

Solenoid Valves

� Third‐party solenoid valves must be able to be manually triggered at the applicator.

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Mount the Applicator 1. Relieve system pressure before installing or replacing a applicator. Refer to Safety. See Figures 4 and 5 to mount a applicator.

Figure 4: Remove the Solenoid and Disconnect the Hose (when) replacing existing applicators

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Mount the Applicator (contd)

13 mm (1/2 in.) (customer supplied)

Figure 5: Install the Applicator onto a Mounting Bar

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Install the Solenoid Valve

Solenoid valves must be connected to an air supply and to a triggering device, such as a pattern controller or timer. Solenoids work withAOAC or AOSC applicators. If solenoid valves were not specified when the applicator was ordered, they must be customer‐installed.

CAUTION! Risk of solenoid valve failure. Solenoid valves must be rated for the output voltage of the triggering device (pattern

controller, timer, PLC, etc.) and for use in high‐temperature applications. Refer to Installation Guidelines.

See Figures 6 and 7.

Figure 6: Install a Saturn Solenoid onto an AOAC applicator

Figure 7: Install a Saturn Solenoid onto an AOSC applicator



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 powersupply.

� 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.The supply 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 damage

the 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

Blue Series Pneumatic Applicators 27


CAUTION! Solenoid valves must be rated for the output

voltage of the triggering device. Make sure the ratings

match.

3. Thread a customer‐supplied 0.75-0.34 mm2 (18-22AWG) three‐conductor cable through the housingstrain relief.

4. Connect the positive and negative wires of theconductor cable to terminals 1 and 2 (polarity doesnot matter), and the ground wire to the groundterminal.

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 Triggering Device to an SP Solenoid Valve

See Figure 10. Connect the solenoid valve cable to the solenoid valve and to the triggeringdevice.

CAUTION! Do not use a spiked signal. Doing so will destroy the internally spiked

valve.

CAUTION! The input signal to the solenoid should not exceed 24 VDC. Doing so

will destroy the solenoid.

1. Connect the brown and blue wires to the 24 VDC signal.

Brown: 24VDC

Black: Not used forthis solenoid

Blue: 24VDC

Figure 10: Connecting the cable to an SP solenoid valve

2. Go to Connecting the Hose.

1 2



Connect the Hose

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

1. See Figure 11. Connect the hose swivel fitting to the applicator hose connector or in‐linefilter. Use two wrenches to tighten the hose fitting.

2. Connect the applicator cordset to the hose.

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

4. Insulate the hose‐to‐applicator connector.

Figure 11: Connect the Hose (SolidBlue applicator without an in‐line filter shown)



Flush the Applicator

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

CAUTION! This equipment is factory tested with Nordson Type R fluid containing

polyester adipate plasticizer. Certain adhesives may react with the Type R fluid

residue to form a solid gum that can be difficult to remove. Consult with your

adhesive 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 applicators until it is time to start the system and flush theapplicators. The sharp needle on these applicators is exposed whenever thenozzle 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 applicators.

4. Flush the applicators as appropriate for the type of applicator:

For all applicators except ClassicBlue zero and reduced cavity applicators

A. 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 applicators

A. Relieve system hydraulic pressure and disable the applicator. Refer to Safety.

B. Remove the applicator module.

C. Re‐pressurize the system; then place the applicator 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 applicator, hose, and melter.



Operation

WARNING! SolidBlue S and SureBead S applicator modules are adjustable.

Adjusting the applicator modules for low air pressure operation without making acorresponding reduction in system hydraulic pressure may cause the applicator

modules to remain open. Refer to applicator Module Adjustments to properly

adjust the operating air pressure for these modules if the applicators must beoperated at a low air pressure.

WARNING! SolidBlue A and SureBead A applicator modules operate as air‐open,air‐close valves. The loss or elimination of air pressure to the applicator solenoid

valve without a corresponding reduction in system hydraulic pressure may cause

the applicator modules to remain open.

Applicator Module Adjustment

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

NOTE: Adjusting the spring tension on SolidBlue S and SureBead S applicators doesnot adjust stroke length.

Adjust a ClassicBlue Zero Cavity Module

ClassicBlue zero cavity applicators are equipped with a micro‐adjuster that allows the nozzleflow rate to be decreased up to 30 percent from the maximum flow rate set at the factory.

WARNING! System pressurized! Relieve system pressure before attempting to

adjust the applicator. If the micro‐adjuster is unscrewed too far, hot melt can be

released under pressure. Failure to relieve system pressure can result in personalinjury.



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

2. See Figure 12. Loosen the locking nut.

12

3

Figure 12: 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 the

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

1

2



Operating Under 30 bar (450 psi) Hydraulic Pressure

Increase the applicator air pressure to operate at a hydraulic pressure as low as 14 bar (200psi). Refer to Table 5. If 3.4 bar (50 psi) cannot be achieved, go to Compensating for Lowapplicator Air Pressure.

Table 5 Increasing applicator Air Pressure to Operate at Low Hydraulic Pressure

To operate at this hydraulic�pressure... The minimum applicator air pressurerequired 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 applicator Air Pressure (AOSC Applicators)

If an application requires applicator operation at an air pressure below 3.4�bar (50 psi) and ata hydraulic pressure below 30 bar (450 psi), reduce the applicator 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

applicator module spring tension also reducesthe maximum hydraulic pressure at which the

module will self‐relieve or free‐flow. If the

maximum hydraulic pressure is exceeded, theapplicator module will remain open and

dispense adhesive uncontrollably.

See Figure 13. To reduce the applicator module springtension, loosen the locking nut and turn the adjustmentscrew counterclockwise in 1/2‐turn increments. Each 1/2turn reduces the hydraulic pressure capability by7�bar�(100 psi). Refer to Table 6.

Figure 13: Adjustment screw on

an SolidBlue module

1. Adjustment screw

2. Locking nut



Table 6 Adjusting a SolidBlue and SureBead Module to Operate

at Low applicator Air�Pressure and Low Hydraulic Pressure

Adjustment ScrewPosition

Maximum applicator 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 applicator. Refer to Safety.

2. See Figure 13. 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 this

document before completing any troubleshooting procedure. Failure to observe

safety messages and hazard‐avoidance procedures can result in personal injury,

including death.

Troubleshooting Table

The following table lists the applicator problems that are most likely to occur, the possiblecauses of each problem, and steps for corrective action. Where applicable, cross‐referencesare made to expanded diagnostic procedures�(DPs) provided later in this section or to othersections of this manual.

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Troubleshooting Table

Problem Possible Cause Corrective Action

1. No adhesive output from any module(s) Adhesive level low Add adhesive.

No input power Verify that all disconnect switches and/or circuitbreakers are on and operable.

System not at operatingtemperature

Verify that the READY light is on at the melterand that the hot melt is molten.

Melter, hose or applicatortemperature setting too low.

Adjust. Refer to the specific melter manual.

Air pressure to applicator toolow.

Adjust.

NOTE: Minimum 3.4 bar (50 psi)required. 4.5 bar (65 psi) isrecommended.

Verify adequate pressure from plant air supply.

Verify that the air pressure regulator isoperating correctly.

Low or no hydraulic pressure Refer to the hydraulic system Troubleshootingsection of the melter manual.

Failed solenoid Solenoid muffler clogged. Replace.

Clean or replace solenoid. Refer to DP.1,Check a Solenoid Valve.

Continued...

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1. No adhesive output from any module(s)(contd)

Clogged hose Clean or replace.

Clogged nozzle Clean or replace. Refer to DP.2, Check aClogged Nozzle or Module.

Clogged or failed module Clean, repair or replace. Refer to DP.2, Checka Clogged Nozzle or Module.

Dirty or faulty triggering device Service or replace. Refer to the manual thataccompanied the triggering device.

Faulty encoder Calibrate or replace.

2. No adhesive from some modules(multi‐module applicators only)

Clogged nozzle Clean or replace. Refer to DP.2, Check aClogged Nozzle or Module.

Clogged or failed module Clean, repair or replace. Refer to DP3, Checka Module Operation.

Individual modules not properlyadjusted.

Adjust. Refer to applicator ModuleAdjustments.

3. Uncontrolled adhesive flow from module Hydraulic pressure too high Adjust. Refer to the melter manual.

applicator air pressure lost(AOAC modules only)

Stop the melter pump and restore air pressure.

Module failed with needle inopen position

Clean, repair or replace. Refer to DP3, Checka Module Operation.

Continued...

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Solenoid failed or portedincorrectly

Verify that the solenoid is ported properly.Replace the solenoid if necessary. Refer toDP.1, Check a Solenoid Valve.

4. applicator overheats or underheats Failed heater Replace. Refer to DP.4, Check a Heater.

Failed RTD Replace the cordset. Refer to DP.5, Check aRTD.

No power Verify that all disconnect switches and/or circuitbreakers are on and operable.

Improper temperature setting Adjust temperature. Refer to the meltermanual.

Malfunction in the melter heatercontrol circuit

Refer to the melter manual to diagnose shortcircuit problems.



Diagnostic Procedures (DPs)

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

DP1. Check a Solenoid Valve

1. Place the system into operation.

2. Trigger the applicator 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 applicator 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 applicators.


2. See Figure 14. Remove the nozzle.

WARNING! Risk of personal injury or equipment damage. The sharp needle on

SureBead applicators is exposed whenever the nozzle is removed.

Figure 14: Removing a nozzle

3. Place the applicator back into operation.

4. Trigger the applicator:

� 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 Applicators)

NOTE: This procedure assumes that the triggeringdevice and solenoid valve are functioning normally.

1. See Figure 15. Insert a small Allen wrench orsimilar probe into the top of the module.

2. Manually trigger the applicator at the solenoidvalve:

� 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 15: Checking module operation

DP4. Check a Heater


2. Unplug the applicator cordset from the hose.

3. See Figure 16. 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 16: applicator cordset pins (as viewed from hose end)



DP5. Check a RTD


2. Unplug the applicator cordset from the hose.

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

4. See Figure 16. When the applicator temperature is known, measure the resistance acrossthe RTD circuit (pins 3 and 5).

5. See Figure 17 to determine the expected resistance of the RTD at the known temperature.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 17: RTD resistance vs. temperature



Maintenance

Table 7 provides the recommended schedule for applicator maintenance. Detailedprocedures for weekly and semi‐annual maintenance tasks are provided in the remainder ofthis section.

Table 7 applicator Maintenance Schedule

Frequency Task Notes

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

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

Semi‐annually Inspect the applicator 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

applicator nozzles may become clogged when char, a by‐product of overheating the hotmelt, becomes lodged in the nozzle. The use of an in‐line filter will significantly reduce nozzleclogging.

1. Heat the applicator to operating temperature.


3. Remove nozzles as shown in Table 8.

WARNING! Risk of personal injury or equipment damage. The sharp needle on

SureBead applicators is exposed whenever the nozzle is removed.

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Clean Nozzles

Table 8 Nozzle Removal and Installation Procedures

Nozzle Type Removal Procedure Installation Procedure

Standard nut‐type nozzles (includingSaturn right‐angle and SureBead nozzles)

Use a wrench to loosen the nozzle, thenremove the nozzle by hand (wear safetygloves).

Thread the nozzle onto the modulethreads by hand; then use a torquewrench to tighten the nozzle to 4.5 N�m(40 in.‐lb).

Integrated ClassicBlue right‐angle modulenozzles

Turn the nozzle adapter (3) until the nozzle(2) is accessible, then use a nut driver (1)or small socket to carefully unthread thenozzle from the adapter.

1

2

3

Insert the nozzle into the nut driver orsmall socket and then carefully thread thenozzle into the nozzle adapter. Tighten thenozzle to 0.46 N�m (4 in.‐lb). Do notover‐tighten the nozzle. Turn the nozzleadapter until the nozzle points toward theproduct.

Continued...

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Table 8 Nozzle Removal and Installation Procedures (contd)


ClassicBlue zero cavity module nozzle 1. Scribe or otherwise place a distinctivemark on the side of the nozzle. Use thesame mark on the applicator manifold toidentify the correct replacement locationfor the nozzle.

2. Remove the nozzle by removing the fourscrews that secure it to the module.

3. Remove and discard the nozzle O‐ring.

1. Lubricate and install a new nozzleO‐ring.

2. Install the nozzle on the module,verifying that the needle guide is stillinside the nozzle and that the nozzle isproperly aligned with the needle tip andwith the scribe made earlier.

3. Secure the nozzle with the screwsremoved previously.

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Clean Nozzles (contd)


ClassicBlue reduced cavity module 1. Scribe or otherwise place a distinctivemark on the side of the nozzle. Use thesame mark on the applicator manifold toidentify the correct replacement locationfor the nozzle.

2. Remove the nozzle by removing the fourscrews that secure it to the module.

3. Remove and discard the nozzle O‐ring.

1. Lubricate and install a new nozzleO‐ring.

2. Install the nozzle on the module,verifying that the needle guide is stillinside the nozzle and that the nozzle isproperly aligned with the needle tip andwith the scribe made earlier.

3. Secure the nozzle with the screwsremoved previously.



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 is designed

to heat industrial fluids. Personal injury or property damage can result if Type R

cleaning fluid is heated with an open flame or in an unregulated heating device.

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

2. Remove the nozzles from the cleaning fluid.

CAUTION! Use the correct size precision pin probe

to clean Nordson nozzles. The use of

non‐precision or incorrectly sized probes may

damage the nozzle. The Nordson nozzle cleaning

kit (part 901915) contains a variety of probe sizes.

3. See Figure 18. At the outlet of each nozzle, insert acorrectly 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 8.

Figure 18: Cleaning a nozzle

with a probe (typical)



Inspect the Applicator Wiring 1. De‐energize the system. Refer to Safety.

2. Remove the manifold cover.

3. Check the internal applicator wiring for signs of damage and the terminal blockconnections for tightness.

4. Reinstall the manifold cover on the side closest to where the cordset connects to themanifold. Ensure that the gasket on water‐wash applicators is in good condition andproperly positioned, as shown in Figure�19.

2

1

Figure 19: Correct position of the gasket on water‐wash applicators

1. Gasket 2. Manifold cover

Repair

Troubleshooting activities may identify needed repairs. This section provides procedures forreplacing a applicator 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 applicator cordset. If an RTD fails, replace the entireapplicator cordset. Heaters are terminated inside the manifold and can be replacedindividually.

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 applicator. Refer to Safety.

2. See Figure 20. Unplug the applicator cordset from the hose.

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

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

NOTE: Steps 3 and 4 are not necessary if the applicator is easily accessible and canbe serviced without the need to disconnect the hose.

5. Remove the manifold cover.

Figure 20: Accessing the RTD or heater



Replace the RTD or Heater

See Figure 21.

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 RTD

A. 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 heater

A. 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.

CAUTION! Ensure that the gasket on water‐wash applicators is in good condition

and properly 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 applicator.

6. Plug the applicator cordset into the hose.

7. Restore the system to normal operation.



1

2

3

4

5

6

7

Figure 21: Replace a Heater (SolidBlue S applicator Shown)

1. Corsset

2. Cordset heater leads

3. RTD

4. Ground wire, washer, and screw

5. Heater

6. Terminal Block

7. Gasket, waterwash applicator(shown for reference)



Replace a Module 1. De‐energize the system and disable the applicator. Refer to Safety.

CAUTION! Do not allow adhesive to enter the module air passages. Adhesive that

enters the air passages will obstruct the flow of air and damage the module.

See Figure 22.

3.3 N�m (30 in.‐lb)

O‐lube

Never‐Seez

Figure 22: Replace an Applicator 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. A dash 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

the part. A series of dashes indicates that the part is not saleable. In this case,

you must order 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

dimensions or specifications.

The Note column contains letters that refer to notes at the bottom of

the parts list. These notes provide important information about the

part.The Quantity column tells you how many of the part

is used to manufacture the assembly shown in the

parts list illustration. A dash or AR in this column

indicates that the amount of the item required in the

assembly is not quantifiable.

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



Applicator‐Specific Parts

Single Module, Spring Close, Top Feed

Figure 23: Single module, spring close, top feed



Table 9 Single Module, Spring Close, Top Feed Parts List

Item Part Description Qty Note

1 — Module 1 A

2 — Manifold 1

3 — Pipe plug, 1/16 2

4 — O‐ring plug, 9/16 1

5 — Hex head cap screw, 0.3125‐18 UNC X 1.5 1

6 — Hex head cap screw, 0.3125‐18 UNC X 1 1

7 — Washer, flat, 0.3125 SAE 1

8 326508 Kit, bracket, applicator mounting 1

9 272400 Insulator, applicator mount 1

10 938129 Heater Cartridge, 240V 2 B

11 — Fillister head screw, #5‐40 UNC X 1/4 1

12 — Washer, spring lock, #5 1

13 — Mounting Block with RTD 1 C

14 939586 Housing, connector, plastic 2‐station 1

15 — Pan head screw, slotted, #8‐32 UNC X 1/4 1

16 174918 Applicator cover 1

17 — Round head screw, #5‐40 UNC X 0.4375 1

18 — Lockwasher, external tooth, 0.375 1

19 — Connector, straight, 0.562 X 0.562 X 1.75 1

20 — Cordset 1 C

21 — Solenoid 1 D

22 971265 Connector, male, 1/4 tube X 1/4 NPT 1

23 815965 PFTE Tube, 1/4 OD X 0.01 1

24 157215 Insulator mount 1

25 972623 Fitting, barb, elbow, 1/4 tube X 1/8 NPT 1

26 157204 Swivel block 1

27 — Socket head cap screw, #8-32 UNC X 3/4 2

NS 272385 Kit, Installation 1 E

NOTE A: Refer to Replacement Modules for ordering information

B: Refer to the Heater Selection Tables for Multi Module ApplicatorsC: Refer to Cordsets for cordset ordering information

D: Refer to Saturn Solenoid Valves for ordering information

E: The ship with kit PN272385 is no longer shipped with applicators. This kitmust be ordered separately.

NS: Not Shown



Single Module, Spring Close, Rear Feed

Figure 24: Single module, spring close, rear feed



Table 10 Single Module, Spring Close, Rear Feed


1 — Module 1 A



3 — RTD 1 C

4 1052714 Gasket, water wash, endcover 2

5 1052346 Cover 2

6 — Pan head slotted screw, M2.5 X 5 8

7 939586 Housing, connector, plastic, 2‐station 1

8 — Saturn filter 1 D

9 — Cordset 1 C

10 — Manifold body 1

11 273301 Insulator 1

12 273306 Kit, retainer 1

13 — Flat washer, #6 SAE 2

14 — Hex head cap screw, 1/4‐20 UNC X 0.750 2

15 — Pan head slotted screw, 4-40 UNC X 1.750 2

16 1063229 Kit, solenoid mounting, 3‐way, single module 1

17 — Solenoid 1 E

NS 272385 Kit, Installation 1 F


B: Refer to the Heater Selection Tables for Multi Module ApplicatorsB: Refer to Cordsets for cordset ordering information

C: Refer to Saturn In‐line Filters for filter and filter screen ordering information



NS: Not Shown



Single Module, Air Close

Figure 25: Single module, air close



Table 11 Single Module, Air Close


1 — Module 1 A

2 — RTD 1 B

3 1054626 Heater Cartridge, 200V 1 C

3 1054660 Heater Cartridge, 240V 1 C

4 1052715 Gasket, water wash, endcover 2

5 1041441 Cover 2

6 — Pan head slotted screw, M3 X 5 6

7 939586 Housing, connector, plastic, 2‐station 1


9 1063251 Kit, solenoid mounting, 4‐way, single module 1

10 — Cordset 1 B

11 — Solenoid 1 E

12 — Hex head cap screw, M8 X 25 2

13 — Hex head cap screw, M8 X 45 2

14 — Flat washer, M4 2

15 272384 Kit,Retainer,Gun 1

16 272400 Insulator mount 1

17 — Roll pin, 0.125 X 0.5 1




B: Refer to Cordsets for cordset ordering information

B: Refer to the Heater Selection Tables for Multi Module ApplicatorsC: Refer to Saturn In‐line Filters for filter and filter screen ordering information



NS: Not Shown



Multi Module, Spring Close

Figure 26: Multi module, spring close



Table 12 Multi Module, Spring Close


1 — Module 1 A

2 — RTD 1 B

3 — Heater 1 C

4 — O‐ring plug, 9/16 2

5 — Pipe plug, 1/16 2

6 1056022 Gasket, water wash 2

7 1055300 Cover 2

8 — Pan head slotted screw, M2.5 X 5 8

9 939586 Connector, plastic, 2‐station 1


11 — Cordset 1 B

12 — Solenoid 1 E

13 1063250 Kit, solenoid mounting, 3‐way 1

14 — Slot head cap screw, M3 X 12 2

15 — Spring lock washer, M6 2

16 1026940 Bracket 1

17 1026879 Bracket insulator 1








NS: Not Shown



Multi Module, Air Close

Figure 27: Multi Module, Air Close



Table 13 Multi Module, Air Close


1 — Module 1 A

2 — RTD 1 B

3 — Heater 1 C

4 — O‐ring plug, 9/16 3

5 — Pipe plug, 1/16 4

6 1056023 Gasket, water wash 2

7 1055255 Cover 2

8 — Pan head slotted screw 8

9 939586 Connector, plastic, 2‐station 1


11 — Cordset 1 B

12 — Solenoid 1 E

13 1063252 Kit, solenoid mounting, 3‐way 1

14 — Slot head cap screw, M3 X 12 2

15 — Spring lock washer, M6 2

16 1026940 Bracket 1

17 1026879 Bracket insulator 1


NS 272385 Kit, Installation 1 E






NS: Not Shown



Replacement Module Kits

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

ClassicBlue Modules

Part Description

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 indicates thecolor 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 Note

1055416 Module rebuild kit, ClassicBlue, ZC40 A

1055417 Module rebuild kit, ClassicBlue, ZC32 A

1080675 Module rebuild kit, ClassicBlue,ZE,.008 A

1054376 Module rebuild kit, ClassicBlue, ZE,.012 A




NOTE A: Rebuilds one module

SolidBlue Rebuild Kits


1057974 Module rebuild kit, SolidBlue S A

1057973 Module rebuild kit, SolidBlue S B

1059590 Module rebuild kit, SolidBlue S C

1057970 Module rebuild kit, SolidBlue A A

1057969 Module rebuild kit, SolidBlue A B


B: Rebuilds ten modules

C: Rebuilds 50 modules

SureBead Rebuild Kits


1057966 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


B: Rebuilds ten modules



Solenoid Valves

Saturn Solenoid valves have color coded rings to assist in selecting the correct replacementsolenoid valve. See Figure 28 and Tables 14, 15 and 16. The first ring indicates voltage, thesecond ring indicates air flow (Cv). Solenoid valves are either 3‐way (AOSC) or 4‐way(AOAC).

First ring

Second ring Second ring

First ring

Figure 28: Saturn 3‐way and 4‐way Solenoid Valves

Saturn Ring Identification

Table 14 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

Purple 0.5



Large Cv Saturn Solenoid Part Numbers

Table 15 Large Cv Saturn Solenoids

Part Description

1053894 4‐way, AO/AC, 24VDC, with LED light, not attached (yellow, blue)

1055480 4‐way, AO/AC, 24VDC, without LED light, not attached (yellow, blue)

1055483 4‐way, AO/AC, 24VDC, MOV, with LED light (yellow, blue)

10690204 way, AO/AC, 24 VDC, 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 with LED light, not attached (yellow, green)

1055481 3‐way, AO/SC, 24VDC, without LED light, not attached (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: Large solenoids not attached to applicator use ¼ NPT fittings.

NOTE: 3‐way solenoids are used for air‐open/spring closed (AO/SC) applicators suchas Classic 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.

Saturn Platinum Solenoids

Part Number Description

1095801 3‐way, AO/SC, 24 VDC LED (yellow, purple)

1095802 4‐way, AO/AC, 24 VDC LED (yellow, purple)

Saturn Applicator Jackets

Part Number Description

1065542 Jacket, applicator, BC, single, back, AO/SC

1066184 Jacket, applicator, BC, single, back, AO/AC

NOTE: *For other jackets, contact application engineering.



Small Cv Saturn Solenoid Part Numbers

Table 16 Small Cv Saturn Solenoids

Part Description

1069250 4-way, AO/AC, 24VDC, Q.D. plug with LED light, not attached (yellow,white)

1069209 4-way, AO/AC, 24VDC, Q.D. plug without LED light, not attached(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, not attached (yellow,white)

1069207 3-way, AO/SC, 24VDC, Q.D. plug without LED light, not attached(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: Small solenoids not attached to applicator use 1/8 NPT fittings.

NOTE: 3‐way solenoids are used for air‐open/spring closed (AO/SC) applicators suchas Classic Blue Series, SolidBlue S and SureBead S.

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

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



Remote Mount Kits

AO/SC Modules


1120926 Kit, remote mount, SP, BestChoice, AO/SC A735140 � Flexible connection, ⅛ in. X ⅛ in. (qty 1)

252277 � Air hose, D6, D4, PTFE, natural, 1 M long (1000 mm)

NOTE A: One required for AO/SC

AO/AC Modules


1120926 Kit, remote mount, SP, BestChoice, AO/AC A735140 � Flexible connection, ⅛ in. X ⅛ in. (qty. 2)

252277 � Air hose, D6, D4, PTFE, natural, 1 M long (2000 mm)

NOTE A: Two needed for each solenoid

ItemPart

NumberDescription Qty Illustration

- 735140Kit, flexible connection ⅛” x ⅛”adjustable

30

20

10

14

8 m

m ±

1 m

m

10 733581 Straight connection, ⅛” adjustable 2

20 734819Flexible hose, H-PTFE-8/6 (1 pc = 10cm)

1

30 311484 O-Ring, 7.65 x 1.78, Viton Black 2



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 applicators, bulkmelter connection

264829 Conversion kit, Meltex applicator to Nordson melter, SolidBlue S

226750 Conversion kit, applicator to ITW Dynatec hose, SolidBlue S

309071 Conversion kit, applicator to ITW Dynacontrol hose, SolidBlue S

146907 Cordset, applicator‐unit, 3100/3400 PAL

152127 Cordset, Meltex, sq t couple,5 wire

224908 Cordset, SB (Slautterback)

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 Selection Tables for Multi Module Applicators

200 VAC Cartridge

MininumApplicator

Body Length

MaxmumApplicator

Body Length

Number ofHeaters

Required

.5 inch/13 mmDiameter

HeaterHeater

Wattage

44.6 58.2 1 1054628 200

58.3 69.4 1 1054629 200

69.5 77.2 1 1054630 250

77.3 88.2 1 1054633 250

88.3 102.6 1 1054634 250

102.7 112.3 1 1054635 280

112.4 121.7 1 1054637 300

121.8 134.5 1 1054638 300

134.6 147.5 1 1054639 300

147.6 166.9 1 1054640 350

167.0 173.4 1 1054642 380

173.5 192.8 1 1054644 400

192.9 216.9 1 1054647 440

217.0 238.2 1 1054650 500

238.3 264.1 1 1054652 550

264.2 286.9 1 1054655 600

287.0 295.1 1 1054656 600

295.2 346.9 2 1054640 350

347.0 372.8 2 1054643 350

372.9 398.7 2 1054646 375

398.8 424.6 2 1054648 400

424.7 450.5 2 1054649 425

450.6 489.4 2 1054651 450

489.5 528.3 2 1054653 475

528.4 580.1 2 1054654 500

580.2 610.0 2 1054657 550



240 VAC Cartridge

MinimumApplicator

Body Length

MaximumApplicator

Body Length

Number ofHeaters

Required

.5 inch/13 mmDiameter

HeaterHeater

Wattage

44.6 58.2 1 1054662 200

58.3 69.4 1 1054663 200

69.5 77.2 1 1054664 250

77.3 88.2 1 1054672 250

88.3 102.6 1 1054673 250

102.7 112.3 1 1054675 280

112.4 121.7 1 1054676 300

121.8 134.5 1 1055575 300

134.6 147.5 1 1055576 300

147.6 166.9 1 1054677 350

167.0 173.4 1 1054678 380

173.5 192.8 1 1054659 400

192.9 216.9 1 1054681 440

217.0 238.2 1 1054683 500

238.3 264.1 1 1054685 550

264.2 286.9 1 1054688 600

287.0 295.1 1 1054689 600

295.2 346.9 2 1054677 350

347.0 372.8 2 1054679 350

372.9 398.7 2 1054680 375

398.8 424.6 2 1055578 400

424.7 450.5 2 1054682 425

450.6 489.4 2 1054684 450

489.5 528.3 2 1054686 475

528.4 580.1 2 1054687 500

580.2 610.0 2 1054690 550

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Saturn Nozzles

Saturn Nozzles for SureBead Applicators

SureBead nozzles are similar in design to standard Saturn nozzles, with a gray upper ring to indicate a pressed‐in seat with minimalengagement and a color‐coded lower ring to indicate orifice size. The self‐cleaning action of the integrated nozzle and needle assemblyproduces clean patterns and sharp cutoff. Because of improved design efficiency of the SureBead applicators, adhesive bead volume mayvary slightly from equivalent ClassicBlue RC and ZC modules. Adjust the adhesive pressure to compensate.

Gray RingOrifice Diameter Ring

Figure 29: SureBead Saturn Nozzle

Part Description

339695 Kit, nozzle, .008 (purple)

339696 Kit, nozzle, .012 (green)

339697 Kit, nozzle, .016 (orange)

339698 Kit, nozzle, .020 (beige)

1055563 Kit, nozzle, .032 (gold)

1055560 Kit, nozzle, .040 (turquoise)

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Standard Saturn Nozzles

See Figure 30. Saturn precision nozzles have patented color‐coded rings that provide easy identification of nozzle orifice size. Refer to theAdhesives and Sealants Equipment Guide for a full listing of available Saturn nozzles.

Engagement Length RingOrifice Diameter Ring

Figure 30: Saturn Rings

Orifice Diameter andBottom Ring Color

mm�(in.)

Engagement Length and Top Ring Color mm (in.)

1.3 (0.050) Purple 1.9 (0.075) Brown2.5 (0.100)

Blue3.8 (0.150)

Green7.6 (0.300)

Black

0.20 (0.008) Purple 322008

0.25 (0.010) Blue 322010

0.31 (0.012) Green 322012 322112 322212 322312 322412

0.36 (0.014) Yellow 322014 322114 322314 322414

0.41 (0.016) Orange 322016 322116 322216 322416

0.46 (0.018) Red 322018 322118 322318 322418

0.51 (0.020) Beige 322020 322120

0.53 (0.021) Brown 322421

0.61 (0.024) Gray 322424

0.71 (0.028) Black 322428

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Standard Nozzles

See Figures 31 through 35.

Figure 31: 237XXX, Single‐Orifice Nozzle with Insert, Optional Engagement

237XXX

Single‐orifice withinsert

Engagement

mm (in.)

Orifice Diametermm (in.)

0.20(0.008)

0.25(0.010)

0.31(0.012)

0.36(0.014)

0.41(0.016)

0.46(0.018)

0.51(0.020)

0.61(0.024)

Brass adapter,stainless‐steel insert

1.3 (0.050) 237208 237210 237212 237214 237216 237218 237220 237622

1.9 (0.075) 237621 237312 237314 237316 237318 237320 237623

2.5 (0.100) 237412 237414 237416 237418 237420 237624

3.8 (0.150) 237612 237614 237616 237618 237620 237625

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Standard Nozzles (contd)

Figure 32: 237XXX, Single‐Orifice Nozzle with Insert, Long Engagement

237XXX

Single‐orifice withinsert

Engagement

mm (in.)

Orifice Diameter mm (in.)

0.31(0.012)

0.36(0.014)

0.41(0.016)

0.46(0.018)

0.53(0.021)

0.61(0.024)

0.71(0.028)

Brass adapter,stainless‐steel insert

7.6 (0.300) 237003 237005 237008 237018 237027 237040 237060

Figure 33: 238XXX, Drilled, Single‐Orifice Nozzle, Fixed Engagement

238XXX

Single‐orifice onepiece

Engagement

mm (in.)

Orifice Diameter mm (in.)

0.31(0.012)

0.36(0.014)

0.41(0.016)

0.46(0.018)

0.51(0.020)

0.76(0.030)

0.89(0.035)

1.02(0.040)

Brass2.54 (0.100)

238004 238005 238006 238007 238008 238009 238058 238010

Stainless‐steel 238011 238012 238002 238013 238000 238001 238057 238003

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Single Dual Dual O/A

Triple Quad Triple Radial

A

A A

A BAA

120o 120o

Figure 34: Domed Nozzles, Methods of Measuring Offsets Shown Above (A, B = angle between nozzle orifices orcenterline)

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2380XXDomed Nozzles

Phosphor Bronze

(See Note A)


0.20(0.008)

0.25(0.010)

0.31(0.012)

0.36(0.014)

0.41(0.016)

0.46(0.018)

0.51(0.020)

0.61(0.024)

0.76(0.030)

Single 15� 703299 706078 238015 704891 702927 238016

Single 30� 704542 714977 238017 238018 804520 238019

Single 45� 703464 705512 702598 238020 707218 238021 238022

Single 60� 706057 238023 238024 238025

Dual 15� 238059 238053 238063 238054 130495 238055 238056

Dual 20� 238060 238062 715190 114927 238067

Dual 30� 804871 703270 238506 704936 114928 805512 238500 238026 238501

Dual 45� 238534 238525 238526 238527 238528 238529 238530 238027 238531

Dual 60� 238061 709371 238064 238028 238068 238029 238030

Dual 0/15� 805397 715462 238031 238032 238033

Dual 0/45� 119360 804761 132567 238034 715872 238035 238036

Triple 30� 238037 238065 238038 238069 238039 238071 238040

Triple 45� 238041 238066 238042 238070 238510 238072

Triple 60� 238043 807506 238044 708028 238045 238046

Triple Radial 30� 805257 238047 238048 238049 238050

Quad 40� 709479 714855 714856 808696 238051 238052

NOTE A: Use these nozzles with retaining nut part 152926.

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Dual 90/6030oA

Triple

A

DualSingle

Figure 35: Right‐Angle Nozzles, Methods of Measuring Offsets Shown Above (A = angle between nozzle orifices orcenterline)

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Right‐AngleNozzles

(See Note A)


0.20(0.008)

0.25(0.010)

0.31(0.012)

0.36(0.014)

0.41(0.016)

0.46(0.018)

0.51(0.020)

0.61(0.024)

0.71(0.028)

0.81(0.032)

1.02(0.040)

Single 707867 714847 244518 244519 244520 165774 270853 165775 271022 231149 804832

Dual 15� 165776 273384 804047 165777 271938 165778 165779

Dual 30� 270698 270699 270700 165780 709786 165781 808792

Dual 90/60� 165783 710591 809882 165784 165785

Triple 19� 142898 165786 165787 806540 808625

Triple 22.5� 165788 806199 165789 165790

NOTE A: Right-angle nozzles have a stainless-steel insert, stainless-steel adapter, and brass retaining nut.



Saturn In‐line Filters and Accessories

Refer to Table 17 to select the appropriate filter mesh size based on the orifice diameter ofthe nozzle being used. Refer to Table 17 for Saturn filter part numbers.

Figure 36: Saturn in‐line filter

Table 17 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 18 Saturn Filters and Filter Elements

Description Part

No fitting, 50 mesh 1120049



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



Table 19 Replacement Filter Cartridges

Table 20 In‐line Filter Accessories

Component Part Number Description

1056296Saturn In‐line filter insulatorkit



Applicator‐to‐Hose Connectors

See Figure 37. applicator‐to‐hose connectors are installed between the applicator and hoseto ease hose routing and to help prevent bending or pinching of the hose.

2 31

4

Figure 37: applicator‐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 applicators are shipped with this straight hose connector preinstalled onthe applicator.

B: This is the replacement O-ring for all hose connectors.

Insulating Cuffs

Insulating cuffs are used to insulate hose‐to‐applicator joints.

Part Description

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

273635 Cuff, insulating, 50.8 mm (2.0 in.)

274429 Cuff, insulating, 44 mm (1.75 in.)



Extension Cables

Extension cables are used when an applicator has two cordsets and only one hose will beused.

Part Description

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

728023 Cable, extension, water‐wash applicator to melter, 5.5 m (18 ft)

728093 Cable, extension, water‐wash applicator to AquaGuard melter, 6.1 m(20 ft)

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

Maintenance Accessories

Part Description

132426 Hose/applicator 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.

Applicator 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 applicatoroperation.

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 applicator‐specific drawing provided with this manual.

Dimensions

Refer to the applicator‐specific drawing provided with this manual.

blue series pneumatic applicators -...

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