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Carlisle Fluid Technologies IntelliSpray IS40 User Manual

Spray foam proportioner
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IntelliSpray Spray Foam Proportioner
User Manual
SPECIFICATIONS
Maximum Fluid Pressure
Air Pressure Range
Max Fluid Temperature
Wetted Parts
Page 1 of 143
2500 PSI
(153 bar)
70-130 PSI (4.8 - 9.0 bar)
200 F
94 C
Stainless Steel, Aluminum, Plated
Steel, Chemically Resistant Plastic,
Chemically Resistant O-Rings
DOC PN#: 341162EN A

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Summary of Contents for Carlisle Fluid Technologies IntelliSpray IS40

  • Page 1  IntelliSpray Spray Foam Proportioner User Manual SPECIFICATIONS Maximum Fluid Pressure 2500 PSI (153 bar) Air Pressure Range 70-130 PSI (4.8 - 9.0 bar) Max Fluid Temperature 200 F 94 C Stainless Steel, Aluminum, Plated Wetted Parts Steel, Chemically Resistant Plastic, Chemically Resistant O-Rings DOC PN#: 341162EN A www.carlisle.com...

  • Page 2: Table Of Contents

    Contents Section Page Section Page Warnings Remote monitoring & control Troubleshooting Safety Flushing & Storage Safety with Isocyanates Warranty Information IntelliSpray System IS40 Specifications IS40 Overview Fluid Module Control Module Control Module - Circuit Breakers QuickHeat Overview Installation Overview Installation Instructions Quick-Start Guide IntelliSpray Operations Tips Display Screens Overview...

  • Page 3: Warnings

    In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows: ! WARNING NOTE ! WARNING ! CAUTION in minor ! WARNING Read the following warnings before using this equipment READ THE MANUAL read TIP/CRUSH HAZARD Do not tip unit.

  • Page 4: Safety

    SAFETY PRECAUTIONS PERSONAL PROTECTIVE EQUIPMENT • Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to: ...
  • Page 5 SAFETY PRECAUTIONS FIRE AND EXPLOSION HAZARD • Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:  Use equipment only in well ventilated area.  Eliminate all ignition sources, such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
  • Page 6 IMPORTANT ISOCYANATE INFORMATION Isocyanates (ISO) are catalysts used in two component materials. ISOCYANATE CONDITIONS Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates. Workers exposed to isocyanates can develop a range of short and long-term health problems. •...
  • Page 7 MATERIAL SELF IGNITION FOAM RESINS with 245 FA BLOWING AGENTS Some materials may become self igniting if applied too thick. Read material manufactuer’s warnings and Safe- ty Data Sheet (SDS) Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. KEEP COMPONENTS A and B To reduce frothing, minimize preheating in a circulation system.

  • Page 8: Intellispray System

    INTELLISPRAY SYSTEM The Carlisle IntelliSpray Spray Polyurethane Foam (SPF) system consists of the IS40 Proportioner, QuickHeat Hose, and ST1 Spray Gun. The IntelliSpray system has been designed for ease of use, increased productivity, “best in class” process control, easy service, and real-time ratio control. QuickHeat hose has roughly double the heating power compared to most other SPF hoses and directly heats the fluid from inside the hose, which results in fast and efficient fluid heating, even in cold climate conditions.

  • Page 9: Is40 Specifications

    IS40 - SPECIFICATIONS The IS40 Proportioner is roughly 36” wide, 70” tall, and 32” deep. Eight separate floor mounting holes are located in the base of the unit. and a slotted wall mounting bracket is provided along the top of the unit. The IS40 must be securely attached to the a floor and wall in any mobile or seismic installation.

  • Page 10: Is40 Overview

    IS40 OVERVIEW The Carlisle IS40  Spray Foam Proportioner is a high performance device that delivers Isocyanate (A) and Polyol Resin (B) fluids to a spray gun via Carlisle QuickHeat  hoses. The system continuously monitors and controls A to B fluid output to a 1:1 ratio and is capable of high pressures, temperatures, and flow rates.
  • Page 11 IS40 OVERVIEW The IS40 is a modular system, composes of a Control Module, A and B Fluid Modules, a high strength tubular frame, and software. The frame has integral floor and wall mounting brackets. The A and B Fluid Modules are identical other than motor size, front cover labels, recirculation valve colors, and outlet fluid fittings (JIC5 for A, hose, JIC6 for B hose).
  • Page 12 FLUID MODULE OVERVIEW Preheater: The IS40 uses low mass Preheaters to warm the A and B fluids on the low pressure side of the Fluid Pumps. This allows the Preheaters to rapidly respond to variations in incoming fluid temperature, flow rates, or setpoint changes.

  • Page 13: Fluid Module

    FLUID MODULE The IS40 Fluid Modules independently filter, heat, pressurize, and deliver A and B materials to the QuickHeat hose and recirculation lines. Material is supplied to the Fluid Modules from drums, totes, or other fluid containers. To assure proper operation the IS40 requires the fluid to be provided at a pressure that avoids gear pump cavitation. Depending on the viscosity and flow rate of the fluid, the inlet pressure should be at least 25 psi at all times.
  • Page 14 FLUID MODULE The images below show the IS40 Fluid Module with the cover removed and the Pump Module removed from the Fluid Module. The A and B Fluid Modules are identical except for the following: • The B Servo Motor is slightly larger than the A Servo Motor to account for higher viscosity B Resins that require more torque.
  • Page 15 FLUID MODULE The A and B Fluid Modules have similar controls as described and shown below. Filter Inlet and Outlet Valves. Turn clockwise (CW) 1/4 turn to hard stop for open position. Turn counterclockwise (CCW) 1/4 turn to hard stop for closed position. When in use both valves should be in open position. For filter service set both to closed position.
  • Page 16 FLUID MODULE Fluid Module Motor Mount Pump Module Fluid Pump Frame Cover I/O Module Servo Motor Flow Meter Flow Meter Heater Module Cover High Pressure Module Front Cover Pressure Sensor Check Valve Flow Meter Fluid Preheater Pressure Gage Filter Valves Recirculation Valve Burst Disk DOC PN#: 341162EN A...
  • Page 17 FLUID MODULE OVERVIEW The following figure shows the fluid path and major elements contained in the IS40 Fluid Module. Flow is from left to right indicated by arrows. High Pressure Pump Module Check Pressure Valve Gage Flow Meter Recirculation & Pressure Relief Valve Burst...
  • Page 18 CONTROL MODULE OVERVIEW The IS40 Control Module provides overall system control, touch-screen HMI, power management, circuit protection, motor controls, preheater and hose heater controls, remote connectivity, internal networking, and electrical safety systems. Components are contained in an enclosed sheet metal cabinet that incorporates a thermostatically controlled fan that draws in cooling air through a user serviceable filter in the bottom of the door.

  • Page 19: Control Module

    CONTROL MODULE The function of primary components in the Control Module are described below. Main Panel: Most of the Control Module components are part of the Main Panel assembly. For mobile robustness additional Hook & Loop retention straps are used for DIN rail mounted components. Wiring is contained in capped Raceways.
  • Page 20 CONTROL MODULE The main components of the Control Module are shown in the figure below and described in the following pages. All items and cables in the Control Module are clearer marked to assist in diagnostics and service. HMI/Controller Cellular Modem Cellular Antenna Cooling Fan Dual USB Ports...
  • Page 21 CONTROL MODULE Cooling Fan Main Panel Dual USB Plugs Power Entry Solid State Relays (SSRs) B Fluid Module Motor and A Fluid Module Communication Cables Power Cable B Fluid Module A Fluid Module Motor and Power Cable Communication Cables IS40 Control Module, Front View DOC PN#: 341162EN A www.carlisle.com Page 21 of 143...
  • Page 22 CONTROL MODULE Celluar Modem Controller E-Stop Air Filter IS40 Control Module, Front Door DOC PN#: 341162EN A www.carlisle.com Page 22 of 143...
  • Page 23 CONTROL MODULE Most of the Control Module components are part of the Main Panel and are shown in the following figure. For mobile robustness additional Hook & Loop retention straps are used for DIN rail mounted components. Wiring is contained in capped Raceways and clearly labeled.

  • Page 24: Control Module - Circuit Breakers

    CONTROL MODULE - CIRCUIT BREAKERS WARNING ELECTRICAL SHOCK HAZARD Disconnect all power sources before accessing any electrical connections in the Control Module, Fluid Modules, or Hoses. Equipment must be serviced by trained personnel only. A circuit breaker is a switch designed to automatically protect an electrical circuit from damage caused by overcurrent, overload, or short circuit situations.
  • Page 25 CONTROL MODULE - CIRCUIT BREAKERS The IS40 Control Module Main Panel contains three banks of circuit breakers as shown and described below and in the following page.. . CB Bank 2 24V DC Circuit Breakers CB Bank 1 Mains Breakers Preheater A (50A) Preheater B...
  • Page 26 CONTROL MODULE - CIRCUIT BREAKERS WARNING ELECTRICAL SHOCK HAZARD Disconnect all power sources before accessing any electrical connections in the Control Module, Fluid Modules, or Hoses. Equipment must be serviced by trained personnel only. CB Bank 2: Banks 2 hold individual 24V circuit breakers for the Servo Drives, HMI/PLC, Cooling Fan, QuickHeat Hose Modems, and Fluid Module I/O.

  • Page 27: Quickheat Overview

    QUICKHEAT HOSE - OVERVIEW The IS40 and IS30 proportioners are specifically designed to use Carlisle QuickHeat Hoses. These hoses contain high -power internal electric heating cables, ensuring that all of the heating energy is transmitted directly to the fluid. Quick- Heat hoses are provided in 100, 150 or 200 foot (30, 45, or 60m) lengths.

  • Page 28: Installation Overview

    INSTALLATION - OVERVIEW WARNING NOTE Installation of the IS40 exposes installers and users to high voltages and high fluid pressures. Severe injury or death could results from improper installation or installation techniques. Note: IS40 installation requires that a QuickHeat hose is fully assembled and ready for connection to the IS40. See “QuickHeat Hose Manual”...

  • Page 29: Installation Instructions

    INSTALLATION INSTRUCTIONS 1. Unpack IS40 The IS40 Proportioner is shipped securely mounted to a shock-absorbing dual-layer pallet. Mounting screws are used to secure the base of the unit to the pallet. A dual layer carboard cover, enclosure, and heavy duty plastic bag protects the unit during shipping and storage.
  • Page 30 INSTALLATION INSTRUCTIONS 3. Secure IS40 If the IS40 is to be used in a mobile of seismic environment the all frame must be secured to a rigid floor and wall using 5/16” (or larger) grade 8 fasteners and washers. The IS40 frame has integral floor and wall mounting brackets for this purpose.
  • Page 31 INSTALLATION INSTRUCTIONS 5. Make electrical connections inside IS40 Confirm the IS40 rotary disconnect switch is in the OFF (O) position. Open the Control Module by rotating the upper and lower front cover latches on the right side of the cabinet to the open (vertical) position. Insert appropriately rated 4 conductor power cord through the M40 X 1.5 cable gland provided with each IS40 (suitable for 22mm to 32mm cable diameters).
  • Page 32 INSTALLATION INSTRUCTIONS 6. Connect QuickHeat Hose Using an M3 hex key, remove the two button-head screws holding the master modem cover to the left side of the Control Module (when facing) of the IS40 frame. This will expose the fluid outlet jumper hoses and power and communication cable connectors.
  • Page 33 INSTALLATION INSTRUCTIONS 7. Connect fluid supply and recirculation hoses Beginning with either the A or B fluid module, use use an M4 hex key or T-handle tool and remove the two button head screws holding the cover to the pump module. Remove the cover by pulling it forward and over the valve handle (be sure the recirculation valve handle is aligned with the slot in cover as shown below).
  • Page 34 INSTALLATION INSTRUCTIONS 7. Connect fluid supply and recirculation hoses (continued) Do not overtighten JIC ttings as this may damage and require hose or fitting replacement. Applying spray gun grease to the A side JIC threads will allow easier removal for service if required. Pull the locking pin out, slide the module back to position, engage the locking pin, and secure retention cap screws.
  • Page 35 INSTALLATION INSTRUCTIONS 9. Close the gun manifold valves and remove spray gun from the hose In preparation for purging the system or air, check to be sure the material control valves on the gun manifold are in the closed position and remove the spray gun from the manifold. 10.

  • Page 36: Quick-Start Guide

    QUICK-START GUIDE Due to the IS40’s efficient heating systems and simplified startup process, operators will usually be ready to spray within 10-15 minutes from powering on the system. The following are the minimal steps involved in starting up the IS40 with Job Reporting turned off. See page XX for additional steps required when Job Reporting is turned on. 1.
  • Page 37 QUICK-START GUIDE 4. Enter the desired pressure and temperature The center button will change from START to setpoints using the on-screen “+” and “-” buttons. WARMING, and the button boundary will change from solid white to flashing green to indicate the system is warming up.

  • Page 38: Intellispray Operations Tips

    INTELLISPRAY OPERATION TIPS • The system should always be turned off during transportation. • When spraying is completed, stop the system before coiling up hose on the rack (press stop on display screen). This will avoid the possibility of accidental spraying for excessive leakage if the hose is damaged. •...

  • Page 39: Display Screens Overview

    DISPLAY SCREENS - OVERVIEW The IS40 Proportioner uses a 15.6 inch high resolution capacitive multi-touch color display for all user interaction. The wide-angle display is mounted on the front of the Control Module in portrait mode, similar to how a user interfaces with a mobile phone.
  • Page 40 DISPLAY SCREENS - OVERVIEW A pull-down menu icon is located in the top left corner of all display screens (similar to most mobile Apps). When this is pressed, a full menu of all first-level screens is shown. The following figure provides a summary description of each menu item, along with the manual page number for more information.
  • Page 41 SPRAY SCREEN - OVERVIEW The IS40 Spray Screen is factory set as the default start-up screen . Users can enter and adjust key operating settings via screen buttons, on-screen keyboard, pulldown menus, and pop-up windows. Previous user settings are retained when power is cycled. Pressure, Temperature, and Drum Widgets are used for displaying current values and inputting setpoints and other values.
  • Page 42 SPRAY SCREEN - USER INFORMATION The IS40 Spray Screen displays current operating and system information to the user in easy to understand text and graphics. The following figure describes each information element provided to the user on the Spray Screen.. . Bluetooth connection Serial Number to hose enabled...

  • Page 43: Spray Screens

    SPRAY SCREEN - USER ACTIONS The IS40 Spray Screen also contains dynamic fields for user input and actions.. These are shown in the following figure.. Log button (see page XX) Pull-down menus (see page XX) System Alarms (see page XX) Home and Mode Select button Pressure setpoint...
  • Page 44 SPRAY SCREEN - USE The Spray Screen is the factory default startup screen on the IS40. Users can change the startup screen to Exchange Mode if desired (see page XX). The operator uses the Spray Screen to enter the pressure and temperature setpoints to be maintained at the beginning of the heated whip (e.g.
  • Page 45 SPRAY SCREEN - USE 3. Set Drum Levels The A and B fluid levels are displayed in the To accurately track and display the fluid remaining in respective Drum Widgets as both a numeric value each drum, the user must enter the initial level. If and a moving colored level indicator.
  • Page 46 SPRAY SCREEN - USE 4. Check Fluid Valves Check that inlet fluid lines are pressurized and open, NOTE filter valves are open, and recirculation valve is set to spray position. Selector valve in gun position, pointed down. After the IS40 reaches the temperature setpoints (usually about 10 minutes) the system will then pressurize to the user setpoint pressure and the START button will indicate the system is READY to spray.
  • Page 47 SPRAY SCREEN - OTHER FUNCTIONS The IS40 Spray Screen contains other information and functions that may be helpful to the user. Drum Temperature Fluid Ratio In addition to indicating remaining fluid amount, each The real-time fluid ratio (A/B) is also shown on the on Drum Widget shows the inlet fluid temperature.
  • Page 48 SPRAY SCREEN - OTHER FUNCTIONS Yield Calculator The IS40 provides a tool for calculating material yield If an alarm is active the IS40 will automatically change while spraying. Simply press the button to open the from READY state to STOP state and remain in that Yield Calculator.
  • Page 49 SPRAY SCREEN - OTHER FUNCTIONS Alarm Details The user can see more information on active and past errors or warnings by pressing the alarm icon or the alarm message window. Refer to Page XX for more information on the Alarm Screen. Press to see more information on alarm Active Alarm List...
  • Page 50 EXCHANGE SCREEN - OVERVIEW When in Exchange Mode, the IS40 allows the user to independently Purge or Recirculate either A and/or B fluids. In this manual, the definition and difference between Purge and Recirculate functions are as follows: Purge: Fluid is not returned to the supply drums. Drum level counters are decremented by the amount of fluid purged.
  • Page 51 EXCHANGE SCREEN - OVERVIEW Before starting fluid exchange the user must set the following parameters: • Function: Purge or Recirculate • Material: A-Iso, B-Res, A-Iso and B-Res (both) • Fluid Heating: None, Pre-heat, Hose, Pre-heat and Hose (both) • Method: Manual, Time, Amount, Temp These parameters are selected using the pull down menus on the Exchange Screen.
  • Page 52 EXCHANGE SCREEN - OVERVIEW Prior to starting fluid Exchange (Purge or Recirculation), the following parameters must be selected. Parameter set- tings are retained so the user may not have to select again if performing the same Exchange operation. 1. Select Function 3.
  • Page 53 EXCHANGE SCREEN - OVERVIEW 4. Select Method The IS40 allows the user to operate Exchange func- Press to Press to tions (Purge or Recirculate) manually. In addition, the decrease speed increase speed user can select a Method parameter that will automati- cally stop the Exchange action when completed.
  • Page 54 EXCHANGE SCREEN - OVERVIEW 6. Check Fluid Lines 8. Adjust Motor Speed For the fluid(s) to be Exchanged (purged or Motor speed can be adjusted “on the fly” by pressing the recirculated) check to be sure: - and + buttons above the drum icons. While higher jog speeds reduce the Exchange time, they can also cause •...
  • Page 55 EXCHANGE SCREEN EXAMPLE 1 - INITIAL SYSTEM BLEED When the proportioner and/or hoses are installed, an initial system bleed is required to completely replace air with fluid in the supply hoses, proportioner, and distribution hoses. In addition, if air is introduced to the system (e.g. run- ning the drum pump dry) the same procedure must be performed.
  • Page 56 EXCHANGE SCREEN EXAMPLE 1 - INITIAL SYSTEM BLEED 8. Set B motor speed to 0% by pressing the - button in 12. Close the B-side material control valve on the gun the Motor Speed Widget. manifold. 13. Repeat the process for the A-side if required. 9.
  • Page 57 EXCHANGE SCREEN EXAMPLE 2 - A-SIDE MANUAL PURGE In this example old A side material is purged through the entire system with new A material. Since the material has become very viscous, the user has decided to heat the material at 100F during purging. 1.
  • Page 58 EXCHANGE SCREEN EXAMPLE 2 - A-SIDE MANUAL PURGE 10. Increase motor speed by pressing the + button in the 8. Set the A side temperature to 100F by pressing the Motor Speed Widget. As motor (jog) speed is - and + buttons in the Temperature Widget. increased the pump pressure will rise.
  • Page 59 EXCHANGE SCREEN EXAMPLE 3 - B SIDE PURGE AMOUNT In this example a user wants to purge 3 gallons of B material when doing a change-over from Closed Cell (CC) to Open Cell (OC) resin. The user has decided to operate the hose heaters at 100F during the purge process. 1.
  • Page 60 EXCHANGE SCREEN EXAMPLE 3 - B SIDE PURGE AMOUNT 8. Set the B side temperature by pressing the - and + 11. Press the START button to begin purging and buttons in the Temperature Widget. heating. Note, there is no warmup cycle in Exchange Mode.
  • Page 61 EXCHANGE SCREEN EXAMPLE 4 - PREHEAT B DRUM MATERIAL In this example the material in the B (resin) drum will be heated to 90F before spraying. Once the material reaches the target temperature the IS40 will automatically stop recirculation. 1. Be sure the system is in STOP state. 6.
  • Page 62 EXCHANGE SCREEN EXAMPLE 5 - B SIDE AIR PURGE When changing B-side materials it may be important to minimize mixing of materials and/or fluid waste. Changing from Open to Closed Cell resins is a good example, as is changing between some Open Cell formations. Simply pushing through a different B material is acceptable from a hardware standpoint, but it can require “spraying out”...
  • Page 63 EXCHANGE SCREEN EXAMPLE 5 - B SIDE AIR PURGE 9. Attach the compressed air line and/or open the air 9. Attach the compressed air line and/or open the air valve to apply air pressure into the supply hose. The valve. The pump may start to spin under air pump may start to spin under air pressure alone.
  • Page 64 EXCHANGE SCREEN EXAMPLE 5 - B SIDE AIR PURGE 16. Press the START button to begin purging of the old 13. Turn the output valve to spray position as shown in B fluid and replacing with compressed air. the following figure.. 17.
  • Page 65 ALARM SCREEN - OVERVIEW The IS40 displays and categorizes Alarms as either Errors, or Warnings. Errors Errors occur when the IS40 detects a condition that prevents the system from operating in a safe or controlled manner. Errors are intended to prevent personal injury, equipment or property damage, or spraying outside of acceptable process limits.

  • Page 66: Alarm Screen

    ALARM SCREEN - OVERVIEW If the IS40 is in an ERROR state, the ERROR icon will change to solid red and a pop-up message will appear showing ERROR number and description. Only the most recent ERROR will be displayed. In most cases the information provided in the message window will be sufficient for the user to address and resolve the error prior to restarting the system.
  • Page 67 ALARM SCREEN - OVERVIEW The Alarm Screen contains two tables. The upper table displays any active errors that are preventing the system from operating. Warnings are not displayed in the upper table. The lower table shows previous Errors and Warnings. When an error is addressed and the reset button is pressed, the active error will clear and be displayed in the lower window with other past Alarms.
  • Page 68 ALARM SCREEN - OVERVIEW Additional information can be obtained for any active Alarm by pressing anywhere in the Active Alarm (upper) table. A scrollable pop-up will show suggested trouble-shooting actions. For even more detail, pressing the ? Symbol within the pop-up window will open the Operators Manual to the section that corresponds with the displayed Error. Pop-up window provides trouble shooting help.

  • Page 69: Status Screens

    SYSTEM STATUS SCREENS - OVERVIEW The IS40 System Status Screens can be used for system monitoring and diagnostics. The IS40 has three System Status Screens that can be selected from the Main Menu as shown below. The first two Status Screens provide real-time status and performance measurements.
  • Page 70 SYSTEM STATUS SCREENS - IO PAGE 1 The first System Status Screen (IO PAGE 1) displays real-time temperature and pressure outputs of all A-side and B-side Sensors in the fluid path, from inlet to the end of the hose. The A-side values are shown in the left column, and the B-side values are shown in the right column.
  • Page 71 SYSTEM STATUS SCREENS - IO PAGE 2 IO Page 2 of the System Status screens displays real-time machine status and allows the user to perform diagnostic tests on individual heaters. The three sections to the screen are shown below, and additional details are provided in the following pages.
  • Page 72 SYSTEM STATUS SCREENS - IO PAGE 2 The IS40 monitors connection status between internal systems and displays status in the upper left portion of IO Page 2 (see previous page). A red or green status light is displayed showing connection status of each subsystem. All lights must be green for the IS40 to enter a START state.
  • Page 73 SYSTEM STATUS SCREENS - IO PAGE 2 Page 2 of the System Status screens contains a section for monitoring individual heater zone performance. The temperature and duty cycle for A and B-side heating zones are displayed in the lower part of the screen. Heater power ranges from 0% (off) to 100% (full on).
  • Page 74 SYSTEM STATUS SCREENS - TRENDS The System Status screens also provide real-time graphing capabilities of any sensor, set-point, machine State or performance parameter selected by the user. Trend charts are updated every second. Alll selections and settings are retained, so once defined the same charts will be available any time the TREND screen is opened. To re- center the current time, press REFRESH.
  • Page 75 SYSTEM STATUS SCREENS - TRENDS The Trend screen allows the user to select the parameters to be plotted and the timescale to plot against. Selections and settings are retained variables so previous settings are always active. The following example is provided to demonstrate the features and functions of the Trend screen.
  • Page 76 SYSTEM STATUS SCREENS - TRENDS Select parameters to plot Continue selecting pressure and/or performance parameters to plot using their respective selection tools. Press the save button when selections are completed. Fluid Pressure setpoint (at heated whip connection) Fluid Pressure at heated whip connection (hose end) Fluid pressure at pump outlet Fluid pressure at pump inlet Fluid pressure at filter outlet...
  • Page 77 SYSTEM STATUS SCREENS - TRENDS Select time scale (TREND TIME) After selecting the parameters to plot, select the TREND TIME to use from the pull-down menu and press REFRESH to update the time-scale. This sets the trend chart horizontal axis (in the example below, to 5 minutes). Pressing REFRESH places the current time in the center of the chart.

  • Page 78: Settings Screen

    SETTINGS SCREENS - OVERVIEW The IS40 Settings Screen is accessed from the main menu and has five sections that are described below and in the following pages. Users must have Administrative rights to change any parameter in the Settings Screen. System Information Configuration...
  • Page 79 SETTINGS SCREENS - SYSTEM INFORMATION The System Information section of the Settings screen displays a user defined Rig Name, the Proportioner Serial Number, and the number of hose sections. The Rig Name is left to the user with administrative privileges to define. The Serial Number is set at the factory to match the Serial number on the label inside the Control Module but can be changed by Users with Administrative privileges.
  • Page 80 SETTINGS SCREENS - CONFIGURATION SETTINGS The Configuration section of the Setting Screen allows a user to define units and activate job reporting, remote access, and security controls as shown and defined below. UNITS: Select Imperial (factory default) or Metric units for settings and display. Unit Imperial Metric...
  • Page 81 SETTINGS SCREENS - DISPLAY SETTINGS The Display section of the Setting Screen allows a user with Administrative rights to set date and time values and format, default startup screen, and language. Spray screen and English language are factory set defaults. Display Communication Settings...
  • Page 82 SETTINGS SCREENS - COMMUNICATION SETTINGS Communication settings are provided to show internal network status and for configuring both internal and external network services. Also included are hose configuration and communication settings. Only trained service personnel should make changes to these settings. DOC PN#: 341162EN A www.carlisle.com Page 82 of 143...
  • Page 83 SETTINGS SCREENS - HOSE SETTINGS Hose communication parameters are set at the factory when the Proportioner and Hoses are ordered together. During installation it is a good practice to confirm that the selected Hose communication frequency is different from other IntelliSpray systems that will be in close (e.g. <300 ft, 100M) proximity. The following section describe Hose Configuration settings available to the installer or operator.
  • Page 84 SETTINGS SCREENS - HOSE SETTINGS (CONTINUED) DOC PN#: 341162EN A www.carlisle.com Page 84 of 143...
  • Page 85 Hose Configuration Settings (continued) The Hose Configuration menu also contains modem pairing status and a pairing action function. Pairing of modems is performed at the factory prior to shipping when the proportioner and hoses are ordered together. If hoses or hose sections are replaced in the field, the modems will need to be paired in-situ.
  • Page 86 DOC PN#: 341162EN A www.carlisle.com Page 86 of 143...
  • Page 87 SETTINGS SCREENS - FLUID SUPPLY SETTINGS Fluid Supply Settings The lower section of the IS40 Settings Screen is used to define A and B-side warning and error limits related to fluid inlet pressure and drum levels. These settings protect the IS40 from situations that could damage the equipment and/or inject air into the proportioner and hoses.
  • Page 88 RECIPE SCREENS - OVERVIEW Recipes are collections of system parameter settings that can be created, saved, copied, edited, loaded, and deleted by the user. Up to XX Recipes can be saved on the IS40 for future use. Recipes allow users to quickly configure the IS40 for different materials, job conditions, or user preferences.

  • Page 89: Recipe Screens

    RECIPE SCREENS Parameters are categorized in Pressure, Temperature, Each Recipe is defined by five tables. These tables are Ratio, and Miscellaneous tables. Each table indicates used to enable or disable parameters, set their which parameters are enabled, what their value is, and if respective values, and toggle parameter display markers they are graphically displayed on the Spray Screen (or on or off.
  • Page 90 RECIPE SCREENS - PRESSURE TABLE The Recipe Screen has one table for setting both A and B pressure parameters. Further description of each table parameter field is shown below. Factory default settings are shown in the figure. Press to toggle parameter enable/view settings. Displays error and stops system if value is exceeded anywhere in the system Displays warning if value is exceeded anywhere in the system...
  • Page 91 RECIPE SCREENS - TEMPERATURE TABLES The Recipe Screen has identical but separate tables for A and B Temperature parameters. Further description of each Temperature table parameter field is shown below. Factory default settings are shown in the figure. Press to toggle parameter enable/view settings. Displays error and stops system if fluid temperature exceeds value anywhere in the system.
  • Page 92 RECIPE SCREENS - RATIO AND MISC TABLES The Recipe Screen also contains tables for Ratio and Miscellaneous parameter settings. Further description of reach table and their respective parameter fields is shown below. Press to toggle parameter enable/view settings. Ratio control is always enabled and displayed on the Spray Screen.
  • Page 93 RECIPE SCREENS - RECIPE MANAGEMENT The new Recipe will be displayed in the Recipe selection The current Recipe selection is shown at the bottom right window. The Recipe tables can be edited as needed (per corner of each screen. If no Recipes have been defined next pages) and the new Recipe activated by pressing the the IS40 selects and displays the Default Recipe.
  • Page 94 RECIPE SCREENS - EDITING Parameters in the Recipe Tables can be enabled or Pressing the header of the Pressure Parameter table opens the control window shown below. Pressing the disabled, viewed or hidden, and values changed using Enable column in the Low Error row toggles the icons and popup keyboards.
  • Page 95 RECIPE SCREENS - EDITING The following figure shows the pressure gage in its most To enable viewing the high and low pressure alarm limits basic form as displayed on the Spray Screen. on the pressure gage (both warning and error indicators). The user would toggle their respective view settings to on (green check mark) as shown below.
  • Page 96 REPORTS SCREEN - OVERVIEW The IS40 has extensive reporting capabilities. These are divided into two areas - Job Reports and Audit Reports. Job Reporting capabilities can be turned on or off in the Settings Screen (see page XX). The factory default setting for Job Reports is OFF.
  • Page 97 REPORTS SCREEN - AUDIT REPORT The Audit Report screen shows a time-stamped event table containing all user interactions with the IS40 screens, all alarms, and any notes entered by the user. Events are shown in descending time (most recent at the top). The table can be navigated using the slider at the right of the table or by pressing the Forward and Backward buttons below the table.
  • Page 98 REPORTS SCREEN - AUDIT REPORT The Audit table can be very large, making it difficult to search for specific events of interest. To make searching easier, the following functions are provided on the Audit Report screen. Select Duration Enter the word “pump” in the Filter target window (this will be the target word to filter all events with).
  • Page 99 REPORTS SCREEN - JOB NOTES The IS40 allows users to enter and save notes in the Audit table. These notes can be used to record information that may be of interest in the Audit Report or the Job Report. A LOG icon is shown in the upper right corner of every screen.
  • Page 100 REPORTS SCREEN - JOB REPORTS The IS40 has built-in reporting capabilities that provide users, contractors, and owners the ability to create, save, append and distribute comprehensive Job Reports that include: • Job Information • Job Conditions • System Settings and Performance (including Ratio) •...
  • Page 101 REPORTS SCREEN - JOB REPORTS To enter Job Information press the notepad icon and The IS40 continuously saves all system data and enter information using the on-screen keypad. After the dynamically creates the Job Report for the active desired information is entered, press the APPLY button. (loaded) Job.
  • Page 102 REPORTS SCREEN - JOB REPORTS (LOG ENTRIES) The Job Logging menu consists of 4 selections that allow a user to enter information about the Job. This information is not mandatory for a Job Report. Press on the specific menu item to open a data entry window.
  • Page 103 REPORTS SCREEN - JOB REPORTS (LOG ENTRIES) Job Conditions. This feature allows the user to enter Equipment Entry. The Equipment log allows users to up to 20 different environmental and substate enter up to 10 different spray gun types and measurements for a given job report.
  • Page 104 REPORTS SCREEN - JOB REPORTS (MATERIAL INFO) To include A and B material information on Job Reports, users can enter up to 7 items describing each drum of material used on the job. Entering material information is not mandatory for Job Reports but is hghy recommended for traceability and confirmation of materials used.
  • Page 105 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 106 JOB REPORTS - REPORT MANAGEMENT When Job Reports are enabled, each page of the on-screen Job Report contains a section for Report Management. This is found at the bottom of each screen when viewing a Job Report. This section contains buttons for navigating, exporting, ending, creating, and deleting Job Reports.
  • Page 107 JOB REPORTS - REPORT MANAGEMENT Deletes a Job and all related Job To email a job report, select the Job to email from the DELETE information. When the Delete button drop-down window. is pressed, a window will open that allows the user to The attachment button allows the user to select other review and select the Job Report to delete.
  • Page 108 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 109 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 110 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 111 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 112 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 113 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 114 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 115 REPORTS SCREEN - JOB REPORTS When Job Reporting is ON (see page XX) the IS40 is continuously updating the current Job Report, which can be viewed on-screen by selecting REPORTS > JOB REPORTS from the Main Menu. The Job Report has a main summary page (Page 1) followed by detail pages as shown in the following figures.
  • Page 116 REPORTS SCREEN - JOB REPORTS When a Job Report is emailed or output to a USB storage device, the IS40 converts the report to pdf format. The report consists of the same pages as shown in the previous Job Report screens. The only differences are the pdf format, white background and dark text (suitable for printing), and an additional front page and footer logos that can be customized for the user by Carlisle service staff at installation.

  • Page 117: Regular Service-Fluid Module

    REGULAR SERVICE—FLUID MODULE The IS40 Fluid Modules are designed for easy service. Most components and assemblies are easily accessed from the front of the Fluid Module and can be replaced in several minutes if required with minimum tools and fluid loss. Refer to the IS40 Technical Service Manual for instructions on specific component diagnostics, repair, or replacement.
  • Page 118 FLUID MODULE - REGULAR SERVICE Check Pump TSL Level: The gear pumps in each Fluid Module include a chamber around the drive shafts that is filled with TSL (Throat Seal Liquid) at the factory. This prevents atmospheric moisture from migrating into the shaft seals where it could react with Isocyanate in the A-side pump, causing abrasive crystalline material to form that could damage the shaft seal.
  • Page 119 FLUID MODULE - REGULAR SERVICE Burst Disk Replacement: As an additional safety precaution, a Burst Disk assembly rated for 7000 psi is located in the bottom of the A and B High Pressure Manifolds. In case of rupture high pressure fluid is contained within a well and directed downward and away from other equipment or users.

  • Page 120: Regular Service - Control Module

    REGULAR SERVICE - CONTROL MODULE Air Filter Cleaning: A thermostatically controlled fan in the IS40 Control Module pulls in outside cooling air as needed through a reusable air filter in the bottom of the front door. In typical use removal, cleaning, and reinstallation is recommended every 3 months of use.
  • Page 121 FLUID MODULE - ITEM NUMBERS DOC PN#: 341162EN A www.carlisle.com Page 121 of 143...
  • Page 122 FLUID MODULE - ITEM NUMBERS 79 80 DOC PN#: 341162EN A www.carlisle.com Page 122 of 143...
  • Page 123 FLUID MODULE - ITEM NUMBERS DOC PN#: 341162EN A www.carlisle.com Page 123 of 143...
  • Page 124 FLUID MODULE - ITEM NUMBERS DOC PN#: 341162EN A www.carlisle.com Page 124 of 143...
  • Page 125 FLUID MODULE - PARTS LIST ITEM DESCRIPTION 341000 ASSEMBLY, 7D A FLUID MODULE 341001 ASSEMBLY, 7E B FLUID MODULE 341005 COVER, FRONT, FLUID MODULE A 341019 COVER, FRONT, FLUID MODULE B SCREW, BUTTON HEAD 341007 ASSEMBLY, HEATER MODULE POPULATED SCREW, SOCKET HEAD SCREW, CAPTIVE, SOCKET HEAD 341052 COVER, LOWER, FLUID MODULE...
  • Page 126 FLUID MODULE - PARTS LIST ITEM DESCRIPTION 341045 BODY, FILTER 340991 O-RING, FILTER BODY, 2 PK 341029 O-RING, FILTER BODY, 10 PK 341006 ASSEMBLY, HEATER MODULE NOT POPULATED (INCL 25, 50, 54) 341078 FLOW METER (INCL. CABLE, AND QTY 2 TEM 37) 341095 O-RING, FLOW METER, 2PK SCREW, CAPTIVE, SOCKET HEAD...
  • Page 127 FLUID MODULE - PARTS LIST ITEM DESCRIPTION SCREW, SHCS M4X0.7X16 DIN RAIL DIN END ANCHOR TERMINAL BLOCK ASSY, CABLE GLAND PG11 ASSY, CABLE GLAND PG16 ASSY, CABLE GLAND PG7 CABLE, 341024 MODULE, INPUT, ENCODER 24V 341023 MODULE, INPUT TEMPERATURE, 4 CH 341022 MODULE, INPUT PRESSURE, 4 CH SCREW, SHCS M3X0.5X16...
  • Page 128 FLUID MODULE - PARTS LIST ITEM DESCRIPTION 341004 ASSY, PUMP UNION (INCL 2X52, 53, 54, 115, 2X114) UNUSED ASSY, HIGH PRESSURE MANIFOLD HIGH PRESSURE MANIFOLD HIGH PRESSURE SENSOR 0-5000 PSI 341058 KIT, HIGH PRESSURE SENSOR 0-5000 PSI (INCL 46) PLUG, HP MANIFOLD O-RING, PLUG KIT, HP MANIFOLD PLUG (INCL 126) O-RING, SMALL, CHECK VALVE...
  • Page 129 MAIN PANEL - ITEM NUMBERS 245 246 247 247 X2,4 or 6 DOC PN#: 341162EN A www.carlisle.com Page 129 of 143...
  • Page 130 CONTROL MODULE - PARTS LIST ITEM DESCRIPTION NOTE: Items showing NA for part number are not offered as a standard spare part. These items are not expected to fail, or can be acquired from local hardware outlets. If needed, they can be special ordered from Carlisle through authorized Carlisle Distributors. DOC PN#: 341162EN A www.carlisle.com Page 130 of 143...
  • Page 131 CONTROL MODULE - PARTS LIST ITEM DESCRIPTION ASSY, MAIN PANEL BACK PANEL BLOCK, DISTRIBUTION LINE FILTER, EMC CONTACTOR, MAINS SENCOR, HEATER MAINS CONTACTOR CIRCUIT BREAKER, HEATERS, 60A CIRCUIT BREAKER, 24V POWER SUPPLY, 6A CIRCUIT BREAKER, A PUMP MOTOR, 13A CIRCUIT BREAKER, B PUMP MOTOR, 30A CIRCUIT BREAKER, A AND B PREHEAT, 50A CIRCUIT BREAKER &...
  • Page 132 REMOTE ACCESS Remote access to IS40 systems is via the IntelliSpray Cloud (ISC) which acts as a virtual gateway to all systems accessible to registered users. The ISC URL (web address) is provided when purchasing an IS40. Remote access to IS40 systems is a simple two step process that requires a computer, tablet, or phone equipped with a web browser.
  • Page 133 REMOTE ACCESS - OVERVIEW Each IS40 Proportioner is factory equipped with an internal cellular modem that enables remote access for operating, monitoring, updating, and/or servicing the system. Access by registered users (see previous page) is via any computer, phone, or tablet equipped with a standard browser (e.g. IE, Chrome, Safari). The cellular modem also allows users to email Job Reports and performance data to selected recipients.
  • Page 134 REMOTE SERVICE - OVERVIEW The remote access capabilities of the IS40 enables service providers to connect to any system and provide assistance in the form of remote diagnostics, application optimization, remote software upgrades, and enabling short-term “limp mode” capabilities if hardware failures are encountered. Users can call or text their authorized support contact to initiate a remote support session.
  • Page 135 LIMITED WARRANTY CARLISLE SPRAY TECHNOLOGIES (CST) / CARLISLE SPRAY FOAM INSULATION (CSFI) or CAR- LISLE FLUID TECHNOLOGIES will replace or repair without charge any part/or equipment that fails within the specified time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with our written safety and operating instructions, and has been used under normal operating conditions.

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