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Product Manual For other languages of this service manual and additional product information, please scan the QR code above. www.carlisleft.com 341164 D (01/2024)
SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any W A R NI N G Carlisle system, read and understand all of the technical and safety literature for your The user MUST read and be familiar with the IntelliSpray™ products. This manual contains...
SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Fire Hazard Spray Area Fire extinguishing equipment must be present in the spray area and tested periodically. Improper or inadequate operation and Spray areas must be kept clean to maintenance procedures...
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SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Explosion Hazard Electrostatic arcing must be prevented. Safe Spray Area sparking distance must be maintained between the parts being coated and the applicator. A Improper or inadequate distance of 1 inch for every 10KV of output operation and...
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SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Spray Area Parts being sprayed and operators in the Electrical Discharge spray area must be properly grounded. High Voltage Equipment There is a high voltage Parts being sprayed must be supported on device that can induce an...
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SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Electrical Discharge Unless specifically approved for use in Electrical hazardous locations, the power supply, control High voltage equipment is cabinet, and all other electrical equipment Equipment utilized in the process.
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ISOCYANATE INFORMATION IMPORTANT ISOCYANATE INFORMATION GENERAL HANDLING GUIDELINES Isocyanates (ISO) are catalysts used in two component materials. Fluids with isocyanates that are sprayed or dispensed creates potentially harmful mists, vapors, and atomized particulates. Workers exposed to isocyanates can develop a range of short and long-term health problems.
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Ground the spray gun through a connection to a Carlisle approved grounded fluid supply hose. NOTE ISO that has started to cure will reduce the life and W A R NI N G performance of all wetted parts.
PRODUCT OVERVIEW QUICKHEAT HOSE - OVERVIEW ™ ™ QuickHeat Hoses are specifically designed to work with IntelliSpray™ proportioners. These hoses contain high-power internal electric heating cables, ensuring that all of the heating energy is transmitted directly to the fluid. ™ QuickHeat hoses are provided in: 50, 100, 150 or 200 foot (15, 30, 45, or 60m) lengths for master.
PRODUCT OVERVIEW QUICKHEAT HOSE - CONSTRUCTION ™ HOSE COMPONENTS ™ The QuickHeat hose has the following components: Potted modem (2 halves per hose section) - Part of material hose assembly (non-removable) • Material Hoses (2 per hose section) - Replaceable •...
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PRODUCT OVERVIEW POTTED MODEM STRUCTURE Each hose segment has a potted modem half at the start of the segment (one hose section contains 2 modem halves). The modems may differ depending on whether they are part of a master, mid or smart-end segment. The differences are explained in the installation section of this manual.
PRODUCT OVERVIEW QUICKHEAT HOSE SET CONFIGURATIONS ™ The following figures show how Master, Mid, and Smart-End hose sections are assembled into 4 or 6 Zone sets. The only difference between a 4 and 6 zone set configuration is the presence of a Mid Hose with an integrated Y power splitter.
PRODUCT OVERVIEW CONFIGURATION CONNECTIONS - POWER, FLUID, AND COMMUNICATION 4-Zone Configuration 6-Zone Configuration A (Iso) Material Hose A (Iso) Hose Fluid Connector B (Res) Material Hose B (Res) Hose Fluid Connector Air Hose (for spray gun) Air Hose Connector A Hose Heat Power Cable (240V AC) A (Iso) Hose Power Connector B Hose Heat Power Cable (240V AC) B (Res) Hose Power Connector...
INSTALLATION INSTALLATION Refer to the IS30 and IS40 service manuals for instructions on hose setup, pairing modems and selecting communication frequency. ™ Before operating the QuickHeat Hose, ensure all the following installation steps have been completed. W A R NI N G You should only disconnect and reconnect hoses for maintenance or replacement procedures.
INSTALLATION PROPORTIONER-TO-HOSE CONNECTIONS The first phase of the installation is connecting the master hose NOTE modem to the proportioner system. To achieve this: Prior to assembly uncoil hoses to remove any 1. Identify the Master Hose module through the serial number twists.
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INSTALLATION NOTE QuickHeat™ Hose assembly is compatible only with the IntelliSpray™ Systems. 5. Connect the jumper hose fittings (h) to the bottom modem inputs (i) and tighten using the Flats method (discussed in the “Flats Method” section of the manual). Remove plugs from the modem JIC fittings. 6.
INSTALLATION HOSE TO HOSE CONNECTIONS W A R N I N G Ensure that the system is powered down before continuing. Allowing fittings (A&B) to touch while the system is energized (SELV 24vdc) will cause a fault condition that will require a system reboot. Bridging fittings with a metal tool will also generate the same fault .
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INSTALLATION 8. Connect the power cables from the master hose to their matching cables in the mid modem (Refer to the “Cable Termination” section of this manual). See diagram below for layout and connection points. 9. Insert both assembled cables from modem into the center hole of the of the centering clamp, and reinstall bolts. Tighten clamp around cables with a 3mm Allen wrench.
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INSTALLATION NOTE The Mid hose sections come with temp probe sheaths installed on the modem fluid fittings, to protect the probes from damage. You need to remove those in order to install any mid to a master segment. Keep the temperature probe sheaths, caps and plugs in case it is ever necessary to seal that section separately.
Hose is specially designed for use with the Carlisle ST1™ Air Purge Spray Gun. If you need to use other equipment, we recommend using only Carlisle approved Spray Guns or guns designed solely for the same purpose. www.carlisleft.com 341164 D (01/2024)
OPERATION HOSE USAGE KEY OPERATIONAL REQUIREMENTS All air must be purged from system before use to avoid system malfunction (pressure imbalance errors, chemical • solidification, hot spots in hose). Do not heat hose without fluid to avoid damaging the hose and causing leaks. •...
TROUBLESHOOTING PRODUCT TROUBLESHOOTING If these steps don’t solve your issue, please contact foam technical support at 651.925.4856 Issue Identification ActionResolution Leak between hose A or B material leaking out Power down the system. Trace down source of leak. Start by sections at JIC fitting of jacket or loss of opening jacket 3ft (1m) before and after joint to determine...
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TROUBLESHOOTING Issue Identification Resolution No air pressure Insufficient flow at gun or Inspect hose. Open section near modem (on the downstream audible air leak side of the joint). Inspect swivel fitting. Reconnect or tighten fitting as required. A cut air hose can be spliced with a 1/4in barb to barb fitting.
MAINTENANCE PRODUCT MAINTENANCE W A R N I N G Shut off power and depressurize system before servicing. REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS Continuous use or lack of use of the system may both lead to system malfunctioning. Please conduct regular inspections to the system according to the frequency table below.
MAINTENANCE HOSE SECTION/SEGMENT REPLACEMENT The following procedure is only needed in the case a hose section/segment needs to be replaced due to maintenance procedures or damage. Please refrain from disconnecting and reconnecting the hose section/segments unless required. Hose structure varies depending on the configuration of the system and the process is different whether connecting a Master, Mid or Smart End hose.
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MAINTENANCE SINGLE HOSE SEGMENT - REINSTALLATION 1. Position the new hose segment next to the other material hose within the hose section. 2. Reconnect the fluid fittings and tighten using the “Flats Method” discussed later in this manual. 3. Make any necessary power cable connections (only if power cables had been disconnected). See the “Cable Termination”...
MAINTENANCE WRAPPING NEW HOSE SECTIONS After completing the hose section replacement, wrap the hose section at the fittings and modem. Hose jacket should be re-installed around entire hose length with coated side out. Make sure the Velcro along the hose jacket is fully secured. If the jacket is excessively worn, replace jacket section.
MAINTENANCE CLAMP LOCATION MAPPING It is very important to place the clamps in the locations specified in the diagram below. If clamps need to be removed for maintenance, re-install according to the diagram below. This protects electrical connections from upstream and downstream cable tension caused by pulling and bending the hose.
MAINTENANCE CABLE TERMINATION SECTION 3. Install conductors (with ferrules installed) into main 1. Remove one side connector housing and nut from the connector body, and tighten screws using screwdriver connector in need of termination. (e). (Fig. 7,8). NOTE 2. Slide (1) connector nut, (1) sealing gasket, and (1) housing onto cable that is needing to be connected as Install conductors completely into housing seen in Fig.
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MAINTENANCE 4. Screw connector housing to connector body and Match cables per side tighten until housing bottoms out. (Fig. 9). Fig. 11 6. If necessary, repeat steps 1-6 for other end of connector. Fig. 9 NOTE Make sure A cable (red heat shrink/tape) is 5.
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MANUAL REVISIONS MANUAL CHANGE SUMMARY Date Changes Version 17 Feb 22 1st draft, initial release Revision A 10 Oct 22 2nd draft Revision B 1 Aug 23 3rd draft Revision C 1 Jan 24 4th draft, updated template, pictures, installation & maintenance sections Revision D www.carlisleft.com 341164 D (01/2024)
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WARRANTY POLICY This product is covered by Carlisle Fluid Technologies materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance provided, may invalidate any warranty.
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