Page 1 USER MANUAL 347492 B IntelliSpray™ IS30...
Page 2 ADDITIONAL RESOURCES 347492 B (04/2024) www.carlisleft.com...
Page 3: Table Of Contents
02. TABLE OF CONTENTS CONTENTS SAFETY 1-10 SAFETY PRECAUTIONS ............................. 1 WARNINGS ..............................2 ADDITIONAL SAFETY INFORMATION ......................... 9 EU DECLARATION OF CONFORMITY CB TEST CERTIFICATE IMPORTANT ISOCYANATE INFORMATION 13-14 GENERAL HANDLING GUIDELINES ........................13 MATERIAL SELF IGNITION ..........................14 FOAM RESINS W/245 FA BLOWING AGENTS ....................
Page 4 02. TABLE OF CONTENTS IS30 DISPLAY SPECIFICATIONS ........................55 SPRAY SCREEN–OVERVIEW ..........................57 SPRAY SCREEN–USER INFORMATION ......................58 SPRAY SCREEN–USER ACTIONS ........................59 SPRAY SCREEN–USE ............................60 SPRAY SCREEN–OTHER FUNCTIONS........................ 63 DRUM TEMPERATURE ............................ 63 FLUID COUNTER ............................63 FLUID ................................63 FLOW RATE AND TRIGGER % .........................
Page 5 02. TABLE OF CONTENTS SYSTEM STATUS SCREENS-TREND CHARTS ....................101 SELECT PLOT PARAMETERS ...........................102 SELECT TIME SCALE (TREND TIME) .......................104 SETTINGS SCREENS-OVERVIEW ........................105 SETTINGS SCREENS-SYSTEM INFORMATION ....................106 SETTINGS SCREENS-FIRMWARE UPDATES ......................107 SETTINGS SCREENS-SYSTEM STATUS ......................108 SETTINGS SCREENS-CONFIGURATION SETTINGS ....................109 SETTINGS SCREENS-DISPLAY SETTINGS ......................110 SETTINGS SCREENS-SYSTEM SETTINGS ......................111 SETTINGS SCREENS-HOSE CONFIGURATION ....................112 SETTINGS SCREENS-DRIVE STATUS LOG ......................116...
Page 6 02. TABLE OF CONTENTS MAINTENANCE 171-192 REGULAR MAINTENANCE PROCEDURES & RECOMMENDATIONS FLUID MODULE ITEMS ..........................172 LOW PRESSURE MODULE ..........................174 PUMP MODULE .............................176 HIGH PRESSURE MODULE ..........................178 PUMP I/O MODULE ............................180 FLUID MODULE O-RINGS AND SEALS ......................182 CONTROL MODULE ENCLOSURE ........................184 CONTROL MODULE 200-240V ........................186 CONTROL MODULE 380-415V ........................188 CABLES ................................192...
Page 7: Safety
This will result in improved operation, efficiency, and Before the operation, maintenance, or servicing of longer, trouble-free service with faster and easier this Carlisle Fluid Technologies system, fully read and troubleshooting. If you need the necessary manuals understand all technical and safety literature for your and safety literature for your specific IntelliSpray IntelliSpray products.
Page 8: Warnings
03. SAFETY WARNINGS Spray Foam equipment and materials operate under and/or skin irritation, shortness of breath, sore throat, high pressure and temperature and should only be fever, and even permanent respiratory and/or skin used by trained professionals. The fluids used to create damage and/or sensitization.
Page 9 03. SAFETY KEEP EQUIPMENT GUARDS IN PLACE Do not operate the equipment if the safety devices have been removed. FIRE AND EXPLOSION HAZARD Improper equipment grounding, poor ventilation, open flame, or sparks can cause a hazardous condition resulting in fire or explosion and serious injury. PROJECTILE HAZARD You may be injured by venting liquids that are released under pressure;...
Page 10 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicates possible Indicates possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Fire Hazards Fire extinguishing equipment must be present in the spray area. Periodically run a test to make sure the Improper or unsatisfactory equipment stays usable.
Page 11 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicates possible Indicates possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Explosion Hazard Prevent electrostatic arcing. Spark-safe work distance must be maintained between the applicator Improper or unsatisfactory and the parts to get coated. A span of 1 inch for operation and maintenance every 10KV of output voltage is necessary.
Page 12 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicates possible Indicates possible hazards. Prevention of possible hazards. hazard occurrences. Spray Area High Electrical Discharge Operators in the spray area and the parts to be sprayed must be sufficiently grounded. Voltage Equipment This equipment contains a The parts that get sprayed must be held on high-voltage device that can conveyors or hangers that are correctly grounded.
Page 13 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicates possible Indicates possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Toxic Fluid or Fumes Read the Safety Data Sheet (SDS) for instructions on how to correctly handle specific hazards of the Toxic fluids or fumes can fluids to be used, including the effects of long-term cause serious injury or death if exposure.
Page 14 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicates possible Indicates possible hazards. Prevention of possible hazards. hazard occurrences. Equipment Skin and Clothing Burns Do not touch hot fluid or equipment during operation. and Fluids Equipment surfaces and fluids Do not let clothing touch the equipment during can become very hot during operation or immediately after the equipment is operation.
Page 15: Additional Safety Information
03. SAFETY CAUTION Do not operate the IS30 before this section is read. ADDITIONAL SAFETY INFORMATION The IntelliSpray has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all operations for the IntelliSpray will halt when the E-Stop is engaged. The operator must disengage the E-Stop and reset the system to recover from this state.
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Page 17: 04. Eu Declaration Of Conformity
New Brighton MN 55112 USA Low Voltage and EMC Assessment This Declaration of Conformity / Incorporation is issued Carlisle Fluid Technologies Inc under the sole responsibility of the manufacturer: 7166 4th St. N. Oakdale, MN 55128 USA EU Declaration of Conformity...
Page 18: Cb Test Certificate
04. CB TEST CERTIFICATE 347492 B (04/2024) 12 / 243 www.carlisleft.com...
Page 19: Important Isocyanate Information General Handling Guidelines
05. ISOCYANATE INFORMATION IMPORTANT ISOCYANATE INFORMATION GENERAL HANDLING GUIDELINES • Avoid all skin contact with isocyanates. Everyone in Isocyanates (ISO) are catalysts used in two-component materials. the work area must wear chemically impermeable gloves, protective clothing, and foot covers Fluids with isocyanates that are sprayed or dispensed recommended by the fluid manufacturer and local create potentially harmful mists, vapors, and atomized regulatory authorities.
Page 20: Material Self Ignition
Examine the local electrical code and Proportioner viscosity. manual for instructions on how to ground the equipment. Ground the spray gun through a connection to a Carlisle NOTICE Fluid Technologies approved grounded fluid supply hose. ISO that has started to cure will reduce the life and performance of all wetted parts.
Page 21: Intellispray System Overview
06. SYSTEM OVERVIEW INTELLISPRAY SYSTEM OVERVIEW The Carlisle Fluid Technologies IntelliSpray™ IS30 Spray Polyurethane Foam (SPF) system consists of a Proportioner, QuickHeat™ Hose, and ST1™ Spray Gun. The IntelliSpray system is designed for ease of use, increased productivity, “best in class” process control, easy service, and real-time ratio control.
Page 22 06. SYSTEM OVERVIEW Carlisle IntelliSpray™ Spray Foam Proportioners are high-performance devices that deliver Isocyanate (A) and Polyol Resin (B) fluids to a spray gun via Carlisle Fluid Technologies QuickHeat™ hoses. The Proportioner monitors and controls A to B fluid output to a 1:1 ratio and is capable of high pressures, temperatures, and flow rates.
Page 23: Is30 Specifications
07. SPECIFICATIONS IS30 SPECIFICATIONS The IS30 must be securely attached to the floor and wall The IS30 Proportioner is roughly 32” wide, 68” tall, and 27” in any mobile or seismic installation. For more information, deep. Eight separate floor mounting holes are located at the base of the unit, and a slotted wall mounting bracket is refer to the "INSTALLATION"...
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Page 25: Is30 Overview
08. PRODUCT OVERVIEW IS30 OVERVIEW The IS30 is a modular system composed of a Control Module, A and B Fluid Modules, a high-strength tubular frame, and software. The frame includes integral floor and wall mounting brackets. The A and B Fluid Modules are identical except for motor size, front cover labels, recirculation valve colors, and outlet fluid fittings (JIC 5 for A, hose, JIC 6 for B hose).
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Page 27: Fluid Module
09. FLUID MODULE FLUID MODULE The IS30 Fluid Modules independently filter, heat, pressure of 100 psi. The IS30 will issue an error message pressurize, and deliver A and B materials to the and stop if inlet fluid pressure is either too low or too QuickHeat hose and recirculation lines.
Page 28 09. FLUID MODULE The A and B Fluid Modules have similar controls as recirculation line. Note that it does not stop fluid flow to described and shown below. the gun hoses when in recirculation position. Filter Valve: The IS30 has an internal 1/4 turn ball valve Analog Pressure Gauge: This indicates fluid pressure that prevents the backflow of material when cleaning or in the high-pressure manifold, including the spray gun...
Page 29 09. FLUID MODULE The images below show the IS30 Fluid Module with the • The outlet JIC fitting sizes are unique for A (JIC 5) and covers removed. B (JIC 6) to prevent cross-contamination when installing The A and B Fluid Modules are identical except for the or servicing.
Page 30: Module Assemblies-Overview
09. FLUID MODULE MODULE ASSEMBLIES-OVERVIEW The following figure shows the major IS30 Fluid Module components. Additional breakdowns and parts lists are contained in the "MAINTENANCE" chapter. MODULE ASSEMBLIES DESCRIPTION 1. Low-Pressure Module 3. Preheater Cover 1.1 Preheater 4. Front Cover 1.2 Flow Meter 1.3 Filter Module 5.
Page 31: Module Fluid Pathways
09. FLUID MODULE MODULE FLUID PATHWAYS The following diagram shows the fluid path and major fluidic elements in the IS30 Fluid Modules. Flow is from left to right, as indicated by the arrows. High Pressure Pump Module Check Pressure Valve Gauge Flow Meter Recirculation...
Page 32: Filter Module
09. FLUID MODULE FILTER MODULE The primary fluid handling elements of each A and B Screen to prevent the User from working with fluid Fluid Module and their functions are described below outside recommended temperature limits. • Filter Body: A 7/8" hex head cap holds the filter and shown in the following pages.
Page 33: Low Pressure Module
09. FLUID MODULE LOW-PRESSURE MODULE Preheater Module: The IS30 uses low-mass preheaters These design features allow the preheaters to come to to warm the A and B fluids on the low-pressure side of temperature within several minutes of startup, minimizing the Fluid Pumps.
Page 34: Pump Module
09. FLUID MODULE PUMP MODULE Fluid Pump: The IS30 uses external gear pumps Pump Module: The IS30 uses external gear pumps to pressurize and deliver fluid to the distribution driven by DC Servo Motors to pressurize and deliver (gun) hose. These pumps are specially designed to fluid to the distribution (spray gun) hose.
Page 35: High Pressure Module
09. FLUID MODULE HIGH-PRESSURE MODULE Burst Disk: As an additional safety precaution, a burst High-Pressure Module: The High-Pressure Module disk assembly rated for 7000 psi is located at the back houses the following components: Check Valve: The Check Valve prevents fluid backflow of the High-Pressure Manifold;...
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Page 37: Control Module
10. CONTROL MODULE CONTROL MODULE The IS30 Control Module provides overall system control, The IS30 Control Module provides remote system touch-screen HMI, power management, circuit protection, monitoring, control, and service "out of the box" without motor controls, preheater and hose heater controls, any additional hardware, software, or monthly fees.
Page 38: Control Module-Overview
10. CONTROL MODULE E-Stop Button: When pressed, the E-Stop (Emergency) CONTROL MODULE–OVERVIEW button opens the internal high-voltage disconnects that The functions of primary components in the Control power preheaters, hoses, heaters, and motors. It is Module are described below. provided as a safety device to stop fluid heating and Main Panel: Most Control Module components are pumping without pressing the STOP button on the HMI part of the Main Panel assembly.
Page 39: Control Module-Enclosure
10. CONTROL MODULE CONTROL MODULE–ENCLOSURE 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 clearly marked to assist in diagnostics and service. CONTROL MODULE DESCRIPTION 1.
Page 40 10. CONTROL MODULE INTERIOR DESCRIPTION 1. Cooling Fan 6. EMI Enclosure 2. Main Panel 7. Hose Heat Power 3. Dual USB Plugs 8. Hose Communication 4. Power Cord Entry 9. Hose Power 5. Power Switch 347492 B (04/2024) 34 / 243 www.carlisleft.com...
Page 41 10. CONTROL MODULE DOOR DESCRIPTION 1. HMI 4. Cover Latch (x2) 2. Cellular Modem 5. HMI Controller 3. Emergency Stop Switch 6. Filter Assembly www.carlisleft.com 35 / 243 347492 B (04/2024)
Page 42 10. CONTROL MODULE CONTROL BOARD–200V Most Control Module components are part of the Main The wiring is contained in capped Raceways and is Panel and are shown in the following figure. Additional clearly labeled. All components are clearly labeled on Hook &...
Page 43 10. CONTROL MODULE CONTROL BOARD–400V CONTROL BOARD DESCRIPTION 1. Bank 2 Circuit Breakers (Low Voltage Systems) 2. 24V Electronic Breaker 3. 24V Power Supply 4. Power Supply Circuit Breakers 5. Contactors 6. Main Terminal Blocks 7. Line Filter 8. Panel Ground 9.
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Page 45: 11. Circuit Breakers
11. CIRCUIT BREAKERS CIRCUIT BREAKERS A circuit breaker is a switch designed to automatically Bank 1 (shown below) contains the main circuit breakers protect an electrical circuit from damage caused by that feed all other circuits through Bank 2 and 3, as overcurrent, overload, or short circuit situations.
Page 46 11. CIRCUIT BREAKERS CB Bank 2: Bank 2 contains an AC circuit breaker for the 24V DC Power Supply. It also has an electronic circuit breaker for individual low-voltage circuits for the Servo Drives, HMI/PLC, Cooling Fan, QuickHeat Hose Modems, and Fluid Module I/O.
Page 47: Quickheat™ Hose-Overview
QUICKHEAT™ HOSE-OVERVIEW The IS40 and IS30 proportioners are specifically designed Product Features: to use Carlisle QuickHeat™ Hoses. These hoses contain • Fast and reliable heat. Independent A & B embedded high-power internal electric heating cables, ensuring all heater wire submerged in hose fluid achieving > 100˚F heating energy is transmitted directly to the fluid.
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Page 49: Installation-Overview
13. INSTALLATION INSTALLATION-OVERVIEW Note: IS30 installation requires that a QuickHeat™ hose is fully assembled and ready for connection to the IS30. 7. Connect fluid supply and recirculation hoses to A and B See "QuickHeat™ Hose Manual" for more information. fluid modules. Installation of the IS30 should only be performed 8.
Page 50: Installation Procedure
13. INSTALLATION INSTALLATION PROCEDURE STEP 2. PUT IN PREFERRED LOCATION STEP 1. UNPACK THE UNIT Slide, lift, or “walk” the unit into the desired location. Slide the unit on plastic or carboard sheets to position the The IS30 Proportioner is shipped securely mounted to IS30.
Page 51 13. INSTALLATION STEP 3. SECURE THE UNIT STEP 4. TURN OFF ELECTRICAL POWER If the IS30 is used in a mobile or seismic environment, Verify the IS30 is on a dedicated 80A 200-240V 3-Phase the frame must be secured to a rigid floor and wall using or 60A 380-415V 3-Phase + Neutral protected circuit.
Page 52 13. INSTALLATION STEP 5. MAKE ELECTRICAL CONNECTIONS Open the Control Module by rotating the upper and lower front cover latches on the front of the cabinet to the open (vertical) position. Insert appropriately rated four conductor power cords through the M40 X 1.5 cable gland provided with each IS30 (suitable for 22mm to 32mm cable diameters).
Page 53 13. INSTALLATION STEP 6. QUICKHEAT™ HOSE CONNECTION Lift and slide the Master Modem cover off its bracket. Remove upper and lower hose clamp bolts and outer clam shells. Set the Master modem in its bracket. Note: zip-ties can help hold the modem in place when attaching hoses.
Page 54 13. INSTALLATION STEP 7. FLUID SUPPLY AND RECIRCULATION CONNECTIONS Begin with either the A or B fluid module, and loosen the 5/16” socket head captive screw that holds the module to the IS30 frame. Pull the spring-loaded locking pin on the outside of the module.
Page 55 13. INSTALLATION Connect the recirculation line to the corresponding module (JIC 5 on A module, JIC 6 on B module). Use installation kit PN 341133 to connect to 1/4” NPT recirculation hoses (See figures on the following page). Do not overtighten JIC fittings, which may damage them, and require a hose or fitting replacement.
Page 56 13. INSTALLATION STEP 9. CLOSE GUN MANIFOLD VALVE (30-60 seconds after powering on). AND SPRAY GUN REMOVAL STEP 13. CONFIGURE FOR HOSE SETUP In preparation for purging the system or air, check to be If the Proportioner and Hoses were configured together at sure the material control valves on the gun manifold are the factory, skip this step.
Page 57: 14. Quick Start Guide
14. QUICK START GUIDE QUICK-START GUIDE Due to the IS30's efficient heating systems and simplified The IS30 will display a startup screen while it performs internal system checks. Once completed, the Spray Mode startup process, operators will usually be ready to spray within 10-15 minutes of powering the system.
Page 58 14. QUICK START GUIDE STEP 4. PRESSURE AND TEMPERATURE After the button has been pressed, it will change from START to WARMING; the button boundary will change SETPOINTS from solid white to flashing green to indicate the system Enter the desired pressure and temperature setpoints is in warm-up mode.
Page 59: Intellispray Operation Tips
15. OPERATION TIPS INTELLISPRAY OPERATION TIPS The system should always be turned off during they are set to operate at different hose communication transportation. frequencies to avoid interference and/or cross-talk between systems. Remove and position all hose from the hose rack before turning the system on.
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Page 61: Display Screens
After the proportioner is powered on, the display will indicate that the system is booting up and performing internal hardware checks. A rotating image of the Carlisle Fluid Technologies ST1 spray gun will be shown during startup. If hardware errors are encountered during boot-up, a popup window will appear with the associated error message (see the "TROUBLESHOOTING"...
Page 62 16. DISPLAY SCREENS A pull-down menu icon is located in the top left corner of The following figure provides a summary description of all display screens (similar to most mobile Apps). When each menu item and the page number in this manual for this is pressed, a menu of all first-level screens is shown.
Page 63: Spray Screen-Overview
16. DISPLAY SCREENS SPRAY SCREEN –OVERVIEW The Spray Screen is factory-set as the default start-up This makes sure that the IS30 delivers the most screen. Users can enter and adjust key operating settings consistent performance regardless of material flow via screen buttons, on-screen keyboard, pulldown menus, rates, viscosity, hose length, elevation changes, or and pop-up windows.
Page 64: Spray Screen-User Information
16. DISPLAY SCREENS SPRAY SCREEN –USER INFORMATION The 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. 1.
Page 65: Spray Screen-User Actions
16. DISPLAY SCREENS SPRAY SCREEN –USER ACTIONS The Spray Screen also contains dynamic fields for user input and actions. These are shown in the following figure. 1. Pull-Down Menus (see "DISPLAY SCREENS-OVERVIEW") 2. Home and Mode Select Button 3. Pressure Setpoint (press to decrease) 4.
Page 66: Spray Screen-Use
16. DISPLAY SCREENS SPRAY SCREEN–USE The Spray Screen is the factory default startup screen. systems, there are no preheat temperature setpoints, Users can change the startup screen to Exchange Mode if static pressure controls, knobs, dials, buttons, or levers desired (see "SETTINGS SCREENS-DISPLAY SETTINGS"). to operate.
Page 67 16. DISPLAY SCREENS STEP 3. SET DRUM LEVELS The A and B fluid levels are displayed in the Drum Widgets as both a numeric value and a moving colored level indicator. The system decrements the amount of material sprayed or purged if in Exchange Mode from the Drum level initial drum level entered by the user.
Page 68 16. DISPLAY SCREENS STEP 4. CHECK FLUID VALVES Check that inlet fluid lines are pressurized and open, filter valves are open, and the recirculation valve is set to spray position. STEP 5. START THE PROPORTIONER Press the "START" button at the bottom of the spray screen.
Page 69: Spray Screen-Other Functions
16. DISPLAY SCREENS SPRAY SCREEN–OTHER FUNCTIONS Drum temperature The Spray Screen contains other information and functions that may be helpful to the user. Drum level (graphical) DRUM TEMPERATURE In addition to indicating the remaining fluid amount, each Drum Widget shows the inlet fluid temperature. This Drum level (value) is sensed at the inlet to the proportioner and indicates drum temperature when the material is flowing (e.g.,...
Page 70: Alarms
16. DISPLAY SCREENS ALARMS A red alarm icon and a dialogue box in the upper right section of the Spray Screen indicate active alarms. The Alarm icon is white when there are no active Alarms. Alarms can be either Warnings or Errors. Warning Alarms do not stop the system but must be addressed before they create an Error condition.
Page 71: Alarm Details
16. DISPLAY SCREENS ALARM DETAILS Users can see more information on active and past errors or warnings by pressing the alarm icon or message win- dow. Refer to "ALARM SCREENS" for more information on the Alarm Screen. Press to see more information on alarm Active Alarm List Past (Inactive) Alarm List www.carlisleft.com...
Page 72: Inlet Compensation
16. DISPLAY SCREENS INLET COMPENSATION Icon indicates Inlet Compensation is enabled. When Inlet Compensation is enabled, a small dial icon is shown within the Pressure Widget (as shown). Inlet Compensation is enabled from the factory but can be disabled in the Recipe Pressure Table (see "RECIPE SCREENS").
Page 73: Automatic Viscosity Compensation (Avc™)
16. DISPLAY SCREENS AUTOMATIC VISCOSITY COMPENSATION (AVC™) IS30 Proportioners are equipped with Automatic Viscosity Control (AVC™). When enabled, AVC continuously adjusts DeltaP 207 fluid temperatures throughout the system to minimize viscosity differences between the A (Isocyanate) and B (Resin) materials. At the same time, AVC maintains the user-defined fluid output mix temperature and pressure.
Page 74 16. DISPLAY SCREENS When AVC™ is active, the dynamic pressure difference (DeltaP) is shown in the upper left portion of the Spray Screen. DeltaP is the actual pressure difference between the A and B fluids at the end of the distribution hose (nearest the gun).
Page 75: Automatic Inlet Compensation (Aic)
16. DISPLAY SCREENS AUTOMATIC INLET COMPENSATION (AIC) Gauge icons indicate AIC is active. IS30 proportioners are equipped with Automatic Inlet Compensation (AIC). AIC continuously monitors inlet fluid pressures and adjusts A and/or B gear pump speed as needed to prevent fluid cavitation in the supply lines or low-pressure manifold of the proportioner.
Page 76: Exchange Screen-Overview
The proportioner includes fittings for attaching purge or recirculation hoses to the fluid modules (see "FLUID MODULE"). Carlisle Fluid Technologies provides a recirculation manifold with all ST1™ Spray Gun kits that can be attached to the hose manifold for recirculating from the hose end.
Page 77: Exchange Screen-Use
16. DISPLAY SCREENS EXCHANGE SCREEN–USE These parameters are selected using the pull down menus on the Exchange Screen. Before starting fluid exchange the user must set the The Exchange Screen is context sensitive and will adapt following parameters: to the specific parameters selected. Function: Purge or Recirculate All Exchange parameters are retained from the last time Material: A-ISO, B-RES, A-ISO and B-RES (both)
Page 78 16. DISPLAY SCREENS Prior to starting fluid Exchange (Purge or Recirculation), the following parameters must be selected. Parameter settings are retained so the user may not have to select again if performing the same Exchange operation. STEP 1. SELECT FUNCTION Select desired function Purge or Recirculate.
Page 79 16. DISPLAY SCREENS STEP 4. SELECT METHOD The proportioner allows the user to operate Exchange functions (Purge or Recirculate) manually. In addition, the user can select a Method parameter that will automatically stop the Exchange action when completed. The Method options are shown described and below. The proportioner configures the Exchange screen based on selected parameters.
Page 80 16. DISPLAY SCREENS STEP 6. EXAMINE FLUID LINES For the fluid(s) to be Exchanged (purged or recirculated) check to be sure: • Supply pumps are at pressure • Supply valves are open • Filter valve on the proportioner is open •...
Page 81: Example 1-Initial System Bleed
16. DISPLAY SCREENS EXAMPLE 1–INITIAL SYSTEM BLEED When the proportioner and/or hoses are installed, an If air is not removed from the system properly, the initial system bleed is required to completely replace gear pumps, preheaters, and/or hose heaters can be air with fluid in the supply hoses, proportioner, and damaged.
Page 82 16. DISPLAY SCREENS STEP 8. SET B MOTOR SPEED Set B motor speed to 0% by pressing the — button in the Motor Speed Widget. STEP 9. SYSTEM MODE Press the "START" button to turn on the B Motor. STEP 10. INCREASE B MOTOR SPEED Increase B motor speed by pressing the + button in the Motor Speed Widget.
Page 83: Example 2-A Side Manual Purge
16. DISPLAY SCREENS 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. STEP 1.
Page 84 16. DISPLAY SCREENS STEP 8. SET A SIDE TEMPERATURE Set the A-side temperature to 100°F. Press the – and + buttons in the Temperature Widget. STEP 9. SET B MOTOR SPEED Set B motor speed to 0% by pressing the — button in the Motor Speed Widget.
Page 85: Example 3-B Side Purge Amount
16. DISPLAY SCREENS 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.
Page 86 16. DISPLAY SCREENS STEP 8. SET B SIDE TEMPERATURE Set the B-side temperature. Press the – (8a) and + (8b) buttons in the Temperature Widget. STEP 9. SET PURGE AMOUNT Note that the Target amount to purge now appears next to the B drum icon.
Page 87: Example 4-Preheat B Drum Material
16. DISPLAY SCREENS 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 IS30 will automatically stop recirculation. STEP 1. SYSTEM MODE Be sure the system is in "STOP"...
Page 88 16. DISPLAY SCREENS STEP 8. SYSTEM MODE Press the "START" button to begin the recirculation and fluid heating operation. STEP 9. INCREASE B MOTOR SPEED Increase B motor speed by pressing the + button in the Motor Speed Widget. While most Exchange functions can be operated at 50% or lower motor speed settings, in recirculation mode motor speed can be increased to accelerate preheating the fluid in the drum.
Page 89: Example 5-Side Air Purge
16. DISPLAY SCREENS EXAMPLE 5–SIDE AIR PURGE STEP 4. B SIDE RECIRCULATION Confirm that the B-side recirculation hose is connected to When changing B-side materials, minimizing mixing the B drum or directed into a waste container. different materials and/or fluid waste may be important. Changing from Open to Closed Cell resins is a good STEP 5.
Page 90 16. DISPLAY SCREENS STEP 6. EXCHANGE MODE After selecting Exchange Mode from the main menu: 6a. Select Purge from the "FUNCTION" menu. 6b. Select B-RES from the "MATERIAL" menu. B-RES 6c. Select OFF from the "HEAT" menu. 6d. Select Manual from the "METHOD" menu. WARNING Do not activate the heat mode during an air purge operation.
Page 91 16. DISPLAY SCREENS STEP 12. RECIRCULATION VALVE Turn the recirculation valve to spray position as shown in the following figure. STEP 13. B SIDE MATERIAL CONTROL Remove the spray gun from the hose manifold. Secure or hold the manifold over a waste container and open the B material control valve to catch fluid.
Page 92: Alarm Screen-Overview
16. DISPLAY SCREENS ALARM SCREEN–OVERVIEW The IntelliSpray Proportioner displays and categorizes Alarms as either Errors, or Warnings. ERRORS Errors (1) occur when the proportioner 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 93: Alarm Screen-Use
16. DISPLAY SCREENS ALARM SCREEN–USE If the proportioner is in an "ERROR" state, the "ERROR" icon (1) 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 94 16. DISPLAY SCREENS The Alarm Screen contains two tables: The upper table displays any active errors that prevent 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 95 16. DISPLAY SCREENS Additional information can be obtained for any active Error by pressing in the Action box (1). A pop-up window (2) will show more information on the Error Condition and also provide recommended Actions (3) to resolve the Error. All Errors and Actions are also contained in tables at the end of this manual for reference.
Page 96 16. DISPLAY SCREENS The Alarm History table displays previous Alarms (Errors and Warnings) that have occurred over a selected “look- back” time frame, which can be set from the Duration pull-down menu (1). Press Refresh (2) to update the Alarm History Window when changing the Duration selection.
Page 97: System Status Screens-Overview
16. DISPLAY SCREENS SYSTEM STATUS SCREENS–OVERVIEW IO PAGES: Displays real-time sensor and system performance data, and accesses the Sensor Bypass The System Status Screens can be used for system capabilities of the IS30. monitoring and diagnostics. Inlet Health: Provides high resolution real-time plots of The IS30 has three System Status Screens that can be selected inlet pressures.
Page 98: System Status Screens-Io
16. DISPLAY SCREENS SYSTEM STATUS SCREENS–IO PAGE 1 To access the I/O Page 1, select "IO PAGE" (1) from the SYSTEM main menu shown. The first System Status Screen accesses two pages of I/O (Input/Output) information related to system performance. The first I/O Page displays real-time temperature and pressure values of all A and B-side sensors in the fluid path from proportioner inlet to the end of the hose.
Page 99: System Status Screens-Io
16. DISPLAY SCREENS SYSTEM STATUS SCREENS–IO PAGE 2 I/O Page 2 of the System Status screens displays real- time machine performance. The three sections of the screen are shown, and additional details are provided in the following pages. All Errors and Actions are also contained in tables at the end of this manual for reference.
Page 100 16. DISPLAY SCREENS The IS30 monitors connection status of all sub-systems Pump efficiency warning and error limits can be set in and displays status in the upper left portion of IO PAGE 2 the Recipe Screens. If set, these values are shown to the (see previous page).
Page 101 16. DISPLAY SCREENS IO Page 2 of the System Status screens also shows power switch symbol will show a green border. a section for monitoring individual heater zone 1. Solid State Relay status is (On) performance. 2. Heater Zone Power Indicators The temperature and duty cycle for A and B-side heating (green border = power on) zones are displayed in the lower part of the screen.
Page 102: System Status Screens-Sensor Bypass
16. DISPLAY SCREENS SYSTEM STATUS SCREENS The Sensor Bypass Screen is accessed from I/O Screen 1 or I/O Screen 2, as shown. –SENSOR BYPASS In the rare event of a temperature and/or pressure 1. IO PAGE 1 sensor failure, the IS30 Sensor Bypass feature allows the 2.
Page 103 16. DISPLAY SCREENS When a sensor error occurs, it will be logged in the Alarm Screen as an active error (see "ALARM SCREEN-USE"). If the error cannot be corrected, and spraying must continue, press the box next to the sensor or hose section to bypass.
Page 104: System Status Screens-Inlet Health
16. DISPLAY SCREENS SYSTEM STATUS SCREENS–INLET HEALTH The Inlet Health screen provides high resolution real-time plots of selected inlet pressures. The data rate is 10X faster than the Trend Plot option, and can help identify and diagnose performance issues with transfer pumps (e.g. seal or check valve leakage, sticking piston, ice build up, etc).
Page 105 16. DISPLAY SCREENS To input or change Inlet Health parameters, press on the selection tool to open the selection menu. Refer to the following figure to select pressure values to plot and pressure scale range. 1. Selection Menu (press to open). 2.
Page 106 16. DISPLAY SCREENS After closing the selection tool, pressure traces will be displayed. The figure shows an example plot of the A-side pre-filter pressure (blue line), and the A-side pressure at the inlet to the gear pump (red line). The pressure pulsation in the blue line is caused by the cyclic motion of the pneumatic two-ball piston transfer pump.
Page 107: System Status Screens-Trend Charts
16. DISPLAY SCREENS SYSTEM STATUS SCREENS –TREND CHARTS The System Status menu provides access to real-time charting of any sensor, set-point, machine state or performance parameter selected by the user. Trend charts can be helpful for performing system diagnostics or performance optimization. All selections and settings are retained, so once defined the same charts will be available any time the Inlet Heath screen is opened.
Page 108: Select Plot Parameters
16. DISPLAY SCREENS The Trend Chart screen allows the user to select the parameters to be plotted and the timescale to plot against. The following example demonstrates the features and functions of the Trend screen. SELECT PLOT PARAMETERS To create a Temperature Trend chart begin by selecting temperatures to plot.
Page 109 16. DISPLAY SCREENS Continue selecting pressure and/or performance parameters to plot using their respective selection tools. Press the Save button when selections are completed. 1. Set Point (fluid pressure at last hose modem). 2. Hose End ( fluid pressure at last hose modem). 3.
Page 110: Select Time Scale (Trend Time)
16. DISPLAY SCREENS SELECT TIME SCALE (TREND TIME) The chart can be moved backwards or forwards in time by pressing the "PAGE LEFT" or "PAGE RIGHT" button or After selecting the parameters to plot, select the "TREND by swiping the chart to the right or left with a finger. TIME"...
Page 111: Settings Screens-Overview
16. DISPLAY SCREENS SETTINGS SCREENS–OVERVIEW The Settings Menu is used to access and define various systems settings. These system settings are frequently defined at installation and not usually accessed during normal operation. The Settings Screen is accessed from the main menu and has five sections described in the following pages.
Page 112: Settings Screens-System Information
16. DISPLAY SCREENS SETTINGS SCREENS Use the arrow buttons to move between pages. Firmware can be updated from a USB memory stick using the –SYSTEM INFORMATION Firmware Update feature on the second page. The System Information section of the Settings screen 1.
Page 113: Settings Screens-Firmware Updates
–FIRMWARE UPDATES INFORMATION"). The Firmware Manager window will appear. From time-to-time, Carlisle Fluid Technologies releases updates to the IS30 and/or QuickHeat Hose Firmware. Press the Install button to begin updating. Firmware These updates add capabilities and fixes for have been updates by USB stick take several minutes.
Page 114: Settings Screens-System Status
16. DISPLAY SCREENS SETTINGS SCREENS–SYSTEM STATUS Pressing the System Status displays total System On time and A (Isocyanate) and B (Resin) fluid used over the life of the IS30. A and B fluid trip counters are also shown. Available RAM (Random Access Memory) is also shown in Bytes.
Page 115: Settings Screens-Configuration Settings
16. DISPLAY SCREENS 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. 1. UNITS: Select Imperial (factory default) or Metric units for settings and display.
Page 116: Settings Screens-Display Settings
16. DISPLAY SCREENS SETTINGS SCREENS–DISPLAY SETTINGS 1. Change Date (click box or use arrows to enter or change). The Display section of the Setting Screen allows a user to 2. Change Time (click box or use arrows to enter or set date and time values and format, and default boot-up change).
Page 117: Settings Screens-System Settings
IS30 for emailing Job Reports. Most systems are preconfigured using a generic SMTP email server managed by Carlisle Fluid Technologies. Users can change the parameters to use their own SMTP server. Email server parameters can be restored to factory defaults by pressing the Factory Default button for 3 or more seconds.
Page 118: Settings Screens-Hose Configuration
16. DISPLAY SCREENS SETTINGS SCREENS select hose communication frequency). –HOSE CONFIGURATION 8. Hose Sections (press to specify the number and type of hose sections). Hose Configuration parameters are set at the factory when the Proportioner and Hoses are ordered together 9.
Page 119 16. DISPLAY SCREENS Before changing any Hose Configurations, the system Before initiating another scan press Clear, and when must be in "STOP" state. A warning will appear if changes finished, press the Close button. are attempted when not in "STOP" state. If there are no Advised frequencies, press the help button Pressing the Hose Configuration Frequency button will at the bottom of the screen.
Page 120 16. DISPLAY SCREENS Pressing the Sections button opens a submenu that is used to select the configuration of the hoses connected to the Proportioner. The hose configuration is set at the factory for Proportioners that are preconfigured with the hose assembly.
Page 121 16. DISPLAY SCREENS The Hose Configuration Calibration function is used 4. A-ISO Pressure Calibration (press to open). to check and/or calibrate the Hose and Proportioner 5. B-RES Pressure Calibration (press to open). pressure sensors. This calibration is preformed prior to shipment on systems that are ordered together.
Page 122: Settings Screens-Drive Status Log
16. DISPLAY SCREENS SETTINGS SCREENS–DRIVE STATUS LOG The Drive Status Log retains up to 100 past log entries. Use the scroll bar, or swipe vertically to move through the The Drive Status Log button provides detailed information entries. about the A or B motor drive controllers. This Log is a history of motor drive states, errors, and actions.
Page 123: Settings Screens-Supply Settings
16. DISPLAY SCREENS SETTINGS SCREENS–SUPPLY SETTINGS The system generates an error message and stops if pressure drops below setting. The minimum pressure The Supply Settings function is used to define drum or setting is 25 psi (1.7 bar). tote size, as well as A and B-side inlet pressure warning Inlet low pressure warning limit.
Page 124: Settings Screens-Preheaters
16. DISPLAY SCREENS SETTINGS SCREENS–PRE-HEATERS The IS30 is shipped with one preheater in each fluid module. The proportioner can be field upgraded from one to two preheaters per fluid module. Adding a second preheater will increase the heating power and temperature rise through the preheaters, which can reduce drum conditioning times or provide more heating power when operating with a shorter distribution hose.
Page 125: Settings Screens-Yield Calculator
16. DISPLAY SCREENS SETTINGS SCREENS–YIELD CALCULATOR (accessed by clicking the question mark icon). 10. The total spray volume in Board Feet will be The Material section of Settings Screen is used to access automatically calculated. a Yield Calculator and a Material library for defining, editing, exporting and importing A (ISO) and B (Resin) 11.
Page 126 16. DISPLAY SCREENS Note: Green items must be entered to perform a yield calculation, other input fields are optional. User Inputs 1. Entry Number (press - and + buttons to select the entry number). 2. Time (press to apply the optional date and time- stamp test entry).
Page 127 16. DISPLAY SCREENS For user convenience, the Yield Calculator includes embedded calculators for determining test area and average foam thickness. This can eliminate guesswork and/or use of external hand calculators. To access these embedded calculators press the associated question mark icon next to the respective entry.
Page 128: Settings Screens-Material Data
16. DISPLAY SCREENS SETTINGS SCREENS–MATERIAL DATA An optional Material library is also accessed via the Settings Screen. This feature allows users to define, edit, save, and delete information and properties for both A and B materials. This information is used in performing yield calculations and also simplifies information entry for Job Reporting.
Page 129 16. DISPLAY SCREENS Select Delete Material and select from the drop-down menu to delete a material. Select Import Material List to import a material or materials from a USB device attached to the unit. Select Export Material List to export all materials in the material library to a USB device attached to the proportioner.
Page 130: Security
16. DISPLAY SCREENS SECURITY When Security is enabled ("ON") in the Setting Screen user access and permissions will be controlled. Security is enabled or disabled in the Settings Screen as shown. Only users with administration permissions can change the setting and/or create, edit, or delete users. When Security is "OFF"...
Page 131 16. DISPLAY SCREENS Pressing the User Icon will open the User Management menu. A user with an Administrative role can switch users, change passwords, and add, edit, or delete users. A user with a Sprayer role will only have the ability to switch user or change their own password.
Page 132 16. DISPLAY SCREENS To Add or Edit a user, select the corresponding item from the menu and complete the sections (shown below). After entering the User name and password, select the Group the User is assigned to. Groups are either Administrators or Sprayers.
Page 133 16. DISPLAY SCREENS www.carlisleft.com 127 / 243 347492 B (04/2024)
Page 134: Recipe Screens-Overview
16. DISPLAY SCREENS RECIPE SCREENS–OVERVIEW Recipe parameters are displayed and edited using five parameter tables. Recipes are collections of system parameter settings 1. Recipe Help that can be created, saved, copied, edited, loaded, and deleted by the user. 2. Parameters Tables (5) 3.
Page 135 16. DISPLAY SCREENS Each Recipe is defined by five tables. These tables are used to enable or disable parameters, set their respective values, and toggle parameter display markers on or off. While this may seem excessive, having full access to all parameters allows users to tailor their IS30 to their specific needs.
Page 136 16. DISPLAY SCREENS 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. 1. Press to toggle parameter enable/view settings. 2.
Page 137 16. DISPLAY SCREENS 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. 1. Press to toggle parameter enable/view settings. 2.
Page 138 16. DISPLAY SCREENS The Recipe Screen also contains tables for Ratio, AVC™ (Automatic Viscosity Control) and Miscellaneous parameter settings. Further description of reach table and their respective parameter fields is shown below. 1. Press to toggle parameter enable/view settings. 2. Press to enable License Key. 3.
Page 139: Recipe Screens-Management
16. DISPLAY SCREENS RECIPE SCREENS–RECIPE MANAGEMENT Load a recipe: The current Recipe selection is shown at the bottom right corner of each screen. If no Recipes have been defined the Proportioner selects and displays the Default Recipe. The Default Recipe can be modified, but never deleted.
Page 140 16. DISPLAY SCREENS Copy a recipe: Press the "COPY" button, then select the Recipe to copy from, enter a new Recipe name, and press the Apply button. The new Recipe will be displayed in the Recipe selection window. The Recipe tables can be edited as needed (per next pages) and the new Recipe activated by pressing the "LOAD"...
Page 141 16. DISPLAY SCREENS Make a new recipe: The new Recipe will be displayed in the Recipe selection window. The Recipe tables can be edited as needed (per next pages) and the new Recipe activated by pressing the "LOAD" button. Use the "NEW" button to create a new Recipe. Enter the new Recipe name and press Apply.
Page 142 16. DISPLAY SCREENS Delete a recipe: To delete the Recipe, first select it then press the "DELETE" button and then confirm the action by pressing the Apply button. 1. Currently Selected Recipe 2. Recipe Menu (press to open menu and select the recipe to be deleted).
Page 143: Recipe Screens-Editing
16. DISPLAY SCREENS RECIPE SCREENS–EDITING 1. Pressure (p ress to change, enable, or view settings). 2. Press to change value. Parameters in the Recipe Tables can be enabled or 3. Press to toggle setting. disabled, viewed or hidden, and values changed using icons and popup keyboards.
Page 144 16. DISPLAY SCREENS The following figure shows the pressure gauge in its most basic form as displayed on the Spray Screen. High and low alarm parameters are enabled in this example but are not indicated on the gauge. The current Recipe table is shown below.
Page 145: Reports-Overview
16. DISPLAY SCREENS REPORTS–OVERVIEW Audit Reports contain a record of user interactions with the IS30 screens, system alarms, and any Log Notes The IS30 Proportioner has extensive reporting entered by the user. capabilities. These capabilities are divided into two areas: Reports are accessed from the Main Menu.
Page 146: Reports-Audit Report
16. DISPLAY SCREENS REPORTS–AUDIT REPORT The Audit Report screen shows a time-stamped event table containing user interactions with the IS30 screens, system alarms, and any notes entered by the user. Events are shown in descending time (most recent at the top).
Page 147 16. DISPLAY SCREENS 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 The user can select a “look-back” duration using the Duration drop down menu.
Page 148: Reports-Job Notes
16. DISPLAY SCREENS REPORTS–JOB NOTES The IS30 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 149: Job Reports-Overview
16. DISPLAY SCREENS JOB REPORTS–OVERVIEW The IS30 has built-in Job reporting capabilities that provides users, contractors, and/or 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 150 16. DISPLAY SCREENS To enter Job Information press the notepad icon and enter information using the on-screen keypad. After the desired information is entered, press the "APPLY" button. Finally, press the "LOAD" button to start the new Job. The IntelliSpray Proportioner continuously saves all system data and dynamically creates the Job Report for the active (loaded) Job.
Page 151 16. DISPLAY SCREENS 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. User Entry: Job Notes that will be included in the Job Report.
Page 152: Job Reports-Log Entries
16. DISPLAY SCREENS JOB REPORTS–LOG ENTRIES Job Conditions: This feature allows the user to enter up to 20 different environmental and substate measurements for a given Job Report. The time the conditions are measured can be automatically time stamped or the time can be manually entered by the user.
Page 153: Job Reports-Material Data
2. Scan (press to scan). 3. Drum Level (enter the fluid level using the keypad icon). Use a Carlisle drum dip stick or equivalent to accurately measure the fluid level before entering. 4. Drum Number (increment the drum number by pressing the + button).
Page 154: Job Reports-Report Content
16. DISPLAY SCREENS JOB REPORTS–REPORT CONTENT When Job Reporting is "ON" the unit is continuously updating the currently active 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 is followed by 8 additional pages containing detailed information about ambient conditions, materials, yield calculations, sprayers, and equipment used on the job.
Page 155: Job Reports-Report Management
16. DISPLAY SCREENS JOB REPORTS–REPORT MANAGEMENT Each page of the on-screen Job Report contains a section for Report Management. This section contains buttons for navigating, exporting, ending, creating, and deleting Job Reports. Creates a new Job, or loads (continues) an existing Job. Loading an existing Job allows the user to continue logging information from a prior incomplete Jobs.
Page 156 16. DISPLAY SCREENS DELETE: Deletes a Job and information for that Job. When the Delete button is pressed, a window will open that allows the user to review and select the Job Report to delete. Since this is a non-recoverable action, a confirmation is required.
Page 157: Languages
16. DISPLAY SCREENS LANGUAGES IntelliSpray Proportioners can display text in any of the following languages: • English (Factory Default) • Spanish • Chinese • Greek • German • Polish • Italian • Dutch • French • Japanese To change the setting, select the desired language from the drop down menu.
Page 158: Variable Ratio Operation
16. DISPLAY SCREENS VARIABLE RATIO OPERATION 2. Navigate to the Recipe screen: Menu –> Recipe (not shown). (OPTIONAL FEATURE PN 347682) 3. Navigate from there to the column that is labeled ENABLE VARIABLE RATIO "RATIO" and contains the arrow buttons. To enable variable ratio, complete the following steps: 4.
Page 159: Variable Ratio Operation-Enable First Time
16. DISPLAY SCREENS ENABLE FIRST TIME 3. The Ratio Control indicator on the Recipe screen will  change from a red The events that will occur once Variable Ratio is enabled  4..to a green checkmark for the first time: 5.
Page 160 16. DISPLAY SCREENS 7. If the Ratio Control field is disabled, it can only be turned back on using the Ratio Control field. 8. To enable the Ratio Control, check the box next to "License Key", then press the License Key option to reactivate the license key.
Page 161: Servicing
17. SERVICING SERVICING The IS30 Fluid Modules are designed for easy service. 17. Torque the filter body to the manifold at 30 ft-lb. Most components and assemblies are easily accessed 18. Open the inlet ball valve and the filter isolation valve. from the front of the Fluid Module and can be replaced in minutes with minimum tools and fluid loss.
Page 162: Quickheat™ Hose Connection
17. SERVICING QUICKHEAT™ HOSE CONNECTION 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 may damage the shaft seal.
Page 163: Burst Disk Replacement
17. SERVICING BURST DISK REPLACEMENT Burst Disk Replacement: As an additional safety 11. Apply grease to the threads and O-ring on the new precaution against over-pressure conditions, Burst Disk Burst Disk assembly (which includes a new O-ring). assemblies rated for 7000 psi are located on the back of 12.
Page 164: Filter Maintenance
17. SERVICING FILTER MAINTENANCE Air Filter Cleaning: A thermostatically controlled fan in the IS30 Control Module pulls outside cooling air as needed through a reusable air filter at the bottom of the front door. In typical use, removal, cleaning, and reinstallation are recommended every three months.
Page 165: 18. Troubleshooting
18. TROUBLESHOOTING SYSTEM ERRORS AND ACTION When an error occurs, the IS30 automatically enters the The Alarm Screen provides users with more information "STOP" state and turns off power to heaters and motors. on the error condition and recommended actions. If the system is in an error state, the user must eliminate The following tables contain the same information that is the error condition and press the "RESET"...
Page 166 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action Drive A Over Current Error. Drive is overloaded. Reduce the system pressure. Drive B Over Current Error. Drive is overloaded. Reduce the system pressure. Drive A Over Voltage Error. Incorrect AC supply voltage. Verifly for correct supply voltage per configuration.
Page 167 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. Preheater A is too hot. 1. Let the preheater (and/or purge fluid through the preheater). PreHeat Overtemp A. 2. Temperature sensor failure. 2. Examine the temperature sensor connector. 1. Clean or replace the filter element. 1.
Page 168 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. A side pressure exceeds maximum system setpoint. 1. Lower the pressure set point. 2. A side gun manifold valve 2. Raise the pressure error limit in the Recipes turned off. screen.
Page 169 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. B drum pump off. 1. Verify that the B drum pump is providing 100 2. B drum pump pressure -300 psi at the proportioner. too low. 2. Verify that the B supply line valves are open. 3.
Page 170 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. B drum pump off. 1. Verify that the B drum pump is providing 100 2. B drum pump pressure -300 psi at the proportioner. too low. 2. Verify the B inlet and filter valves are open. 3.
Page 171 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. Verify pressure reading matches the analog pressure gauge B Post-Gear Pump Pressure 2. Examine for cavitation. Sensor failure. Sensor Error. 3. Examine the connector. 4. Replace the sensor. 1. Heater cable disconnected or connected to the incorrect Hose Under Temp B Middle 1 Examine the hose power connections.
Page 172 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action SMOSE MM - Event Memory Cycle the power. Contact technical service and Firmware error. Pool is empty. enable limp mode. 1. Examine the modem connection cable. SMOSE MM - Flash Parameter Bad connection between Storage system error.
Page 173 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action 1. Examine the modem connection cable. SMOSE M1 - Multiple master Bad connection between modems detected on RF link. modem A and B sides. 2. Cycle the power. SMOSE M1 - Arbitration lost 1.
Page 174 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action SMOSE M1 - Other errors: 1. Examine the modem connection cable. Bad connection between OverUnderRun, DMA Error or modem A and B sides. 2. Cycle the power. Bus Error. SMOSE M1 - Arbitration lost 1.
Page 175 18. TROUBLESHOOTING SYSTEM ERRORS Error No. Alarm Description Condition Action SMOSE ME - Hose A Hardware Failure. Cycle the power. temperature out of range. SMOSE ME - Hose B Hardware Failure. Cycle the power. temperature out of range. SMOSE ME - Event Memory Pool Firmware Failure.
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Page 177: 19. Maintenance
19. MAINTENANCE REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS Material Purge Regular Inspection Thoroughly purge the system after job completion. Continuous use or lack of use of the system can cause Failure to do so can cause clogs, leaks, or cross- a system malfunction. Do regular interval system contamination of materials when the system is inspections as shown at the table below.
Page 178: Fluid Module Items
19. MAINTENANCE FLUID MODULE ITEMS 347492 B (04/2024) 172 / 243 www.carlisleft.com...
Page 179 19. MAINTENANCE FLUID MODULE ITEMS Qty Used Item Description (Per Module) 347484 A SIDE FLUID MODULE 347485 B SIDE FLUID MODULE 347494 A SIDE FLUID MODULE COVER (INCL. 3) 347495 B SIDE FLUID MODULE COVER (INCL. 3) BUTTON HEAD SCREW, M6 x 1.0 x 12 LG, SST 347496 LOW PRESSURE MODULE POPULATED 347497...
Page 180: Low Pressure Module
19. MAINTENANCE LOW PRESSURE MODULE Note: Installation kit PN 341133 includes 90 degree sweeps (x2), ball valves (x2), and JIC to NPT fittings for recirculation line fittings on high pressure manifolds. 347492 B (04/2024) 174 / 243 www.carlisleft.com...
Page 181 19. MAINTENANCE LOW PRESSURE MODULE Qty Used Item Description (Per Module) 347496 LOW PRESSURE MODULE POPULATED SOCKET HEAD CAP SCREW, M8 x 1.25 x 50 LG, SST 347466 FILTER O-RING KIT (INCL. 5, 6) 10 PK 347468 FILTER BODY KIT (INCL. 4, 5, 6, 26) 347508 O-RING, FILTER, BALL VALVE (3 PK) O-RING, INLET FITTING, FILTER MODULE, FLOWMETER, PREHEATER, BURST...
Page 182: Pump Module
19. MAINTENANCE PUMP MODULE 347492 B (04/2024) 176 / 243 www.carlisleft.com...
Page 183 19. MAINTENANCE PUMP MODULE Qty Used Item Description (Per Module) 347498 PUMP MODULE 347486 ASSEMBLY, PUMP (INCL. 3-11) 347570 PUMP, GEAR (INCL. 8 x2, 7) 347572 O-RING, PUMP UNIONS (2 PK) 347573 FITTING, UNION, GROOVED (INCL. 4 x1, 6 x2) 347566 SEAL, UNION NIPPLE (3 PK) 347574...
Page 184: High Pressure Module
19. MAINTENANCE HIGH PRESSURE MODULE 347492 B (04/2024) 178 / 243 www.carlisleft.com...
Page 185 19. MAINTENANCE HIGH PRESSURE MODULE Qty Used Item Description (Per Module) 347489 A SIDE HIGH PRESSURE MODULE 347500 B SIDE HIGH PRESSURE MODULE 347593 HANDLE KIT, RED RECIRCULATION A VALVE (INCL. 3, 4, 5, 22) HANDLE KIT, BLUE RECIRCULATION B VALVE (INCL. 3, 4, 5, 22) 347664 347592 NUT, RECIRCULATION VALVE...
Page 186: Pump I/O Module
19. MAINTENANCE PUMP I/O MODULE 347492 B (04/2024) 180 / 243 www.carlisleft.com...
Page 187 19. MAINTENANCE PUMP I/O MODULE Qty Used Item Description (Per Module) 347480 PUMP I/O MODULE-CIRCUIT BOARD (DISTRIBUTOR ONLY) STANDOFF, KEYSTONE I/O ENCLOSURE, FLUID MODULE CONNECTOR, FLUID MODULE POWER SOCKET HEAD CAP SCREW, M4 x 0.7 x 16 LG, BO SEE CABLES CABLE, ENCODER CABLE NUT DIN RAIL...
Page 188: Fluid Module O-Rings And Seals
19. MAINTENANCE FLUID MODULE O-RINGS AND SEALS 347492 B (04/2024) 182 / 243 www.carlisleft.com...
Page 189 19. MAINTENANCE FLUID MODULE O-RINGS AND SEALS Qty Used Item Description (Per Module) O-RING, INLET FITTING, FILTER MODULE, FLOWMETER, PREHEATER, BURST 347505 DISK, CHECK VALVE, RECIRCULATION VALVE, (8 PK) 347506 SEAL, TEMPERATURE SENSOR (2 PK) 347507 O-RING, PRESSURE SENSOR (4 PK) 347508 O-RING, FILTER, BALL VALVE (3 PK) 347566...
Page 190: Control Module Enclosure
19. MAINTENANCE CONTROL MODULE ENCLOSURE 347492 B (04/2024) 184 / 243 www.carlisleft.com...
Page 191 19. MAINTENANCE CONTROL MODULE ENCLOSURE Qty Used Item Description (Per Module) CONTROL MODULE COVER ASSEMBLY 347458 10" HMI WITH CODESYS CONTROL MODULE PLATE COVER SCREW CELLULAR MODEM (US, CA, MEX ONLY) CELLULAR MODEM (EU ONLY) 347607 COVER STRUT ASSEMBLY COVER GASKET AIR FILTER BRACKET SCREWS AIR FILTER BRACKET 347459...
Page 192: Control Module 200-240V
19. MAINTENANCE IS30 CONTROL MODULE CONTROL PANEL 200V-240V 15 16 18 15 347492 B (04/2024) 186 / 243 www.carlisleft.com...
Page 193 19. MAINTENANCE CONTROL MODULE 200V-240V CONTROL PANEL Qty Used Item Description (Per Module) 341015 HEATER SSRS 347631 HOSE HEAT GFCI 15A 347678 HOSE COMM RESET 347645 HOSE COMM RELAY 340993 TERMINAL BLOCK RELAY 341017 ECAT COUPLER 341020 ECAT DIGITAL INPUT 8CH 341021 ECAT DIGITAL OUTPUT 16CH 341018...
Page 194: Control Module 380-415V
19. MAINTENANCE IS30 CONTROL MODULE CONTROL PANEL 380V-415V 347492 B (04/2024) 188 / 243 www.carlisleft.com...
Page 195 19. MAINTENANCE CONTROL MODULE 380V-415V CONTROL PANEL Qty Used Item Description (Per Module) IS30 EU BACK PANEL TERMINAL END BLOCK 340979 THERMOSTAT DIN RAIL ADAPTER 1049497 347601 DISTRIBUTION BLOCK 4/6 347602 DISTRIBUTION BLOCK 4/12 347603 DISTRIBUTION BLOCK 4/18 BECKHOFF BUS END CAP 341018 ECAT JUNCTION 2CH 341021...
Page 196 19. MAINTENANCE CONTROL MODULE 380V-415V CONTROL PANEL (cont.) Item Description (Per Module) M8 x 1.25 x 20 mm HEX BOLT M8 EXTERNAL TOOTH LOCKWASHER 347688 FERRITE 250OHM (NOT SHOWN) IS30 CE CAGE - ASSEMBLY VELCRO STRAP 1/2" BLK 330 (NOT SHOWN) 347492 B (04/2024) 190 / 243 www.carlisleft.com...
Page 197: Cables
19. MAINTENANCE CABLES-REFER TO WIRING DIAGRAMS FOR CBL NUMBER CONTROL MODULE Cable No. Description CBL2007 347633 A-ISO ZONE 1 HOSE HEAT CBL2010 347634 B-RES ZONE 1 HOSE HEAT CBL2014 347635 B-RES ZONE 1 HOSE HEAT CBL2017 347636 B-RES ZONE 2 HOSE HEAT CBL3017 347637 HOSE MASTER MODEM POWER...
Page 198: Schematics
20. SCHEMATICS–200V ELECTRICAL DIAGRAMS WIRE GAUGE (UNLESS NOTED) USE MIN 75 DEGREE C COPPER WIRE American Wire Gauge AWG) Diameter (Inches) Cross Sectional Area (mm Ampacity (75° C Copper) 0.2292 26.65 0.2043 21.14 0.162 13.29 0.1285 8.36 0.1019 5.26 0.0808 3.31 0.0641 2.08...
Page 199 20. SCHEMATICS–200V WIRE REFERENCE COLOR RED_GRY RED w/GREY STRIPE GRY_RED GREY w/WHITE STRIPE WHT_BRN WHITE w/BROWN STRIPE BRN_WHT BROWN w/WHITE STRIPE WHT_GRY WHITE w/GREY STRIPE GRY_WHT GREY w/WHITE STRIPE RED_BLU RED w/BLUE STRIPE BLU/RED BLUE w/RED STRIPE RED/ORG RED w/ORANGE STRIPE ORG/RED ORANGE w/RED STRIPE RED/GRN...
Page 200 20. SCHEMATICS–200V LEGEND DESCRIPTIONS NUMBERING CODE XX???? = COMPONENT TYPE ??XX?? = SHEET ????XX = COLUMN WIRE WIRE CONNECTION CROSS CABLE NUMBER CIRCUIT BREAKER CORE IDENTIFIER WITH RATING CB???? CBL???? COLOR TERMINAL BLOCK CONTROL WIRE NUMBER RELAY COIL CR???? ???? TB??? CONTROL RELAY PUSHBUTTON...
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Page 214 20. SCHEMATICS–200V DRAWING 15 PJ7101 ETHERCAT CABLE M12 - STRAIGHT - 4-PIN MALE - D-CODED CBL7027 from 7027 OPTION LENGTHS AVAILABLE (See Note 2) PORT A 09140062733 PJ7107 3019 3019 24VDC SUPPLY from 3021 3019 3019 24VDC SUPLLY from 3023 7109 6109 7109...
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Page 220 20. SCHEMATICS–400V ELECTRICAL DIAGRAMS WIRE GAUGE (UNLESS NOTED) USE MIN 75 DEGREE C COPPER WIRE American Wire Gauge AWG) Diameter (Inches) Cross Sectional Area (mm Ampacity (75° C Copper) 0.2292 26.65 0.2043 21.14 0.162 13.29 0.1285 8.36 0.1019 5.26 0.0808 3.31 0.0641 2.08...
Page 221: Electrical Diagrams 380-415V
20. SCHEMATICS–400V WIRE REFERENCE COLOR RED_GRY RED w/GREY STRIPE GRY_RED GREY w/WHITE STRIPE WHT_BRN WHITE w/BROWN STRIPE BRN_WHT BROWN w/WHITE STRIPE WHT_GRY WHITE w/GREY STRIPE GRY_WHT GREY w/WHITE STRIPE RED_BLU RED w/BLUE STRIPE BLU/RED BLUE w/RED STRIPE RED/ORG RED w/ORANGE STRIPE ORG/RED ORANGE w/RED STRIPE RED/GRN...
Page 222 20. SCHEMATICS–400V DRAWING 1 LEGEND DESCRIPTIONS NUMBERING CODE XX???? = COMPONENT TYPE ??XX?? = SHEET ????XX = COLUMN WIRE WIRE CONNECTION CROSS CABLE NUMBER CIRCUIT BREAKER CORE IDENTIFIER WITH RATING CB???? CBL???? COLOR TERMINAL BLOCK CONTROL WIRE NUMBER RELAY COIL CR???? ???? TB???
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Page 242: Remote Access
21. REMOTE ACCESS REMOTE ACCESS Remote access to IntelliSpray systems is via the STEP 1. Select IS30 IntelliSpray Cloud IntelliSpray Cloud (ISC), a virtual gateway to all systems accessible to registered users. The ISC URL (web An example of the ISC gateway shown in a standard address) is provided when purchasing an IntelliSpray browser is shown in the following figure.
Page 243 21. REMOTE ACCESS Cellular Modem Antenna Each IntelliSpray Proportioner is factory-equipped with an internal cellular modem that enables remote access to operate, monitor, update, and/or service 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).
Page 244 Proportioner. All parties can simultaneously connect to a Proportioner if required to resolve issues or answer questions. Regional Carlisle Field Specialist Note: A user does not have to be in the spray rig to (Second Level Support)
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Page 246: 22. Manual Revisions
22. MANUAL REVISIONS MANUAL CHANGE SUMMARY Date Description Version 12/01/2022 Initial release. 12/21/2022 Updated electrical schematics. 03/13/2023 Updated images and expanded instructions. 11/15/2023 Formatting changes to the document. Added 400V model configuration. 347492 B (04/2024) 240 /243 www.carlisleft.com...
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Page 248: Warranty
This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty. The use of parts or accessories from sources other than Carlisle Fluid Technologies will void all warranties. Failure to follow reasonable maintenance guidance provided can invalidate the warranty.
Page 249 Carlisle Fluid Technologies is a global leader in innovative finishing technologies. Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice. BGK™, Binks®, DeVilbiss®, Hosco®, MS®, and Ransburg® are registered trademarks of Carlisle Fluid Technologies, LLC. ©2024 Carlisle Fluid Technologies, LLC. All rights reserved.

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