Carlisle Fluid Technologies IntelliSpray IS40 User manual

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User Manual
IntelliSpray Spray Foam Proportioner
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
Wetted Parts Stainless Steel, Aluminum, Plated Steel, Chemically Resistant Plastic,
Chemically Resistant O-Rings


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Section Page
Warnings 3
Safety 4
Safety with Isocyanates 6
IntelliSpray System 8
IS40 Specifications 9
IS40 Overview 10
Fluid Module 12
Control Module 18
Control Module - Circuit Breakers 23
QuickHeat Overview 26
Installation Overview 29
Installation Instructions 30
Quick-Start Guide 37
IntelliSpray Operations Tips 39
Display Screens Overview 40
Spray Screens 42
Exchange Screens 51
Exchange Screen Examples 55
Alarm Screen 66
Status Screens 70
Settings Screen 79
Recipe Screens 84
Report Screens 92
Regular Service - Fluid Module 113
Regular Service - Control Module 116
Fluid Module Items 117
Control Module Items 125
Harness Items 131
Section Page
Remote monitoring & control nn
Troubleshooting nn
Flushing & Storage nn
Warranty Information nn
Contents

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In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
! WARNING NOTE
or
in
! WARNING
or
in minor
! CAUTION
AUTOMATIC EQUIPMENT Automatic equipment may start
suddenly without warning.
INSPECT THE EQUIPMENT DAILY Inspect the equipment for
worn or broken parts on a daily basis. Do not operate the equip-
ment if you are uncertain about its condition.
NEVER MODIFY THE EQUIPMENT Do not modify the equipment
unless the manufacturer provides written approval.
NOISE HAZARD You may be injured by loud noise. Hearing
protection may be required when using this equipment.
READ THE MANUAL read
and all safety, and maintenance
in the
TRAINING All must be before
equipment.
EQUIPMENT HAZARD can cause the
to or start and result in
injury.
LOCK OUT / TAG-OUT Failure to de-energize, disconnect, lock
out and tag-out all power sources before performing equipment
maintenance could cause serious injury or death.
PRESSURE RELIEF PROCEDURE Always follow the pressure
relief procedure in the equipment instruction manual.
KEEP EQUIPMENT GUARDS IN PLACE Do not operate the
equipment if the safety devices have been removed.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE OF
AN EMERGENCY
WEAR SAFETY GLASSES Failure to wear safety glasses with
side shields could result in serious eye injury or blindness.
PROJECTILE HAZARD You may be injured by venting liquids or
gases that are released under pressure, or flying debris.
STATIC CHARGE Fluid may develop a static charge that must be
dissipated through proper grounding of the equipment, objects to
be sprayed and all other electrically conductive objects in the dis-
pensing area. Improper grounding or sparks can cause a hazard-
ous condition and result in fire, explosion or electric shock and
other serious injury.
PROP 65 WARNING WARNING: This product contains chemicals
known to the State of California
WEAR RESPIRATOR Toxic fumes can cause serious injury or
death if inhaled. Wear a respirator as recommended by the fluid
and solvent manufacturer’s Safety Data Sheet.
TOXIC FLUID & FUMES Hazardous fluid or toxic fumes can
cause serious injury or death if splashed in the eyes or on the skin,
inhaled, injected or swallowed. LEARN and KNOW the specific
hazards or the fluids you are using.
FIRE AND EXPLOSION HAZARD Improper equipment ground-
ing, poor ventilation, open flame or sparks can cause a hazardous
condition and result in fire or explosion and serious injury.
MEDICAL ALERT Any injury caused by high pressure liquid can
be serious. If you are injured or even suspect an injury:
 Go to an emergency room immediately.
 Tell the doctor you suspect an injection injury.
 Show the doctor this medical information or the medical alert
card provided with your airless spray equipment.
GET IMMEDIATE MEDICAL ATTENTION To prevent contact with
the fluid, please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or fingers over the spray tip.
• Never attempt to stop or deflect fluid leaks with your hand,
body, glove or rag.
It is the of the to this to the of the
PINCH POINT HAZARD Moving parts can crush and cut. Pinch
points are basically any areas where there are moving parts.
Read the following warnings before using this equipment
! 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.
TIP/CRUSH HAZARD Do not tip unit. In mobile or seismic installa-
tions be sure unit is secured to floor and wall per instructions.

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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:
 A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves,
protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory
authority.
 Protective eyewear and hearing protection.
TOXIC FLUID OR FUMES HAZARD
• Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are
using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area well ventilated and
always wear appropriate personal protective equipment. See Personal Protective Equipment warnings in this
manual.
• Store hazardous fluid in approved containers and dispose of it according to applicable guidelines.
SKIN INJECTION HAZARD
• High-pressure fluid from gun, hose or fitting leaks, or ruptured components may pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate medical treatment.
• Do not point the spray gun at anyone or at any part of the body.
• Do not put your hand or fingers over the gun fluid nozzle or any fittings in the hose or proportioner.
• Do not attempt to stop or deflect leaks with your hand, body, glove, or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Follow Pressure Relief Procedure, page XX before cleaning, checking, or servicing equipment.
• Use lowest possible pressure when purging, recirculating, or troubleshooting.
• Check hoses, couplings, and fittings daily. Service or replace leaking, worn, or damaged parts immediately.
High pressure hose sections cannot be recoupled; replace the hose section.
BURN HAZARD
• Equipment surfaces and fluid can become very hot during operation. To avoid burns, do not touch hot fluid
or equipment..

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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).
 Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
 Keep the work area free of debris, including solvent, rags, and gasoline.
 Ground equipment and conductive objects (install ground rod or clamp rig to known electrical ground).
 Hold spray gun firmly to side of grounded pail when triggering into pail.
 If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you
identify and correct the problem.
EQUIPMENT MISUSE HAZARD
• Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call your Carlisle distributor for information.
• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment. Use only Carlilse parts and accessories.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents. Such use can cause serious chemical reaction and equipment rupture, and result in
death, serious injury, and property damage.

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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.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards
and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are
trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s
application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.which could
cause off-gassing and offensive odors. Equipment must be carefully maintained and operated according to
instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air
respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves,
protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing.
After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective
equipment must stay out of the work area during application and after application for the time period specified by
the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommen- dations of
the fluid manufacturer and local regulatory authority. Posting a sign such as the following outside the work area
is recommended:
IMPORTANT ISOCYANATE INFORMATION
Isocyanates (ISO) are catalysts used in two component materials.
ISOCYANATE CONDITIONS
WARNING
TOXIC FUME
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL AFTER:
DATE:_______TIME: ______

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MATERIAL SELF IGNITION
Some materials may become self igniting if applied too
thick. Read material manufactuer’s warnings and Safe-
ty Data Sheet (SDS)
KEEP COMPONENTS A and B
SEPARATE
Avoid cross contamination of A and B materials. Cured
material in fluid lines and passages could cause serious
injury or damage equipment.
Never interchange component A and component B wet-
ted parts
Never use solvent on one side that has been contami-
MOISTURE SENSITIVITY of ISO-
CYANATES
Exposure to moisture, such as humidity, will cause ISO
to partially cure and form small, hard, abrasive crystals.
These become suspended in the fluid and can damage
equipment. Eventually, a film will develop on the sur-
face and the ISO will begin to gel and increase in vis-
cosity.
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere in the
empty headspace of the container.
• Never store ISO in an open container.
• Keep the ISO pump reservoir filled with appropri-
ate lubricant. The lubricant creates a barrier be-
tween the ISO and the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Always lubricate threaded parts with an appropri-
ate lubricant when reassembling.
NOTE
FOAM RESINS with 245 FA
BLOWING AGENTS
Some foam blowing agents will froth at temperatures above
90°F (33°C) when not under pressure, especially if agitated.
To reduce frothing, minimize preheating in a circulation
system. Follow resin manufacturers guidelines.
CHANGING MATERIALS
Avoid equipment damage and downtime when chang-
ing materials or flushing for service or storage.
• Flush equipment multiple times to make sure it is
clean.
• Always clean the fluid strainers after flushing
• Check with the material manufacturer for chemical
compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all wetted
parts, and change hoses.
NOTE
GROUNDING
Check local electrical code and proportioner manual for
grounding instructions.
Ground spray gun through connection to a Carlisle ap-
proved grounded fluid supply hose.

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ST1 Spray Gun
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. QuickHeat
hoses have embedded temperature and pressure sensors, independent A and B hose heating, and up to 6
independent heating zones to improve to improve temperature control . QuickHeat hoses provide sensor power
and signal communication without cables or connectors, eliminating failure points and improving reliability.
QuickHeat hoses include a snag-proof, abrasion resistant outer hose wrap that is sealed with industrial-grade Hook
& Loop material to allow individual A or B side hose replacement.
The ST1 gun has improved ergonomics, lower weight,
easier service, and a wider range of output and pattern
control with configurable chamber/tip combinations.
The system will work with other high pressure spray foam
guns that have compatible hose manifolds.
Refer to the QuickHeat Hose manual and ST1 Gun
Manual for more information on each.
IS40 Proportioner
QuickHeat Hose

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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. Refer to page XX for installation
instructions.
Weight 585 lbs (260 kg)
Max Fluid Pressure 2250 psi (155 Bar)
Operating Temperature 32/120 F (0-50 C)
Humidity 0-85% Non Condensing
Input Voltage 200-240V
Frequency 50/60 Hz
Phase 3
Full Load Amps 78 A
Max. Disconnect 100 A
SCCR 5 kA
Other physical, operating, and electrical
specifications are show in the table to the right. The
electrical specifications include the maximum hose
length that can be powered by the IS40 and motor
current at stall load. Typical current draw in most
applications is under 60 Amps (3 phase), but
installers and owners should consult with their
authorized Carlisle Service Provider to determine the
minimum size circuit for specific installations.
Generator size is left to the rig builder to determine
based on these specifications along with other
electrical loads in the rig.
IS40 Physical, Environmental, and Electrical Specifications

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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. Efficient, high
power preheaters along with independent A and B multizone internal
hose heating assures fluid temperatures are controlled to user
settings. Pressure and temperature sensing near the spray gun
provide consistent performance regardless of hose length, fluid
viscosities, or environmental conditions.
The IS40 Control Module is built with components used in high duty-
cycle rugged industrial environments. The heart of the control
module is an industrial grade controller that senses over 30 inputs
(flow, temperature, pressure) and drives over 10 outputs at up to
1000 times per second. The controller stores job data, recipes,
historical performance information, user information and alarm
histories. Software can be updated remotely or with a USB memory
stick. A 15.4” high-strength touch-screen allows the user to monitor
and control the proportioner and hoses. The IS40 Control Module
provides remote system monitoring, control and service “out of the
box” without any additional hardware, software, or monthly fees.
The Control Module also includes power management, circuit
protection, motor control, heater power, remote connectivity, internal
I/O, and electrical safety systems. Diagnostics and repair are made simple via clear messages and monitoring
screens. If needed, component replacement is fast and simple. The Control Module includes a thermostatically
controlled cooling fan that draws in outside air through a user-cleanable filter.
The IS40 Proportioner uses independent Fluid Modules that contain temperature and pressure sensors, fluid filters,
shutoff and recirculation valves, fluid preheaters, servo motors, flow meters, pressure gages, and direct-drive external
gear pumps specifically designed to handle spray foam materials. This independent, compact, modular design
approach allows the system to deliver material “on-ratio” whenever the gun is triggered. For ease of service, Fluid
Module can be partially or fully extracted from the IS40 frame. All common service components can be accessed
from the front of the module and replaced in the field if minutes.
The IS40 Proportioner is specifically designed to use Carlisle QuickHeat hoses. These unique hoses contain high-
power internal electric heating cables, ensuring that all of the heating energy is transmitted to the fluid. QuickHeat
hoses are provided in 100 and 150 foot lengths. Heated whip hoses are available in 20 and 40 foot lengths. Unheated
whips are available in 6 and 10 foot lengths. Each length of heated hose begins with a fluid manifold or “modem” that
contains pressure and/or temperature sensors, heater cable connectors, and electronics used to send information
over the hose to the Control Module. With this approach no sensor power or communication cables are required,
which are a common source of hose failures in other systems. This approach allows the IS40 to receive more
information from multiple sensing locations at each hose junction. It also allows projection of information down the
hose to a remote monitoring and control devices. More information about QuickHeat hoses is contained in the
QuickHeat Hose Manual.
Finally, the IS40 Control and Fluid Modules are mounted in a high-strength tubular steel frame that protects the
modules and provides multiple horizontal and vertical mounting points.
IS40 OVERVIEW

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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). The figure below and on the following pages will help the user become familiarized with the IS40 Proportioner.
Cellular Antenna
A Fluid Module B Fluid Module
Frame
HMI
Wall Mounting Points
Floor Mounting Points
QuickHeat Hose
Connection Cover
On/Off Switch
Emergency Stop
Control Module

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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. Each Preheater has 22 individual channels for fluid flow that run down and back through the heat
exchanger. Mutli-zone interleaved etched foil heaters are firmly bonded to the top and bottom of the heat
exchanger. This approach eliminates direct heater element contact with fluids (as with immersion heaters) and
increases heat transfer area to fluids by up to a factor of 4 (compared to other systems). This allows the heater
elements to operate at lower temperatures than typical immersion heaters, increasing reliability and reducing the risk
of material charring. Redundant temperature sensors are bonded to the top and bottom of the heat exchangers to
control fluid temperature. A fail-safe replaceable thermal fuse is mounted on the top of each heater assembly to
prevent thermal run-aways if all other control systems fails. All of these design features allow the Preheaters to
come to temperature within several minutes of startup, minimizing warmup time.
Pre-pump Pressure Sensor: This pressure sensor is used to confirm the supply (e.g. drum) pump is providing
enough pressure to prevent gear pump cavitation.
Pre-pump Temperature Sensor: This sensor monitors the temperature of fluid leaving the Preheater and also used
to control fluid temperature when preheating drum material in Exchange mode.
Flow Meter: High precision gear flow meters continuously measure fluid flow to delver A:B fluid on-ratio.
Fluid Pump: The IS40 uses external gear pumps to pressurize and deliver fluid to the distribution (gun) hose .
These pumps are specially designed for compatibility with Isocyanates and Resins used in Spray Foam insulation.
They include integrated shaft lubrication housings, hardened wear plates, and specially coated journal bearings and
shafts for long life.
High Pressure Module: TheHigh Pressure Module houses the following components:
• Check Valve. The Ball Check Valve prevents fluid backflow to the low pressure side of the IS40 Fluid Modules.
• Pressure Sensor: A pressure sensor is mounted in the High Pressure Manifold and used to prevent system
overpressure. It is also used for automatic hose pressure sensor calibration.
• Pressure Gage: An analog pressure gage allows the user to read pressure in the hoses even when the system
in not powered.
• Recirculation and Pressure Relief Valve: The Recirculation valve controls flow to the recirculation fitting and
includes a pressure relief valve that opens at approximately 3000 psi.
• Burst Disk: As an additional safety precaution, a burst disk assembly rated for 7000 psi is located in the bottom
of the High Pressure Manifold,. In case of rupture high pressure fluid is contained within a well and directed
downward and away from other equipment or users. The Burst Disk assembly is a service items that should be
replaced annually or more often based on the properties of fluids being sprayed..
• Hose fittings. JIC fittings for both recirculation and distribution (gun) hoses are located at the bottom of the High
Pressure Module. Fittings are clearing identified by embossed labels in the manifold.
FLUID MODULE OVERVIEW
Heat Exchanger
Laminated Heaters
(Top and Bottom)
Front Heater Manifold
Rear Heater Manifold
Temperature Sensor
(Top and Bottom)

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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. To avoid
gear pump cavitation supply pumps should be sized to provide at least 2 GPM continuous flow at an inlet fluid
pressure of 200 psi. The IS40 will issue an error message and stop if inlet fluid pressure is either too low or too high.
The IS40 Fluid Modules are highly integrated to reduce size, complexity, and number of fluid fittings. With their
modular design approach they can be easily serviced while in the proportioner or completely removed or reinstalled
within minutes. With the exception of minor differences, the A and B fluid modules are identical.
The following images shows the locations of primary components and features in each Fluid Module.
Motor Encoder Connector
Power Cable Connector
Communication Connector
Motor Power Connector
Locking Pin
Servo Motor
Fluid Outlet Fittings
Rear Handle
Filter Module Valves
Front Handle
Recirculation Valve
Pressure Gage
Front Cover
TSL Fill Hole
TSL Sight Gage
Inlet Filter
Frame

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Flow Meter Pump
Recirculation hose fitting
Jumper hose fitting (to gun)
Filter Module
Preheater (enclosed in frame)
High Pressure Module
Drip tray
Pump
Pump Inlet Union
Pump Outlet Union
Pump Plate Motor Mount
Servo Motor
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.
• The A and B covers have different labels on them (A and B).
• The Recirculation valve handles are different colors (red for A, blue for B)
• The outlet JIC fitting sizes are unique for A (JIC 5) and B (JIC 6) to prevent cross-contamination when installing or
servicing.
• The spring loaded locking pin is located on opposite sides for easier access.

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Recirculation Valve handle.
5/16” captive socket head cap screws
(two each module)
M4 cover screws
(two each module)
Spray Position
(handle pointing down).
Recirculation Position
(handle pointing left)
Analog Pressure Gage
Filter Inlet Valve
Filter Outlet Valve
Closed = 1/4 turn CCW
Open = 1/4 turn CW
TSL Reservoir Site Gage Window
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. See page XX for filter service instructions.
Recirculation Valve. Pointing the handle to the drum icon opens flow to the recirculation line. Note it does not stop
fluid flow to the gun hoses. Pointing the handle to the spray gun icon closes flow to the recirculation line, and all flow
will be through the gun hoses.
Analog Pressure Gage: This indicates fluid pressure in the high pressure manifold, including the spray gun hoses.
TSL Reservoir Site Gage: This allows the user to see the TSL fill tube level from the front of the machine. The gear
pumps have a TSL chamber around their input shaft and shaft seals to protect the shaft seal from ISO crystallization
and contamination. Once filled at the factory, the IS40 rarely requires and TSL fluid maintenance as long as the fill
tube cover is in place. If the TSL fluid becomes discolored it should be drained and changed. A drain plug is
provided on the bottom of the pump for this.
Cover Screws: Remove for cover removal. The cover should be in place when the unit is in use.
Captive Screws: These hold the module to the frame, and should always be engaged except when servicing the
module.

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FLUID MODULE
Frame
Heater Module
Front Cover
Flow Meter
Flow Meter
I/O Module
High Pressure Module
Cover
Cover
Fluid Pump
Servo Motor
Pump Module Motor Mount
Fluid Preheater
Flow Meter
Filter Valves
Fluid Module
Recirculation Valve
Pressure Gage
Burst Disk
Pressure Sensor
Check Valve

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Flow Meter
Pump
Preheater
FilterValve Valve
Supply Hose
Fitting
Filter Module
Recirculation
& Pressure
Relief
Valve
Check
Valve
Burst
Disk
Recirculation
Fitting Gun Hose
Fitting
High Pressure
Module
P
P
PP
T
T
P
TTemperature Sensor
Pressure Sensor
Pressure
Gage
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.
The main elements of each A and B Fluid Modules and their functions are described below and shown in the following
pages.
Filter Module: The Filter Module consists the following components mounted in a machined aluminum manifold.
• Inlet and outlet valves. Two 1/4 turn cartridge “poppet” style valves are used to control the inlet and outlet flow
through the filter. The valves are closed when turned counter-clockwise (CCW), and open when turned
clockwise (CW). Icons on the Fluid Module covers indicate position of the valves. When both valves are in the
closed position the user can service the filter elements with minimal fluid loss. The Fluid Modules are at a height
that allows the User to place a bucket under the filter module to collect any drips during maintenance.
• Inlet temperature sensor. The Filter Module contains an inlet temperature sensor that indicates the temperature
of incoming material. The inlet temperature for each material is displayed on drum icons shown on the Spray
Screen. Warning and Error alarms can be set in the Menus Screen to prevent the User from working with fluid
that is outside recommended temperature limits.
• Filter Cap. The 7/8” hex head Filter Cap holds the filter body and elements in place. This is a straight thread
cap that has a sealing O-ring that should be checked and replaced if needed when servicing the filter elements.
• Filter Body: The Filter Body is held in place by the Filter Cap and holds the Filter Elements.
• Filter Elements: Each Filter Body holds two 40 mesh filter elements that can be easily cleaned or replaced.
• Pressure Sensors: The Filter Module has two sensors that measure pressure on each side of the filters. These
sensors allow the IS40 to alerts the user when the filters need to be cleaned or replaced.

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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.
The IS40 Control Module is built with components used in high duty-cycle industrial environments. The heart of the
control module is an industrial grade controller that senses over 30 inputs (flow, temperature, pressure) and drives
over 10 outputs at up to 1000 times per second. The controller stores job data, recipes, historical performance
information, user information and alarm histories. Software can be updated remotely or with a USB memory stick.
The 15.4” high-strength touch-screen allows the user to monitor and control the proportioner and hoses. The IS40
Control Module provides remote system monitoring, control and service “out of the box” without any additional
hardware, software, or monthly fees.
The IS40 Control Module is designed for front-access service while in the proportioner. All components can be
replaced in minutes with simple hand-tools. All items are labeled and all wiring clearly tagged.
The following pages show the location and function of primary components in the Control Module. Refer to the IS40
Service Manual for information on diagnostics, service, and component replacement.
Always be sure the rotary power switch is in the OFF position before opening the Control
Module. Due to electrical shock hazards service of the Control Module must be performed
by trained personnel only.
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.
WARNING
!

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Page 19 of 143
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. Additional information on the Main Panel is contained in the following pages.
HMI/Controller: The IS40 uses a 15.4” TFT mutiTouch HMI (Human Machine Interface) that also contains an industrial
Controller, The Controller performs all machine monitoring and control functions and while the HMI acts as the
interface to the User. This “all in one” device eliminates the need for a separate PLC (Programmable Logic
Controller). The HMI/Controller in the IS40 is specifically designed for the wide range of environmental and mobile
conditions Spray Foam equipment is subject to.
Solid State Relays (SSRs): The IS40 has individual SSRs mounted on heat sinks for all heating zones (A and B
preheaters A and B hose sections). SSRs control heating power by modulating current to the respective heating
zones. Indicator lights on each SSR show when current is being applied to the respective heating zone. When the
light is on or flashing, current is flowing to the respective heating zone.
Cellular Modem and Antenna The Cellular Modem and Antenna allow the IS40 to connect to available cellular
networks. This allows Users to monitor and/or control the IS40 from any standard web-browser on their phone, tablet,
or computer. It also allows Users to email Job Reports to selected recipients, and allows Authorized Service Providers
and to access the unit for remote service and software upgrades.
Cooling Fan: A thermostatically controlled cooling fan pulls external air through a user-serviceable filter in the front
door of the he Control Module. This helps prevent component overheating in hot environments.
E-Stop Button: When pressed, the E(mergency )Stop Button opens the internal high-voltage disconnects that power
preheaters, hoses heaters, and motors. It is provided as a safety device to stop fluid heating and pumping without
pressing the STOP button on the HMI screen.
Air Filter. Cooling air is drawn through a user-serviceable air filter in the Control Module door. See page XX for air
filter cleaning instructions.
Power Switch: The IS40 rotary Power Switch disconnects all voltage to the unit. It also allows use of a-safety lock-
out padlock for preventing accidentally powering on the system when servicing. The switch is on when pointed to at
the I and off when pointed at the O.
USB Ports: Dual USB ports are provided on the side of the Control Module for attaching accessories (e.g. hand-held
scanner for scanning drums and memory sticks used for transferring information (e.g. job reports, software updates).
Cable Gland: A M40 X 1.5 cable gland is provided with each IS40 that is suitable for 22mm to 32mm cable
diameters). In most installations 2/4 SOOW power cable is suitable but installers are responsible for selecting the
proper cable size and insulation based on installation configuration, cable length, and environmental conditions.

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Page 20 of 143
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.
Power Switch
Dual USB Ports
Cable Gland
Cellular Antenna
Cover Latches (2X)
Solid State Relays
(SSRs)
Cooling Fan
Cellular Modem
HMI/Controller
E-Stop Button
Main Panel
Air Filter (not shown)
IS40 Control Module