Carlisle IntelliSpray IS30 User manual

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IS30 User Manual 347492EN Rev A Page 1 of 192
User Manual
IntelliSpray™ Spray Foam Proportioner
SPECIFICATIONS
Maximum Fluid Pressure 2500 PSI (172 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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Contents
Section Page
1.0 Warnings 4
2.0 Safety Precautions 6
3.0 Important Isocyanate Information 8
4.0 IntelliSpray System Overview 11
5.0 IS30 Specifications 13
6.0 IS30 Overview 14
7.0 IS30 Fluid Module 15
8.0 IS30 Control Module 23
8.1 IS30 Circuit Breakers 29
9.0 QuickHeat Hose Overview 31
10.0 IS30 Installation Overview 33
10.1 IS30 Installation Instructions 34
11.0 IS30 Quick-Start Guide 41
12.0 IntelliSpray Operation Tips 43
13.0 Display Screens Overview 44
14.0 Spray Screen Overview 46
14.1 User Information 47
14.2 User Actions 48
14.3 Use 49
14.4 Other Functions 52
14.5 Automatic Viscosity Compensation 55
14.6 Automatic Inlet Compensation 57
15.0 Exchange Screen Overview 58
15.1 Exchange Screen Use 59
15.2 Example 1: Initial Bleed 63
15.3 Example 2: A Side Manual Purge 64
15.4 Example 3: B Side Purge Amount 67
15.5 Example 4: Preheat B Drum 69
15.6 Example 5: B Side Air Purge 70
16.0 Alarm Screen Overview 73
16.1 Alarm Screen Use 74
17.0 Status Screens Overview 78
17.1 I/O Page 1 79
17.2 I/O Page 2 80
17.3 Sensor Bypass 83
17.4 Inlet Health 85
17.5 Trend Charts 88
Section Page
18.0 Settings Screens Overview 92
18.1 System Information 93
18.2 Firmware Updates 94
18.3 System Status 95
18.4 Configuration Settings 96
18.5 Display Settings 97
18.6 System Settings 98
18.7 Hose Configuration 99
18.8 Drive Status Log 103
18.9 Supply Settings 104
18.10 Preheaters 105
18.11 Yield Calculator 106
18.12 Material Data 109
18.13 Security 111
19.0 Recipes Screens Overview 115
19.1 Recipe Management 120
19.2 Recipe Editing 121
20.0 Report Screens Overview 123
20.1 Audit Report 124
20.2 Job Notes 126
20.3 Job Reports 127
20.4 Log Entries 130
20.5 Material Info 131
20.6 Report Content 132
20.7 Report Management 133
21.0 Languages 135
22.0 IS30 Regular Service 136
23.0 System Errors and Actions 140
24.0 IS30 Fluid Module Items 147
24.1 IS30 O-Rings and Seals 156
25.0 IS30 Control Module Items 158
26.0 IS30 Cables 162
27.0 IS30 Wiring Diagrams 163
28.0 Remote Access 185
Warranty Information 188
CB Test Certificate 189
Declaration of Conformity 190
Contents

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IS30 User Manual 347492EN Rev A Page 4 of 192
Spray Foam equipment and materials operate under high pressure and temperature and should only be used by trained
professionals. The fluids used to create polyurethane foam insulation are hazardous. Unprotected exposure during handling and
use may cause lung, ear, and/or skin irration, shortness of breath, sore throat, fever, and even permanent respiratory and/or skin
damage and/or sensitization. Always refer to the material Safety Data Sheets for proper handling, transportation, storage, and
disposal.
In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
or
in
CAUTION
!
NOTE
1.0 WARNINGS
Read and understand all the warnings in this section and elsewhere in this manual
WARNING
!
AUTOMATIC EQUIPMENT Automatic equipment may start suddenly without warning.
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 be-
fore performing equipment maintenance could cause serious injury or death.
NEVER MODIFY THE EQUIPMENT Do not modify the equipment unless the manufacturer provides
written approval.
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.
INSPECT THE EQUIPMENT DAILY Inspect the equipment for worn or broken parts on a daily basis.
Do not operate the equipment if you are uncertain about its condition.
TIP/CRUSH HAZARD Do not tip unit. In mobile or seismic installations be sure unit is secured to floor
and wall per instructions.
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.
WARNING
!
or
in

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NOISE HAZARD You may be injured by loud noises from support equipment (generators, compressors,
transfer pumps). Hearing protection should be used.
PROJECTILE HAZARD You may be injured by venting liquids that are released under pressure, or flying
debris.
KEEP EQUIPMENT GUARDS IN PLACE Do not operate the equipment if the safety devices have been
removed.
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 dispensing
area. Improper grounding or sparks can cause a hazardous condition and result in fire, explosion or
electric shock and other serious injury.
ELECTRICAL SHOCK HAZARD Disconnect all power sources before accessing any electrical connec-
tions in the Control Module, Fluid Modules, or Hoses. Equipment must be serviced by trained personnel
only.
PINCH POINT HAZARD Moving parts can crush and cut. Pinch points are basically any areas where
there are moving parts.
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 grounding, poor ventilation, open flame or
sparks can cause a hazardous condition and result in fire or explosion and serious injury.
PROP 65 WARNING WARNING: This product contains chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
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.
• Always have the tip guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before spraying.
• Always lock the gun trigger safety when you stop spraying.
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 spray
equipment.
• Tell the doctor what kind of fluid you were spraying or dispensing.
• Refer to the Material Safety Data Sheet for specific information.
1.0 WARNINGS (Continued)
Read and understand all the warnings in this section and elsewhere in this manual
WARNING
!

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2.0 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.
• Relieve pressure in supply hoses, proportioner, and Quickheat hone 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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2.0 SAFETY PRECAUTIONS (Continued)
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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Isocyanates (ISO) are catalysts used in two component materials.
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particu-
lates. 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 in-
structions 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. Af-
ter 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:
3.0 IMPORTANT ISOCYANATE INFORMATION
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: ______
GENERAL HANDLING GUIDELINES

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IS30 User Manual 347492EN Rev A Page 9 of 192
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
ISOCYANATES
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.
3.0 IMPORTANT ISOCYANATE INFORMATION (Continued)

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ST1™ Spray Gun
IS40™ Proportioner
QuickHeat™Hose
IS30™ Proportioner
4.0 INTELLISPRAY SYSTEM OVERVIEW
The Carlisle IntelliSpray Spray Polyurethane Foam (SPF) system consists of an IS40 or IS30 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™ hoses have roughly double the heating power compared to most other SPF hoses and directly heat 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 4
independent heating zones 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 wide range of output and pattern control
with configurable chamber and tip combinations.
The system will also 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.
WARNING
!

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Carlisle IntelliSpray™ Spray Foam Proportioners are high
performance devices that deliver Isocyanate (A) and Polyol Resin
(B) fluids to a spray gun via Carlisle QuickHeat hoses. The
Proportioner 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, elevation changes, or environmental
conditions.
The 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” (IS40) or 10.1” (IS30) high-strength touch-screen allows the
user to monitor and control the proportioner and hoses. The Control
Module provides “Out Of Box” remote system monitoring and control
without any additional hardware or software. 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. 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.
IntelliSpray Proportioners use 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 Proportioner frame. All common service components can be
accessed from the front of the module and replaced on-site using simple hand tools in minutes.
IntelliSpray Proportioners are 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 100,150, and 200 foot lengths. Heated whip hoses are available in 20 and 40 foot
lengths. Unheated whips are available in 3, 6 and 10 foot lengths. Each length of heated hose begins with a fluid
manifold or “modem” that contains temperature and/or pressure 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 IS30 and IS40 to receive more information from multiple sensing locations at each hose junction. It also
allows projection of information down the hose to remote monitoring and control devices. More information about
QuickHeat hoses is contained in the QuickHeat Hose Manual.
Finally, IntelliSpray Control and Fluid Modules are mounted in a high-strength tubular steel frame that protect the
modules from damage and provide multiple horizontal and vertical mounting points.
4.0 INTELLISPRAY SYSTEM OVERVIEW (Continued)

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5.0 IS30 - SPECIFICATIONS
The IS30 Proportioner is roughly 32” wide, 68” tall, and 27” deep. Eight separate floor mounting holes are located in
the base of the unit. and a slotted wall mounting bracket is provided along the back of the unit. The IS30 must be
securely attached to the a floor and wall in any mobile or seismic installation. Refer to Section 10.1 for installation
instructions.
Weight 415 lbs (188 kg)
Max Fluid Pressure 2500 psi (172 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 67 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 IS30 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.
IS30 Physical, Environmental, and Electrical Specifications

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6.0 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
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 the following Sections will help the user become familiarized with the IS30 Proportioner.
Cellular Antenna
A Fluid Module B Fluid Module
Frame
HMI
Wall Mounting Bracket
Floor Mounting Points
QuickHeat Hose
Connection Cover
On/Off Switch
Emergency Stop
Control Module
Status Light

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7.0 IS30 FLUID MODULE
The IS30 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 IS30 requires the fluid to be provided at a pressure that avoids 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 cavitation
supply pumps should be sized to provide at least 2 GPM continuous flow at an inlet fluid pressure of 100 psi. The
IS30 will issue an error message and stop if inlet fluid pressure is either too low or too high.
The IS30 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 and reinstalled
within minutes. With the exception of minor differences, the A and B fluid modules are identical.
The following images show the locations of primary components and features in each Fluid Module.
Motor Power Connector
Communication Connector
Heater and Sensor
Power Connector
Spray Hose Fitting
Recirculation
Hose Fitting
Rear Handle
Servo Motor
Filter Module Outlet Valve
Retainer Screw
Recirculation Valve
Pressure Gage
Front Cover
Inlet Filter Cap
Release Pin
Inlet Hose Fitting
Motor Encoder
Connector
Front Handle

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7.0 IS30 FLUID MODULE (Continued)
The A and B Fluid Modules have similar controls as described and shown below.
Filter Outlet Valve. The IS30 has an internal 1/4 turn ball valve that is used to prevent backflow of material when
cleaning or replacing the inlet filter. By closing both the inlet ball valve and the filter outlet valve the inlet filter can be
serviced with very little leakage of fluid. See page Section 22 for filter service instructions.
Recirculation Valve. When the handle is pointed down it is in the Spray position and all flow will be through the
distribution (spray gun) hoses When it is turned 90 degrees counterclockwise (CCW) fluid will also allow flow to the
recirculation line. Note it does not stop fluid flow to the gun hoses when in recirculation position.
Analog Pressure Gage: This indicates fluid pressure in the high pressure manifold, including the spray gun hoses.
Cover Screws: Remove for cover removal. The cover should be in place when the unit is in use.
Captive Retainer Screw: This hold the module to the frame and should always be engaged except when servicing
the module.
Recirculation Valve
Cover Screws (2X)
Retainer Screw
Filter Outlet Valve (inlet not
shown, is part of inlet sweep)
Pressure Gage

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7.0 IS30 FLUID MODULE (Continued)
The images below show the IS30 Fluid Module with the covers removed. The A and B Fluid Modules are identical
except for the following:
• 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.
Flow Meter
High Pressure Module
Pump
Pressure Sensor
(5000 psi)
Check Valve
Pre & Post Filter
Pressure Sensors
(1000 psi)
Pre-pump Pressure
Sensor (1000 psi)
Pre-pump
Temperature
Sensor
Inlet
Temperature
Sensor
Fluid Module
Electronics Module
Fluid Preheater
Module (cover
removed)

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7.0 IS30 FLUID MODULE (Continued)
The following figure shows the major items in the IS30 Fluid Module. Additional breakdowns and parts lists are
contained in Section 24.
Motor Mount
Servo Motor
Preheater Cover
Fluid Module Frame
High Pressure Module
Electronics Module
Preheater
High Pressure Module Bracket
Pump Module
Flow Meter
Low Pressure Module
Filter Module
Cover
Pump

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7.0 IS30 FLUID MODULE (Continued)
The following figure shows the fluid path and major fluidic elements contained in the IS30 Fluid Modules. Flow is from
left to right indicated by arrows.
The main fluid handling 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. Inlet and outlet ball valves are provided that can be used to isolate the filter element
module. 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 Body. A 7/8” hex head cap holds the filter body and filter element 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.
Always grease the threads (especially the A side) to prevent the filter cap threads from locking.
• Filter Elements: Each Filter Body holds one 30 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 filter element.
These sensors allow the IS30 to alert the user when the filters need to be cleaned or replaced.
Flow Meter
Pump
Preheater
Filter
Ball
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
Ball
Valve

EN
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IS30 User Manual 347492EN Rev A Page 20 of 192
Preheater Module: The IS30 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 14 individual channels for fluid flow that run down and back through the heat
exchanger. An etched foil heater blanket is firmly bonded to the outside 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. A
temperature sensor is attached to the heat exchanger as part of the fluid temperature control electronics. A fail-safe
replaceable thermal fuse is mounted on 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.
7.0 IS30 FLUID MODULE (Continued)
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.
Filter Manifold
Filter Isolation Valve
Filter Inlet Pressure Sensor
Filter Outlet Pressure Sensor
JIC 12M Inlet Fitting
Filter Body
Filter Element (30 Mesh)
Inlet Temperature Sensor
IS30 Filter Module