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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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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