Carlisle IS40 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

READ BEFORE INSTALLATION. REFER TO IS40 USERS MANUAL FOR
COMPLETE INSTALLATION AND USE INSTRUCTIONS.
Intro Guide 343064 Rev A

INSTALLATION - OVERVIEW
Note: IS40 installation requires that a QuickHeatä hose is fully assembled and ready for connection to the IS40.
See “QuickHeat Hose Manual” for more information.
Installation of the IS40 should only be performed by individuals with prior knowledge of installing and servicing Spray
Foam equipment. Installation involves mechanical, electrical and fluid connections. Default out-of-box software
settings are usually adequate for initial system use, but can be changed by the installer to meet specific needs.
Every IS40 is equipped for remote support and can be accessed by authorized Carlisle service agents to assist in
system installation, configuration, and/or service.
The following steps outline installation of the IS40. Additional details for each step are contained in the IS40 Users
manual.
1. Unpack unit and remove from shipping pallet.
2. Place unit in desired location.
3. For mobile or seismic environments make mechanical connections to floor and wall of structure.
4. Check to be sure power to the IS40 circuit is off (turn off breaker at distribution or main panel).
5. Make 200-240V 3 Phase electrical and ground wire connection inside IS40 Control Module.
6. Connect fully assembled QuickHeat hose master modem to fluid jumper hoses.
7. Connect fluid supply and recirculation hoses to A and B fluid modules.
8. Set Fluid Module valves to spray position for purging.
9. Close gun manifold material control valves and remove spray gun from hose.
10. Open fluid supply lines and pressurize drum pumps to provide inlet fluid pressure of 150 - 200 psi
• 2:1 drum pump air pressure of 75 - 100 psi
• 3:1 drum pump air pressure of 50 - 70 psi
11. Energize IS40 power circuit at distribution or main panel.
12. Turn on IS40 power switch (side of control panel). Startup screen will appear in 30 - 60 seconds..
13. If the Proportioner and Hoses were configured together at the factory skip steps 13a to 13d
a. From main menu, open Settings > Hose
b. Select hose configuration
c. Pair hose modems
d. Scan and select a recommended communication frequency
14. Purge A and B fluid sections (and hoses if new or empty) to eliminate any air.
15. Follow Quick Start instructions to begin spraying.
Installation of the IS40 exposes installers and
users to high voltages and high fluid pressures.
Severe injury or death could results from
improper installation or installation techniques.
WARNING
!
NOTE
Page 1 of 5 Intro Guide 343064 Rev A

INITIAL SYSTEM BLEED
When the proportioner and/or hoses are installed, an initial system bleed is required to completely replace air with
fluid in the supply hoses, proportioner, and distribution hoses. In addition, if air is introduced to the system (e.g. run-
ning the drum pump dry) the same procedure must be performed. If air is not removed from the system properly,
the gear pumps, preheaters, and/or hose heaters can be damaged. Air pockets can also create off-ratio condi-
tions.
In this example the operation is shown for the B side. The same procedure would also be used for the A side.
2. Check that supply lines, recirculation hoses, and
distribution hoses are properly connected.
3. Check the analog pressure gage on the fluid module
to be bled. Relieve pressure by turning the outlet
valve to the recirculation position. Once pressure is
relieved, turn the outlet valve back to the gun position.
Filter inlet and outlet
valves in open position
Outlet valve in spray
position
Fluid in hoses and proportioner may be
under high pressure. System must be
depressurized prior to performing any
service function.
WARNING
!
6. Remove the spray gun from the hose manifold.
Secure or hold the manifold over a waste container
and open the B-side material control valve to catch
fluid. Fluid may begin flowing out of the manifold at
this point. This is acceptable.
1. Be sure the system is in STOP state.
7. After selecting Exchange Mode from the main menu:
• Select Purge from the FUNCTION menu.
• Select B-RES from the MATERIAL menu.
• Select Off from the HEAT menu.
4. Set filter valves to open position (turn clockwise to
stop) and set the output valve to spray position as
shown in the following figure.
5. Activate B-side transfer pump.
WARNING
!
Page 2 of 5 Intro Guide 343064 Rev A

8. Set B motor speed to 0% by pressing the - button in
the Motor Speed Widget.
INITIAL SYSTEM BLEED
9. Press the START button.
10. Increase B motor speed by pressing the + button in
the Motor Speed Widget. Motor speeds should be
limited to 5% or less until fluid has filled the Fluid
Modules to avoid damage to the pump bearings and
internal surfaces. Once pressure starts to build
motor speed can be increased but should remain
below 50% until distribution hoses are filled.
11. Press STOP when a steady stream of fluid flows
from the manifold and all air has been replaced with
fluid.
12. Close the B-side material control valve on the gun
manifold.
13. Repeat the process for the A-side if required.
Never run gear pumps faster than 5%
speed in Exchange Mode when dry, and
do not run for more than 10 seconds when
dry at this speed. Presence of fluid in the
pump is essential to protect bearings and
seals.
WARNING
!
Page 3 of 5 Intro Guide 343064 Rev A

QUICK-START GUIDE
1. Before starting the IS40, remove all hose from the
rack and position for spraying. Be sure the drum
pumps are on and A and B fluid module valves on
are in the proper position for spraying.
Due to the IS40’s efficient heating systems and simplified startup process, operators will usually be ready to spray
within 10-15 minutes from powering on the system. The following are the minimal steps involved in starting up the
IS40 with Job Reporting turned off. See the IS40 Users Manual for additional steps required when Job Reporting is
turned on.
2. Turn on the IS40 by rotating the power switch on
the right side of the control module clockwise to the
ON position (indicated by the character “I”).
The IS40 will display a startup screen while it
performs internal system checks. Once completed,
the Spray Mode screen will be displayed. Note that
the Exchange Mode screen can be set as the
default startup screen if desired (see page xx).
3. Check the A-ISO and B-RES fluid levels using a dip-
stick and enter the amount by pressing the respective
drum icon on the screen.
Press to enter drum level.
Both filter valves turned clockwise
Selector valve in gun position,
pointed down.
Page 4 of 5 Intro Guide 343064 Rev A

QUICK-START GUIDE
4. Enter the desired pressure and temperature
setpoints using the on-screen “+” and “-” buttons.
5. Press the START button to begin warming up the
system.
The center button will change from START to
WARMING, and the button boundary will change from
solid white to flashing green to indicate the system is
warming up.
Indicates system is
warming up
When the center button changes from WARMING to
READY the pumps will automatically pressurize the
system to the desired setpoint.
Indicates system is
ready to spray
6. If required, spray out any cold material in the
unheated whip, then proceed with spraying.
7. If drums are changed, enter the new fluid level
and continue spraying. (see step 3).
8. If errors occur, correct the issue, press the
RESET button, then the START button (see step
5).
9. When finished spraying, press the STOP button.
10. To power off the unit, rotate the power switch on
Press “-” to decrease
or “+” to increase A
Press “-” to decrease
or “+” to increase B
Press “-” to decrease or “+” to
Pressure setpoint
A-side temperature
setpoint
B-side temperature
setpoint
Page 5 of 5 Intro Guide 343064 Rev A