- IntelliSpray IS40 Operation Manual 341162 EN [ English ]
341162
IntelliSpray™ IS40
®
www.binks.com341162 D (03/2025)
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Obey local or municipal regulations for product recycling and disposal.
ST1™
QuickHeat™ Hose
IS40™
https://carlisleft.com/en/product/is40-proportioner/
www.binks.com 341162 D (03/2025)
EN INTRODUCTION
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ABOUT THIS MANUAL
ITS PURPOSE
The purpose of this manual is to help you get the most
value from your Binks IntelliSpray™ system. It can
help you to determine how to install, operate, maintain,
and repair your equipment. It provides information and
procedures for routine maintenance and servicing and
offers diagnostic and repair procedures to follow when
trouble occurs.
ITS CONTENTS
This manual is divided into Chapters, each of which is
divided into consecutively numbered Sections.
Chapters will contain text, images, tables, or a
combination of them.
Pages with images will have paragraphs and sentences
with callout numbers that refer to their respective images,
steps, and parts.
Procedures, once described in the text, are not normally
repeated. When it is necessary to refer to another Chapter
or Section, the reference will be given as Chapter and
Section number. Cross references given without the use
of the word Chapter apply to Sections or paragraphs in
the current Chapter.
Chapter 02. Table of Contents.
Chapter 03. EU Declaration of Conformity - A mandatory
document the manufacturer signs to declare the product
complies with the EU requirements.
Chapter 04. Safety - Safety, hazard, and warning rules.
Chapter 05. Isocyanate Information - Important safety and
handling instruction on Isocyanates.
Chapter 06. System Overview - An overview of the IS40™
proportioner system.
Chapter 07. System Specifications - IS40 proportioner
specifications.
Chapter 08. Product Overview - Overview of the IS40
Proportioner
Chapter 09. Fluid Module - Overview of the IS40 fluid
modules.
Chapter 10. Control Module - Overview of the IS40 control
module.
Chapter 11. QuickHeat™ Hose - Overview of using the
QuickHeat hose with the IS40 proportioner.
Chapter 12. Installation - Installation instructions.
Chapter 13. Quick Start Guide - Procedures for getting
started with the IS40.
Chapter 14. Operation Tips - Tips for operating the IS40
sytem.
Chapter 15. Display Screens - Overview of all HMI display
screens.
Chapter 16. Servicing - Servicing instructions for the IS40
Chapter 17. Troubleshooting - Troubleshooting guide for
the IS40.
Chapter 18. Maintenance - Maintenance procedures and
part descriptions for the IS40.
Chapter 19. Schematics - IS40 electrical schematics.
Chapter 20. Remote Access - Details about the remote
access features of the IS40
Chapter 21. Manual Change Summary–The revisions and
changes made to this manual.
Chapter 22. Warranty–Your equipment’s warranty.
TERMINOLOGY USED IN THIS MANUAL
Throughout this manual different chemical names will be
shortened and/or abbreviated for ease of reading.
• Isocyanate: shortened to ISO or referred to as A,
A Material, or A-Side.
• Resin: shortened to RES or referred to as B, B
Material, or B-Side.
WHO SHOULD USE THIS GUIDE
This guide is intended for users with different levels of
knowledge and experience with this system:
Installers: The person(s) who will locate and install this
equipment.
Users: The person(s) who will learn how to operate this
equipment.
Servicers: The person(s) who will service and maintain
this equipment.
This guide assumes all persons who will install, use,
operate, and service this equipment have some
knowledge of the product and its operating system.
MANUAL DISCLAIMER
All current and applicable certifications shown in this
manual confirm Binks' adherence to the strict standards
met to obtain the required regulatory compliances.
This manual was prepared with the most accurate
information current at the time of publishing. Binks does
not accept responsibility for errors in, or omissions from,
the information contained herein.
Please get in touch with your distributor or Binks
Customer Service for additional service information and
assistance.
www.binks.com341162 D (03/2025)
ENINTRODUCTION
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IS40 RELATED MANUALS & PUBLICATIONS
Part Number Description
343064 IS40 Quick Start Guide
336742 ST1™ Service Manual
341164 QuickHeat™ Hose Manual
www.binks.com 341162 D (03/2025)
EN 02 TABLE OF CONTENTS
iii / vi
02 CONTENTS
03 EU DECLARATION OF CONFORMITY 1
04 SAFETY 3
04.1 SAFETY PRECAUTIONS..................................................................................................................................3
04.2 ADDITIONAL SAFETY INFORMATION..........................................................................................................10
05 IMPORTANT ISOCYANATE INFORMATION 11
05.1 GENERAL HANDLING GUIDELINES.............................................................................................................11
05.2 MATERIAL SELF IGNITION............................................................................................................................12
05.3 KEEP COMPONENTS A & B SEPARATE.................................................................................................12
05.4 EXPOSURE TO MOISTURE...........................................................................................................................12
05.5 FOAM RESINS WITH 245 FA BLOWING AGENTS.......................................................................................12
05.6 CHANGING MATERIALS.................................................................................................................................12
05.7 ELECTRICAL GROUND..................................................................................................................................12
06 SYSTEM OVERVIEW 13
07 IS40 SPECIFICATIONS 15
08 IS40 OVERVIEW 17
09 FLUID MODULE 19
09.1 MODULE ASSEMBLIES: OVERVIEW............................................................................................................22
09.2 MODULE FLUID PATHWAYS..........................................................................................................................23
09.3 FILTER MODULE.............................................................................................................................................24
09.4 LOW PRESSURE MODULE............................................................................................................................25
09.5 PUMP MODULE...............................................................................................................................................26
09.6 HIGH PRESSURE MODULE...........................................................................................................................27
10 CONTROL MODULE 29
10.1 CONTROL MODULE: OVERVIEW..................................................................................................................30
10.2 CONTROL MODULE: ENCLOSURE..............................................................................................................31
10.3 MAIN PANEL: 200-240V...................................................................................................................................34
10.4 MAIN PANEL: 380-415V...................................................................................................................................35
10.5. CIRCUIT BREAKERS.....................................................................................................................................36
11 QUICKHEAT™ HOSE 39
12 INSTALLATION 41
12.1 INSTALLATION PROCEDURE........................................................................................................................42
13 QUICK-START GUIDE 49
14 OPERATION TIPS 51
15 DISPLAY SCREENS 53
15.1 DISPLAY SCREENS: OVERVIEW..................................................................................................................53
15.2 DISPLAY SPECIFICATIONS...........................................................................................................................53
15.3 SPRAY SCREEN: OVERVIEW........................................................................................................................55
15.3.1 SPRAY SCREEN: USER INFORMATION...........................................................................................56
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EN02 TABLE OF CONTENTS
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15 DISPLAY SCREENS 53
15.3.2 SPRAY SCREEN: USER ACTIONS.....................................................................................................57
15.3.3 SPRAY SCREEN: USE.........................................................................................................................58
15.3.4 SPRAY SCREEN: OTHER FUNCTIONS.............................................................................................61
15.3.4.1 DRUM TEMPERATURE ..........................................................................................................61
15.3.4.2 FLUID COUNTER.....................................................................................................................61
15.3.4.3 FLUID.........................................................................................................................................61
15.3.4.4 FLOW RATE AND TRIGGER %...............................................................................................61
15.3.4.5 ALARMS....................................................................................................................................62
15.3.4.6 RESET.......................................................................................................................................62
15.3.4.7 PREHEATER TEMPERATURE OFFSET................................................................................62
15.3.4.8 ALARM DETAILS......................................................................................................................63
15.3.4.9 INLET COMPENSATION.........................................................................................................64
15.4 AUTOMATIC VISCOSITY COMPENSATION (AVC™)..................................................................................65
15.5 AUTOMATIC INLET COMPENSATION (AIC).................................................................................................67
15.6 EXCHANGE SCREEN: OVERVIEW...............................................................................................................68
15.6.1 EXCHANGE SCREEN: USE.................................................................................................................69
15.6.2 EXAMPLE 1: INITIAL SYSTEM BLEED..............................................................................................73
15.6.3 EXAMPLE 2: A SIDE MANUAL PURGE...........................................................................................75
15.6.4 EXAMPLE 3: B SIDE PURGE AMOUNT...........................................................................................77
15.6.5 EXAMPLE 4: PREHEAT B DRUM MATERIAL..................................................................................79
15.6.6 EXAMPLE 5: SIDE AIR PURGE...........................................................................................................81
15.7 ALARM SCREEN: OVERVIEW.......................................................................................................................84
15.7.1 ERRORS................................................................................................................................................84
15.7.2 ALARM SCREEN: USE.........................................................................................................................85
15.8 SYSTEM STATUS SCREENS: OVERVIEW...................................................................................................89
15.8.1 SYSTEM STATUS SCREENS: IO PAGE 1..........................................................................................90
15.8.2 SYSTEM STATUS SCREENS: IO PAGE 2..........................................................................................91
15.8.3 SYSTEM STATUS SCREENS: SENSOR BYPASS............................................................................94
15.8.4 SYSTEM STATUS SCREENS: INLET HEALTH..................................................................................96
15.8.5 SYSTEM STATUS SCREENS: TREND CHARTS...............................................................................99
15.8.5.1 SELECT PLOT PARAMETERS ............................................................................................100
15.8.5.2 SELECT TIME SCALE (TREND TIME).................................................................................102
15.9 SETTINGS SCREENS: OVERVIEW.............................................................................................................103
15.9.1 SETTINGS SCREENS: SYSTEM INFORMATION...........................................................................104
15.9.2 SETTINGS SCREENS: FIRMWARE UPDATES...............................................................................105
15.9.3 SETTINGS SCREENS: SYSTEM STATUS.......................................................................................106
15.9.4 SETTINGS SCREENS: CONFIGURATION SETTINGS..................................................................107
15.9.5 SETTINGS SCREENS: DISPLAY SETTINGS..................................................................................108
15.9.6 SETTINGS SCREENS: SYSTEM SETTINGS..................................................................................109
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EN 02 TABLE OF CONTENTS
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15 DISPLAY SCREENS 53
15.9.7 SETTINGS SCREENS: HOSE CONFIGURATION...........................................................................110
15.9.8 SETTINGS SCREENS: DRIVE STATUS LOG..................................................................................114
15.9.9 SETTINGS SCREENS: SUPPLY SETTINGS...................................................................................115
15.9.10 SETTINGS SCREENS: YIELD CALCULATOR...............................................................................116
15.9.11 SETTINGS SCREENS: MATERIAL DATA.......................................................................................119
15.10 SECURITY....................................................................................................................................................121
15.11 RECIPE SCREENS: OVERVIEW................................................................................................................125
15.11.1 RECIPE SCREENS: RECIPE MANAGEMENT...............................................................................130
15.11.2 RECIPE SCREENS: EDITING..........................................................................................................134
15.12 REPORTS: OVERVIEW...............................................................................................................................136
15.12.1 REPORTS: AUDIT REPORT............................................................................................................137
15.12.2 REPORTS: JOB NOTES...................................................................................................................139
15.13 JOB REPORTS: OVERVIEW......................................................................................................................140
15.13.1 JOB REPORTS: LOG ENTRIES......................................................................................................143
15.13.2 JOB REPORTS: MATERIAL DATA...................................................................................................144
15.13.3 JOB REPORTS: REPORT CONTENT.............................................................................................145
15.13.4 JOB REPORTS: REPORT MANAGEMENT....................................................................................146
15.14 LANGUAGES................................................................................................................................................148
15.15 VARIABLE RATIO OPERATION..................................................................................................................149
15.15.1 ENABLE VARIABLE RATIO..............................................................................................................149
15.15.2 ENABLE FIRST TIME.......................................................................................................................150
16 SERVICING 153
16.1 FLUID MODULE DEPRESSURIZATION......................................................................................................153
16.2 INLET FILTER SERVICING...........................................................................................................................153
16.3 CHECK PUMP TSL LEVEL............................................................................................................................154
16.4 BURST DISK REPLACEMENT.....................................................................................................................155
16.4 FILTER MAINTENANCE................................................................................................................................156
17 TROUBLESHOOTING 157
17.1 SYSTEM ERRORS.........................................................................................................................................157
18 MAINTENANCE 173
18.1 REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS .............................................173
18.2 FLUID MODULE.............................................................................................................................................174
18.3 LOW-PRESSURE MODULE..........................................................................................................................176
18.4 PUMP MODULE.............................................................................................................................................178
18.5 HIGH-PRESSURE MODULE.........................................................................................................................180
18.6 PUMP I/O MODULE.......................................................................................................................................182
18.7 FLUID MODULE O-RINGS AND SEALS......................................................................................................184
18.8 IS40 CONTROL MODULE ENCLOSURE.....................................................................................................186
18.9 IS40 CONTROL MODULE CONTROL PANEL 200V-240V..........................................................................188
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EN02 TABLE OF CONTENTS
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18 MAINTENANCE 173
18.10 IS40 CONTROL MODULE CONTROL PANEL 380V-415V........................................................................192
18.11 IS40 CABLES................................................................................................................................................196
18.12 IS40 ACCESSORIES AND KITS.................................................................................................................197
19 ELECTRICAL SCHEMATICS 199
19.1 ELECTRICAL DIAGRAMS 200V-240V..........................................................................................................199
19.2 ELECTRICAL DIAGRAMS 380V-400V..........................................................................................................221
20 REMOTE ACCESS 243
21 MANUAL REVISIONS 247
22 WARRANTY 249
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EN 03 EU DECLARATION OF CONFORMITY
EN
Providing all conditions of safe use / installation stated within the product manuals have been complied with and also
installed in accordance with any applicable local codes of practice.
Low Voltage and EMC Assessment
Executive President: Engineering and
Operations, Shoreview, MN, 55126.
USA
F. A. Sutter
6-3-25
Signed for and on behalf of
Binks US LLC:
Document Part No.
Product Description / Object of Declaration:
Fast Set Polyurethane Foams and PolyureasThis Product is designed for use with:
IntelliSpray™ Spray Foam Proportioner IS 30/IS 40
Suitable for use in hazardous area:
This Declaration of Conformity / Incorporation is
issued under the sole responsibility of the
manufacturer:
Binks US LLC.
3760 Victoria St N
Shoreview, MN 55126. USA
Protection Level: Not Applicable
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
Notified body details and role: TUV SUD America Inc, 141 14th St NW,
New Brighton, MN 55112 USA. Cert Nos
NC72180349.1/NC72170911.1/NC72193266.1
INTERTEK Testing Services NA, 545 E. Algonquin Rd,
Arlington, IL 60005 USA. Cert No. 105047444MIN-004
EMC Directive 2014/30/EU
Low Voltage Directive 2014/35/EU
RoHS Directive 2011/65/EU
by complying with the following statutory documents and harmonised standards:
EN 61000-6-2:2005/AC:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments
EN 61000-6-4:2007/A1:2011 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial
environments.
EN 61000-3-11:2000 (>16A) Electromagnetic compatibility (EMC) - Part 3-11: Limits - Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage supply systems
EN 61000-3-12:2011 (>16A) Electromagnetic compatibility (EMC) - Part 3-12: Limits - Limits for harmonic currents produced by
equipment connected to public low-voltage systems with input current.
UL 61010-1:2012 Ed.3+R:2019/CSA C22.2#61010-1-12:2012 Ed.3+U1;U2;A1 Electrical Equipment for Measurement, Control, and
Laboratory Use; Part 1: General Requirements
UL 61010-2-051:2019 Ed.4/CSA C22.2#61010-2-051:2019 Ed.4 Safety Requirements for Electrical Equipment for Measurement,
Control and Laboratory Use – Part 2- 051: Particular Requirements for Laboratory Equipment for Mixing and Stirring
UL 61010-2-010:2019 Ed.4/CSA C22.2#61010-2-010:2019 Ed.4 Safety Requirements for Electrical Equipment for Measurement,
Control and Laboratory Use - Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials
EN 63000: 2018 Technical documentation for the assessment according to REACH
EN 60204-1:2018 Safety of Machinery. Electrical equipment of machines
FCC 47 CFR Part 15-Radio Frequency Devices, Subpart B – Unintentional Radiators
ICES-001, Issue 5:2020 Class A Industrial, Scientific, and Medical (ISM) Equipment
EU Declaration of Conformity
03 EU DECLARATION OF CONFORMITY
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EN03 EU DECLARATION OF CONFORMITY
Ref. Certif. No.
US/9719/ITS-A1
IEC SYSTEM FOR MUTUAL RECOGNITION OF TEST CERTIFICATES FOR ELECTRICAL EQUIPMENT (IECEE) CB
SCHEME
CB TEST CERTIFICATE
Product
Name and address of the applicant
Name and address of the manufacturer
Name and address of the factory
Ratings and principal characteristics
Trademark / Brand (if any)
Customer's Testing Facility (CTF) Stage used
Model / Type Ref.
Additional information (if necessary may also be
reported on page 2)
A sample of the product was tested and found to be in
conformity with
As shown in the Test Report Ref. No. which forms part
of this Certificate
Note: When more than one factory, please report on page 2
IntelliSpray Spray Foam Proportioner
Binks US LLC
3760 Victoria St. N.
Shoreview, MN, 55126
United States of America
Binks US LLC
3760 Victoria St. N.
Shoreview, MN, 55126
United States of America
Binks US LLC
3760 Victoria St. N.
Shoreview, MN, 55126
United States of America
Additional information on page 2
IS30: 200-240Vac, 67A, 50/60Hz, 3 Phase
IS40: 200-240Vac, 78A, 50/60Hz, 3 Phase
Binks // IntelliSpray
CTF Stage 1
IS30, IS40
A1: Updated Applicant, Manufacturer & Factory Information. Also Updated
Trademark & Marking Labels. Original Certificate Issued: 12/14/2022
Additional information on page 2
IEC 61010-1:2010/AMD1:2016, IEC 61010-2-010:2019, IEC
61010-2-051:2018
Comments:
Refer to the Test Report for the Summary of Compliance with National
Deviations
105047444MIN-001, 105047444MIN-002, 105047444MIN-003
Intertek Testing Services NA, Inc.
545 E. Algonquin Road , Arlington Heights
IL 60005
United States of America
Date: 2025-07-08 Signature: Matt Snyder
This CB Test Certificate is issued by the National Certification Body
page 1 of 1
EN 04 SAFETY
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04 SAFETY
04.1 SAFETY PRECAUTIONS
Before the operation, maintenance, or servicing of this
Binks system; fully read and understand all technical
and safety literature for your product. This manual
contains information that is important for you to know and
understand.
This information relates to USER SAFETY and the
PREVENTION OF EQUIPMENT PROBLEMS.
To help you understand this information, we use
recognizable ANSI Z535 and ISO warning boxes and
symbols throughout this manual. Please obey these
safety sections.
Careful study and continued use of this manual will
provide a better understanding of the equipment functions
and procedures.
This understanding will result in improved operation,
efficiency, and longer, trouble-free service with faster and
easier troubleshooting. If you need the necessary safety
literature for your specific system, contact your local Binks
representative or Binks directly.
WARNING
WARNING!: Indicates a hazardous situation that, if not
avoided, could result in death or severe injury.
CAUTION
Caution!: Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury, or
equipment damage.
NOTICE
Notice: Indicates information considered important but
not hazard related.
DANGER
DANGER!: Indicates a hazardous situation that, if not
avoided, will result in death or severe injury.
SAFETY
Safety: Indicates a type of safety instruction, or a
separate panel on a safety placard, where specific
safety-related instructions or procedures are described.
WARNING
The hazards shown on the pages that follow can occur
during the normal use of this Binks equipment, but not all
listed hazards will be applicable to your product model or
equipment.
Repairs may only be performed by personnel
authorized by Binks.
WARNING
The user MUST read and be familiar with the Safety
Section in this manual and the safety literature therein
identified.
Only trained personnel can operate this equipment.
All personnel who operate, clean, or maintain this
equipment MUST fully read and understand this
manual! To operate and service the equipment, follow all
WARNINGS and safety requirements.
The user must be aware of and adhere to ALL local
building and fire codes and ordinances, as well as NFPA
33 AND EN 16985 SAFETY STANDARDS, LATEST
EDITION, or applicable country safety standards, before
the installation, operation, or servicing of this equipment.
NOTICE
This manual lists standard specifications and service
procedures. Differences can occur between this literature
and your equipment.
Differences in local or municipal codes, manufacturer
or plant requirements, material delivery requirements,
and more can make variations unpreventable. To
find these differences, compare this manual to your
system installation drawings and other applicable Binks
equipment manuals.
EN04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Spray Areas Fire Hazards
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire hazard.
If the safety interlocks are disabled
during operation, protection against
accidental arcing is shut off and can
cause a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable.
Keep spray areas clean to prevent the build-up of
combustible residues.
Do not smoke in the spray area.
The high voltage supplied to the atomizer must be
turned off before the equipment is cleaned, flushed
or maintained.
Spray booth ventilation must be kept at the rates as
set by NFPA-33, OSHA, country, local, and municipal
codes.
If flammable or combustible solvents are used to
clean the equipment, ventilate the area.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
the output voltage is necessary.
Do an equipment test only in areas free of
combustible material. The test may necessitate the
high voltage to be on, but only as instructed.
Non-factory replacement parts or unauthorized
equipment modifications can cause a fire or injury.
Non-factory replacement parts or unauthorized
equipment modifications can cause a fire or injury.
The key switch bypass is used only during setup
operation.
Do no production work with disabled safety
interlocks.
Set up and operate the paint procedure and
equipment under NFPA-33, NEC, OSHA, local,
municipal, country, and European Health and Safety
Norms.
EN 04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Spray Areas Explosion Hazard
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire or
explosion hazard.
If the safety interlocks are disabled
during operation, protection against
accidental arcing is shut off and can
cause a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
output voltage is necessary.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
If equipped, set the current overload sensitivity as
described in the related section of the equipment
manual. If incorrectly set, the current overload
sensitivity for protection against accidental arcing is
turned off and can cause a fire or explosion.
Frequent power supply shutdown indicates a
problem in the system, which requires correction.
Always turn off the control panel power before the
system is flushed, cleaned, or servicing the spray
system equipment. Make sure no objects are within
the spark-safe work distance before the high voltage
is turned on.
The control panel must interlock with the ventilation
system and conveyor in accordance with NFPA-33,
EN 50176.
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable. Do an equipment test only
in areas free of combustible material.
General
Use and
Maintenance
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire hazard.
Personnel must be correctly trained
in the operation and maintenance of
this equipment.
Train all personnel in accordance with the
requirements of NFPA-33, EN 60079-0.
Before equipment operation, personnel must read
and understand these instructions and safety
precautions.
Obey appropriate local, municipal, state, and
national codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms, and your
insurance company requirements.
EN04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Spray Area
High Voltage
Equipment
Electrical Discharge
This equipment contains a high
voltage device that can cause
an electrostatic induction on
ungrounded objects. This electrical
charge is capable of igniting coating
materials.
Insufficient ground will cause a
spark hazard. A spark can ignite
many coating materials and cause
a fire or explosion.
Operators in the spray area and the parts to be
sprayed must be sufficiently grounded.
All conductive objects inside the spray area must be
grounded.
Hold the parts that get sprayed on conveyors or
hangers that are correctly grounded. The resistance
between the parts and the earth-ground must not be
more than 1 MΩ. Refer to: NFPA-33.
Before the equipment is operated, ground all
operators. They cannot wear rubber-soled insulated
shoes. Wear ground straps on wrists or legs for
sufficient ground contact.
Operators must not wear or carry ungrounded metal
objects.
When used, operators must make complete contact
with the applicator handle and electrostatic gun. Use
conductive gloves or gloves with the palm section
cut out.
Operators must wear grounded footwear.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES FOR GUIDANCE TO
CORRECTLY GROUND THE OPERATOR.
Except for objects needed for the high-voltage
process, all electrically conductive objects in the
spray area are to be grounded. Supply a grounded
conductive floor in the spray area.
Except for objects needed for the high-voltage
process, all electrically conductive objects in the
spray area are to be grounded. Supply a grounded
conductive floor in the spray area.
Always turn off the applicator voltage before the
system is flushed, cleaned, or when servicing the
spray system equipment.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
Do not install an applicator into a fluid system if the
solvent supply is ungrounded.
Do not touch an energized applicator electrode.
EN 04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Spray Areas Toxic Fluid or Fumes
Toxic fluids or fumes can cause
severe injury or death if splashed in
the eyes or on the skin, or if inhaled
or swallowed.
Read the Safety Data Sheet (SDS) for instructions
to know and understand how to handle the specific
hazards of the fluids used, and the effects of long-
term exposure.
During the spray, clean, or servicing of equipment,
or when in the work area, keep the work area fully
ventilated.
Always wear personal protective equipment (PPE)
when in the work area or during equipment operation.
Refer to the Personal Protective Equipment warnings
in this manual.
Store hazardous fluid in approved containers and
refer to local, municipal, state, and national codes
governing the disposal of hazardous fluids.
Spray
Area and
Equipment
Use
High-pressure fluid sprayed from
the gun, hose fittings, or ruptured/
damaged components can pierce
the skin.
While this injury can appear as
cut skin, this is a severe injury that
can result in the amputation of the
affected area.
Do not point or operate the spray gun at the body
part of a person.
Do not put your hand or fingers over the gun fluid
nozzle or fittings in the hose or Proportioner.
Do not try to stop or deflect leaks with your hand,
glove, body, or shop rag.
Do not blowback fluid, as the equipment is not an
air spray system.
Relieve pressure in the supply hoses, Proportioner,
and QuickHeat™ hose before the equipment is
inspected, cleaned, or serviced.
Use the lowest possible pressure to recirculate,
purge, or troubleshoot the equipment.
Examine the hoses, couplings, and fittings every day.
Service or immediately replace parts that leak, are
worn, or are damaged. Replace high-pressure hose
sections. They cannot be recoupled or serviced.
EN04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Equipment
and Fluids
Skin and Clothing Burns
Equipment surfaces and fluids can
become very hot during operation.
Do not touch hot fluid or equipment during operation.
Do not let clothing touch the equipment during
operation or immediately after the equipment is
stopped.
Let the equipment fully cool before the examination
or servicing of the component.
Pressurized
Aluminum
Parts
The use of certain solvents and
chemicals can cause equipment
damage and severe personal injury.
Do not use 1,1,1-trichloroethane, methylene chloride
or other halogenated hydrocarbon solvents or fluids
that contain such solvents.
These solvents can cause a severe chemical
reaction and equipment rupture that results in
equipment and property damage, serious bodily
injury, or death.
EN 04 SAFETY
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AREAS
Indicate possible
hazard occurrences
HAZARDS
Indicate possible hazards
SAFEGUARDS
Prevention of possible hazards
Spray Areas Do Not Touch
The effect of paint flow rates and
formulations on the quality of
atomization can cause the turbines
to rotate at high speeds.
Do not use a rag or gloved hand against the bell
edge to stop or slow down a bell during rotation.
Do not try to clean the bell edge during rotation.
EN04 SAFETY
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04.2 ADDITIONAL SAFETY INFORMATION
The IntelliSpray™ has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all
operations for the IntelliSpray will halt when the E-Stop is engaged. The operator must disengage the E-Stop and reset
the system to recover from this state.
Observe all local or municipal safety measures and wear approved protective equipment when servicing this equipment.
Clean all spilled chemicals and materials and do all work in a clean and organized environment to prevent personal
injury and equipment damage.
If the operation of this equipment, sensors, switches, or other ancillary equipment occurs in the presence of flammable
gases and vapors, connect this equipment through intrinsic-safe or Zener barriers. Classify them as a ‘simple apparatus’
or approve them for use in these areas.
NOTICE
During the initial commission of the equipment and at periodic times throughout equipment life, visually examine all fluid
fittings for leaks.
Periodically, it is necessary to visually examine all pieces of this equipment for signs of noticeable degradation due to
chemicals or other conditions in the equipment’s environment.
CAUTION
Only operate the equipment after you have read this section.
DANGER
To prevent injury or electrocution while the system is under power, do not contact, disconnect, or manipulate electrical
connections or devices. The main disconnect on the right side of the controller can be locked out. Follow the proper
Lockout–Tagout (LOTO) procedures for internal controller electrical work.
Only qualified electrical personnel can perform the work if diagnosis and troubleshooting are not possible during
working conditions.
WARNING
To prevent possible chemical spillage when personnel are not on site, air and fluid supplies for the equipment must be
disabled when the equipment idles for an extended period, such as an end-of-day shutdown.
SAFETY
Obey local or municipal regulations that require installed fire suppression for equipment operation.
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EN EN 05 ISOCYANATE INFORMATION
05 IMPORTANT ISOCYANATE
INFORMATION
05.1 GENERAL HANDLING GUIDELINES
Isocyanates (ISO) are catalysts used in two component
materials.
Fluids with isocyanates that are sprayed or dispensed
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) for 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 adjusted equipment
may result in unsatisfactory cured material which
can off-gas and make offensive odors. Refer to the
instruction in the manual to correctly maintain and
operate the equipment.
• To prevent inhalation of isocyanate mists, vapors
and atomized particulates, everyone in the work
area must wear applicable respiratory protection.
Always wear a correctly fitted respirator that includes
a supplied-air respirator. Refer to the instructions in
the fluid manufacturer’s SDS for correct work area
airflow.
• Avoid all skin contact with isocyanates. Everyone in
the work area must wear chemically impermeable
gloves, protective clothing, and foot cover
recommended by the fluid manufacturer and local
regulatory authorities. Follow all fluid manufacturer
recommendations, to include the discard of
contaminated clothing. Do not eat or drink after
equipment use until hands and face have been
washed.
• Hazard from exposure to isocyanates continues after
spray use. Anyone without correct personal protective
equipment must stay out of the work area during and
after the application, and for the time period specified
by the fluid manufacturer. This time period is usually a
minimum of 24 hours.
• Warn others who may enter work area of hazard
from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local
regulatory authority.
• It is recommended to post a sign outside the work as
the one shown below:
WARNING
DO NOT ENTER UNTIL AFTER:
DO NOT ENTER DURING SPRAY
FOAM APPLICATION OR FOR ─
HOURS AFTER APPLICATION IS
COMPLETE
TOXIC FUME HAZARD
DATE: TIME:
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EN EN05 ISOCYANATE INFORMATION
05.2 MATERIAL SELF IGNITION
Some materials may become self-igniting if applied too
thick. Read material manufacturer's warnings and Safety
Data Sheet
05.3 KEEP COMPONENTS A & B
SEPARATE
Prevent cross contamination of A and B materials.
Cured material in fluid lines and passages can cause
serious personal injury or equipment damage.
Never interchange the wetted parts of components A
and B.
Never use solvent on one side that is contaminated with
fluid from the other side.
05.4 EXPOSURE TO MOISTURE
ISO will start to cure and form small, hard, abrasive
crystals when exposed to moisture and humidity.
These crystals become suspended in the fluid and can
cause equipment damage. Over time, a film will form on
the surface and the ISO will get thicker with increased
viscosity.
Take the following steps to prevent damage to spray gun
components due to cured ISO:
• A sealed container with a desiccant dryer in the vent,
or a nitrogen atmosphere in the empty head space of
the container must be used.
• ISO must not be stored in an open container.
• The ISO pump reservoir must be kept filled with
applicable lubricant. The lubricant creates a barrier
between the ISO and the atmosphere.
• Only ISO compatible moisture-proof hoses must be
used.
• Reclaimed solvents, which may contain moisture,
must not be used.
• Solvent containers must be closed when not in use.
• Assemble threaded parts only with the correct
lubricant.
05.5 FOAM RESINS WITH 245 FA BLOWING
AGENTS
Some materials may become self-igniting if applied too
thick. Read material manufacturer's warnings and Safety
Data Sheet (SDS).
05.6 CHANGING MATERIALS
Prevent equipment damage and downtime during material
changes and flushes for service or storage.
• Flush equipment multiple times to make sure it is fully
clean.
• The fluid strainers must be cleaned after all flushes.
Speak with the material manufacturer for information
on chemical compatibility.
• When there is a change between epoxies, urethanes,
or polyureas, all wetted parts must be disassembled
and cleaned, and the hoses changed.
05.7 ELECTRICAL GROUND
Examine the local electrical code and Proportioner
manual for instructions on how to correctly ground the
equipment.
Ground the spray gun through a connection to a Binks
approved grounded fluid supply hose.
ISO that has started to cure will reduce the life and
performance of all wetted parts.
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EN EN 06 SYSTEM OVERVIEW
The Binks® IntelliSpray™ IS40™ Spray Polyurethane
Foam (SPF) system consists of a Proportioner,
QuickHeat™ Hose, and ST1™ Spray Gun. The IntelliSpray
system is designed for ease of use, increased productivity,
best in class process control, easy service, and real-time
ratio control.
QuickHeat hoses have approximately double the heat
power compared to most other SPF hoses. QuickHeat
hoses directly heat the fluid from inside the hose, for fast
and efficient fluid heating, even in cold climate conditions.
QuickHeat hoses have embedded temperature and
pressure sensors, independent A and B heated hoses
and up to 4 separate heating zones to improve temperature
control.
QuickHeat hoses supply sensor power and signal
communication without cables or connectors, eliminate
failure points, and improve reliability. QuickHeat hoses
include a snag-proof, abrasion-resistant outer hose wrap
sealed with industrial-grade Hook & Loop material for
individual A or B-side hose replacement.
The ST1 gun has improved ergonomics, lower weight, ease
of service, and a wide range of output and pattern control
with configurable chamber and tip combinations.
The system will also work with high-pressure spray foam
guns with compatible hose manifolds.
Refer to the QuickHeat Hose Manual (Manual # 341164)
and ST1 Gun Manual (Manual # 336742) for more
information.
06 SYSTEM OVERVIEW
WARNING
For professional use only. Not for use in explosive
environments or atmospheres. Equipment must not be
installed in outdoor locations.
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EN EN06 SYSTEM OVERVIEW
IntelliSpray Spray Foam Proportioners are high
performance devices that deliver Isocyanate (A) and
Polyol Resin (B) fluids to a spray gun via QuickHeat
hoses.
The Proportioner monitors and controls A to B fluid
output to a 1:1 ratio and is capable of high pressures,
temperatures, and flow rates. Efficient, high-power
preheaters along with independent A and B multi-zone
internal hose heating ensures user settings control fluid
temperatures.
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 has 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 ten outputs up to 1000 times per second.
The controller stores job data, recipes, historical
performance information, user information, and alarm
histories. The software can be updated remotely or with
a USB memory stick. A 15.6 (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 additional
hardware or software. The Control Module includes
power management, circuit protection, motor control,
heater power, remote connectivity, internal I/O, and
electrical safety systems. The Control Module includes
a thermostatically controlled cooling fan that draws in
outside air through a user cleanable filter.
Diagnostics and repair are made simple via clear
messages and monitoring screens, while Component
replacement is fast and simple.
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 gauges,
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.
The Fluid Module can be partially or fully extracted from
the Proportioner frame, for ease of service. 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
Binks 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 50, 100, 150 and
200 foot lengths (main hose lengths). The Smart Ends
(connected as extensions to the main hose sections)
are provided in 20, 25, and 40 foot lengths, with the 25
foot version having increased flexibility. Connected to
the end of the Smart End is an unheated, insulated whip.
This comes in 3, 4, 6, and 10 foot lengths, with the 4 foot
version having increased flexibility.
Each length of heated hose begins with a fluid manifold or
modem that may contain 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
the 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
protects the modules from damage and provides multiple
horizontal and vertical mounting points.
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EN EN 07 SPECIFICATIONS
07 IS40 SPECIFICATIONS
The IS40™ Proportioner is roughly 36 inches wide, 70
inches tall, and 32 inches 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. For more
information, refer to Chapter 12 Installation.
The table to the right shows other physical,
operating, and electrical specifications. 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 IntelliSpray 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.
Physical, Environmental,
and Electrical Specifications
Weight 585 lbs (260 kg)
Maximum Fluid Pressure 2250 psi (155 Bar)
Operating Temperature 32/120° F (0-50° C)
Humidity 0-85% Non Condensing
Input Voltage 200-240V or 380-415V
Frequency 50/60 Hz
Phase 3PH or 3PH+N
Full Load Amps 78A or 56A
Maximum Disconnect 100 A
SCCR 5 kA
Top Bottom
Left Side
3.88
25.56
23.76
26.88
32.55
20.37
Front
39.40
35.22
56.00
70.25
33.75
Back Side
32.75
30.75
1.50 R0.20
TYP
HANGING
CABLES
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EN EN07 SPECIFICATIONS
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EN EN 08 PRODUCT OVERVIEW
08 IS40 OVERVIEW
The IS40™ 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 (JIC 5 for A hose,
JIC 6 for B hose). The figure below and the following Sections will help the user become familiarized with the IS40
Proportioner.
IS40
1. Wall Mounting Bracket
2. Cellular Antenna
3. Power Cord Inlet
4. Cover Latches (x2)
5. On/Off Switch
6. Control Module
7. HMI
8. Emergency stop button
9. B Fluid Module
10. Floor Mounting Brackets
11. A Fluid Module
12. Frame
13. Hose Power
14. Hose Communication
15. QuickHeat™ Hose
Connection Cover
10
3
6
7
2
5
9
11
13
14
15
1
8
12
4
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EN EN08. PRODUCT OVERVIEW
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EN EN 09 FLUID MODULES
09 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 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 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 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.
MODULE DESCRIPTION - GENERAL
1. Frame
2. Servo Motor
3. TSL Fill Hole
4. Pressure Gauge
5. Recirculation Valve
6. Front Handle
7. Cover Retainer Screw
8. Filter Module Valves
9. Inlet Filter
10. Front Cover
11. Release Pin
12. Communication Connector
13. Rear Handle
14. Motor Power Connector
15. Motor Encoder Connector
16. Fluid Outlet Fittings
16
13
15
12
1
3
68
11
2
7 5
4
9
10
14
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EN EN09 FLUID MODULES
The A and B Fluid Modules have similar controls as
described and shown below.
Filter Outlet Valve (8): The IS40 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
Chapter 16 Servicing for filter service instructions.
Recirculation Valve (4): 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 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 Gauge (3): This indicates fluid
pressure in the high pressure manifold, including the
spray gun hoses.
Cover Screws (5): 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.
MODULE COMPONENTS - FRONT
(A MODULE SHOWN)
1. Cover
2. TSL Sight Gauge
3. Pressure Gauge
4. Recirculation Valve
5. Cover Retainer Screw
6. Handle
7. Filter Module Valves
8. Inlet Filter
9. Release Pin
3
457
9
8
1
2
6
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EN EN 09 FLUID MODULES
The images below show the IS40 Fluid Module with the
covers removed.
The A and B Fluid Modules are identical except for the
following:
• The B Servo Motor is slighter larger than the A
Servo Motor due to the higher viscosity B Resins
that require more pump torque.
• The A and B covers have different labels attached
to 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.
MODULE COMPONENTS (WITHOUT COVER)
1. I/O Module (inside frame)
2. Pump
3. Flow Meter
4. Filter Module
5. Drip Tray
6. Recirculation Hose Fitting
7. High Pressure Module
8. Jumper Hose Fitting (to gun)
9. Fluid Preheater Module
(enclosed in frame)
3
6
8
9
5
1
2
4
7
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EN EN09 FLUID MODULES
09.1 MODULE ASSEMBLIES: OVERVIEW
The following figure shows the major IS40 Fluid Module
components. Additional breakdowns and parts lists are
contained in Chapter 18: Maintenance.
MODULE ASSEMBLY COMPONENTS
1. Front Cover
2. Filter Module
3. Flow Meter
4. Low Pressure Module
5. Frame
6. Fluid Pump
7. Servo Motor
8. Motor Mount
9. High Pressure Module
5
8
9
1
2
4
7
6
3
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EN EN 09 FLUID MODULES
09.2 MODULE FLUID PATHWAYS
The following diagram shows the fluid path and major
fluidic elements contained in the IS40 Fluid Modules.
Flow is from left to right indicated by arrows.
Pump
High Pressure
Module
Check
Valve
Pressure
Gauge
Recirculation
& Pressure
Relief Valve
Recirculation
Fitting
Gun Hose
Fitting
Burst Disk
Temperature Sensor
Pressure Sensor
P
T
P
P
T
P
T
P
Preheater
Flow Meter
Filter Module
Filter
Ball
Valve
Supply Hose
Fitting
Ball
Valve
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EN EN09 FLUID MODULES
FILTER MODULE DESCRIPTION
1. Inlet Filter Cap
2. Filter Body
3. Filter Element (40 Mesh)
4. Pre Filter Inlet Pressure Sensor
5. Post Filter Pressure Sensor
6. Filter Manifold
7. JIC M12 Inlet Fitting
8. Filter Module Valves
09.3 FILTER MODULE
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 (8): Inlet and outlet 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 col-
lect 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 (2): A 7/8 hex head cap (1) 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 lock-
ing.
• Filter Elements (3): Each Filter Body holds two 40
mesh filter elements that can be easily cleaned or
replaced.
• Pressure Sensors (4 and 5): The Filter Module has
two sensors that measure pressure on each side of
the filter element. These sensors allow the IS40 to
alert the user when the filters need to be cleaned or
replaced.
1
5
8
7
6
2
3
4
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EN EN 09 FLUID MODULES
09.4 LOW PRESSURE MODULE
Preheater Module (6): 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.
An etched multi-zone interleaved 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 lets the heater elements to operate
at lower temperatures than typical immersion heaters,
increasing reliability and reducing the risk of material
charring.
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.
Pre-pump Pressure Sensor (3): 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 (2): 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 (4): High precision gear flow meters
continuously measure fluid flow to delver A:B fluid on-
ratio.
LOW PRESSURE MODULE DESCRIPTION
1. Filter Module
2. Pre-pump Temperature Sensor
3. Pre-pump Pressure Sensor
4. Flow Meter
5. I/O Electronics
6. Preheater Module
7. Thermal Fuse
8. Temperature Sensor
64
1
2
3
8
5
7
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EN EN09 FLUID MODULES
09.5 PUMP MODULE
Pump Module: The IS40 uses external gear pumps
directly driven by DC Servo Motors to pressurize and
deliver fluid to the distribution (spray gun) hose. This
approach minimizes size and response time, while
maximizing pumping efficiency.
Fluid Pump (1): 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.
PUMP MODULE DESCRIPTION
1. Fluid Pump
2. Fluid Union (M) x2
3. Shaft Coupler
4. DC Servo Motor
5. Pump Mount
1
2
3
5
2
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EN EN 09 FLUID MODULES
09.6 HIGH PRESSURE MODULE
High Pressure Module: The High Pressure Module
houses the following components:
Check Valve (3): The Check Valve prevents fluid
backflow to the low pressure side of the IS40 Fluid
Modules.
Pressure Sensor (2): 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 (see Chapter 15.9.7 Settings Screen:
Hose Configuration) and when hose sensor bypass mode
is enabled (Chapter 15.8.3 System Status Screens:
Sensor Bypass).
Pressure Gage (4): An analog pressure gauge allows the
user to read pressure in the distribution hoses even when
the system in not powered.
Recirculation and Pressure Relief Valve (5): The
Recirculation valve controls flow to the recirculation
hose and includes a pressure relief valve that opens at
approximately 3000 psi.
Burst Disk (7): As an additional safety precaution, a
burst disk assembly rated for 7000 psi is located at the
back 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 (see Chapter 16 Servicing.).
Hose fittings (6 and 8): 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 on the manifold.
HIGH PRESSURE MODULE DESCRIPTION
1. Fluid Union (F)
2. Pressure Sensor
3. Check Valve (not shown)
4. Pressure Gauge
5. Recirculation Valve
6. Recirculation: JIC 5M (ISO) or JIC 6M (Resin) Hose
Fittings
7. Burst Disk
8. Gun Hose: JIC 5M (ISO) or JIC 6M (Resin) Hose
Fittings
1
2
4
8
6
5
7
3
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EN EN09 FLUID MODULES
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EN EN 10 CONTROL MODULE
10 CONTROL MODULE
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 constructed 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 15.6 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. 200-240V and
380-415V wiring diagrams are provided in Chapter 19
Electrical Schematics.
The following pages show the location and function of
primary components in the Control Module. For additional
views and parts list, see Chapter 18 Maintenance.
Always be sure the rotary power switch is in the OFF
position before opening the Control Module. Due to
electrical shock hazards, the servicing of the Control
Module must be done by trained personnel only.
WARNING
ELECTRICAL SHOCK HAZARD: Motor drives contain capacitors that have stored electrical energy for up to 15
minutes after power is shut off. Wait 15 minutes before you disconnect the power cables between the motor drives
and the motors.
WARNING
ELECTRICAL SHOCK HAZARD: Disconnect all power sources before accessing any electrical connections in the
Control Module, Fluid Modules, or Hoses. Equipment must only be serviced by qualified persons.
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EN EN10 CONTROL MODULE
10.1 CONTROL MODULE: OVERVIEW
The functions 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 15.6 TFT muti-touch
HMI (Human Machine Interface) that also contains an
industrial Controller, The Controller performs all machine
monitoring and control functions 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 a heat sink 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 enables users to email Job
Reports to selected recipients, and allows authorized
IntelliSpray service providers to access the system for
remote service and software upgrades.
Cooling Fan: A thermostatically controlled cooling fan
pulls vexternal air through a user-serviceable filter.
This helps prevent component overheating in hot
environments.
E-Stop Button: When pressed, the E-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. See Chapter 16 Servicing
for air filter cleaning instructions.
Power Switch: The IS40 rotary Power Switch
disconnects all voltage to the unit. It also allows use of
a 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 and
transferring information (e.g. hand-held scanner for
scanning drums and memory sticks for transferring job
reports, software updates, etc).
Cable Gland: An M40 X 1.5 cable gland is provided
with each IS40 that is suitable for 22mm to 32mm cable
diameters). A 2/4 SOOW power cable is suitable for most
installations, 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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EN EN 10 CONTROL MODULE
10.2 CONTROL MODULE: ENCLOSURE
The main components of the Control Module are shown
in the figure below and described in the following pages.
All items and cables in the Control Module are clearer
marked to assist in diagnostics and service.
CONTROL MODULE DESCRIPTION
1. HMI/Controller
2. Cellular Modem
3. Cooling fan
4. Cellular Antenna
5. Dual USB Ports
6. Power Switch
7. Cover Latches (x2)
8. Emergency Stop Button
9. Air Filter (behind door flange)
3
4
5
6
8
9
1
2
7
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EN EN10 CONTROL MODULE
INTERIOR DESCRIPTION
1. Cooling Fan
2. Main Power Cable Gland
3. Power Switch
4. Main Panel
5. B Fluid Module Motor/Communication Cables
6. A Fluid Module Motor/Communication Cables
7. B Fluid Module Power Cable
8. A Fluid Module Power Cable
9. Solid State Relays (SSRs)
2
3
5678
9
1
4
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EN EN 10 CONTROL MODULE
1
4
2
DOOR DESCRIPTION
1. HMI
2. Cellular Modem
3. Emergency Stop Switch (behind filter assembly)
4. HMI Controller
5. Filter Assembly
5
3
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EN EN10 CONTROL MODULE
10.3 MAIN PANEL: 200-240V
Most Control Module components are part of the Main
Panel and are shown in the following figure. Additional
Hook & Loop retention straps are used for DIN rail
mounted components for mobile robustness.
Wiring is contained in capped Raceways and clearly
labeled. All components are clearly labeled on the Main
Panel. Wiring schematics are contained in Chapter 19
Schematics.
CONTROL BOARD DESCRIPTION
1. Bank 2 Circuit Breakers
(Low Voltage Systems)
2. Low Voltage Circuit Breakers
3. 24V Power Supply
4. Power Supply Circuit
Breaker
5. Contactors
6. Main Terminal Blocks
7. Bank 1 Circuit Breakers
(Heating and Motors)
8. Panel Ground
9. B (Resin) Motor Drive
10. A (ISO) Motor Drive
11. Thermostat
12. Terminal Blocks
13. EtherCat Coupler
14. I/O Modules
15. EtherCat Modules
16. Relays
17. Diode Zener
18. Fluid Module Heat Circuit Breakers
19. Hose Heat GFI
20. Bank 3 Circuit Breakers
(Heating Zones)
6
9
10
5
11
12
13
14
15
16
17
8
4321
19
20
18
7
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EN EN 10 CONTROL MODULE
CONTROL BOARD DESCRIPTION
1. Bank 2 Circuit Breaker
(Low Voltage Systems)
2. Low Voltage Circuit Breakers
3. 24V Power Supply
4. Power Supply Circuit
Breakers
5. Contactors
6. Main Terminal Blocks
7. Bank 1 Circuit Breakers
(Heating and Motors)
8. Panel Ground
9. Power Line Filter
10. B (Resin) Motor Drive
11. A (ISO) Motor Drive
12. Thermostat
13. Terminal Blocks
14. EtherCat Coupler
15. I/O Modules
16. EtherCat Modules
17. Relays
18. Diode Zener
19. Pre Heat Circuit Breakers
20. Hose Heat GFIs
21. Neutral Distribution Block
22. Terminal Block, Ground
23. Bank 3 Circuit Breakers
(Heating Zones)
10.4 MAIN PANEL: 380-415V
6
9
10
11
5
12
13
14
15
16
17
18
8
4321
20
21
22
23
19
7
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EN EN10 CONTROL MODULE
10.5. CIRCUIT BREAKERS
A circuit breaker is a switch designed to automatically
protect an electrical circuit from damage caused by
overcurrent, overload, or short circuit situations.
Protective relays inside the circuit breaker detect a fault
and trip to open contacts that interrupt current flow.
Circuit breakers contained in the IS40™ Main Panel
prevent protect all electrical circuits and components in
the IS40 Proportioner and QuickHeat™ hoses.
Circuit breakers and their electrical hierarchy also allow
easier identification and isolation of the location or
component that causes the fault.
If a circuit breaker opens (trips) there is always an
underlying reason that should be investigated and
resolved by a trained technician.
In most cases resetting (closing) a circuit breaker will not
resolve the underlying issue.
The IS40 Circuit Breakers are contained in several banks
as shown on the previous page.
Bank 1 (shown on this page) contains the Main circuit
breakers that feed circuits through Bank 3 shown on the
next page. Circuit Breakers are clearly labeled on the
panel.
The purpose and status of circuit breakers in each Bank
are shown and described below and in the following page
CB Bank 1: Bank 1 contains either 200 or 400V main
circuit breakers for Heating (preheaters and hoses) and
A and B Pump Motors.
Breakers are closed (hot) when switched upward when
viewing from the front of the panel. A red indicator is
also shown when the breakers are closed. When open
or tripped, the breaker switches are pointed down when
viewing from the front, and green indicators are visible.
Bank 1 Breaker Closed/Hot
Bank 1 Breaker Open/Tripped
WARNING
ELECTRICAL SHOCK HAZARD: Disconnect all
power sources before accessing any electrical
connections in the Control Module, Fluid Modules, or
Hoses. Equipment must only be serviced by qualified
persons.
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EN EN 10 CONTROL MODULE
CB Bank 2: Bank 2 contains an AC circuit breaker for the
24V DC Power Supply. It also has a series of individual
24V circuit breakers for the servo drives, HMI/PLC and
safety circuit, Smose power, and the A and B fluid
modules.
When tripped, a breaker will pop outward slightly and a
red indicator LED will show when the unit is powered on.
CB Bank 3: Bank 3 contains individual circuit breakers
for the A and B Preheaters and each section of the A
and B hoses (up to 2 hose sections or 4 individual hose
heating zones).
Hose circuit breakers also act as GFIs (Ground Fault
Interrupts) to protect personnel or property from electrical
current leakage from the hose.
Breakers are hot (closed or ON) when switched to the
right (when viewing from the front). When closed a red
indicator is also shown for each pole of each breaker.
When open or tripped (OFF), the breaker switches are
pointed to the left when viewing from the front, and also
show green indicators.
CB Bank 3: Bank 3 contains individual circuit breakers
for the A and B Preheaters and each section of the A
and B hoses (up to 2 hose sections or 4 individual hose
heating zones).
Hose circuit breakers also act as GFIs (Ground Fault
Interrupts) to protect personnel or property from electrical
current leakage from the hose.
Breakers are hot (closed or ON) when switched to the
right (when viewing from the front). When closed a red
indicator is also shown for each pole of each breaker.
When open or tripped (OFF), the breaker switches are
pointed to the left when viewing from the front, and also
show green indicators.
Bank 3 Breaker Tripped
Press to Reset (Close)
Bank 3 Breaker Open/
Tripped (OFF)
Bank 3 Breaker Open/
Closed/Hot (ON)
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EN EN10 CONTROL MODULE
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EN EN 11 QUICK HEAT HOSE
11 QUICKHEAT™ HOSE
The IS30™ and IS40™ proportioners are specifically
designed to use Binks QuickHeat™ Hoses. These hoses
contain high-power internal electric heating cables,
ensuring all heating energy is transmitted directly to the
fluid.
QuickHeat hoses are provided in 50, 100, 150, and
200 foot lengths (main hose lengths). The Smart Ends
(connected as extensions to the main hose sections)
are provided in 20, 25, and 40 foot lengths, with the 25
foot version having increased flexibility. Connected to
the end of the Smart End is an unheated, insulated whip.
This comes in 3, 4, 6, and 10 foot lengths, with the 4 foot
version having increased flexibility.
Each length of a heated hose begins with a fluid
manifold or modem that may contain pressure and/
or temperature sensors, heater cable connectors, and
electronics used to send information over the hose to
the Proportioner Control Module. With this approach,
no sensor power or communication cables are required,
which are a common source of hose failures in other
systems. It also provides the architecture for two-way
communication between the hose, proportioner, and
remote devices.
The QuickHeat hose has roughly double the heating
power compared to most other SPF hoses. It 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 & B hose heating,
and up to four independent heating zones to improve
temperature control.
QuickHeat hoses provide sensor power and signal
communication without cables or connectors, providing
high reliability while reducing failure points.
QuickHeat hoses include a snag and abrasion-resistant
outer hose wrap that is sealed with industrial-grade hook
& loop material to allow individual A or B-side hose
replacement.
Product Features:
• Fast and reliable heat. Independent A & B
embedded heater wire submerged in hose fluid
achieving > 100˚F (37˚C) DeltaT in under 15
minutes on average.
• Real-time system control. Pressure and
temperature data communicated and controlled
within the hose to spray gun to maximize control
and accuracy.
• Cut service costs. Reduced need for service with
fully potted electronics/sensors and the ability
to replace A & B side independently when
needed.
• Reduced electrical connections, resulting in
fewer maintenance issues.
• More heat control and less risk. Independent
heat sensors allow the system to adjust
temperature.
• Lighter and more flexible hoses for less sprayer
fatigue.
Refer to the QuickHeat Hose Product Manual for more in-
formation and instructions on assembling and connecting
QuickHeat hose to the IS30 or IS40 Proportioners.
WARNING
ELECTRICAL SHOCK HAZARD: Disconnect all power sources before accessing any electrical connections in the
Control Module, Fluid Modules, or Hoses. Equipment must only be serviced by qualified persons.
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EN EN11 QUICK HEAT HOSE
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EN EN 12 INSTALLATION
12 INSTALLATION
Note: IS40™ installation requires that a QuickHeat™
hose is fully assembled and ready for connection to the
IS40. See the QuickHeat Hose Manual (Doc #341164) 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 IntelliSpray™ service agents to
assist in system installation, configuration, and/or service.
The following steps outline installation of the IS40.
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). Verify if
the IS40 is on a dedicated 80A 200-240V 3 phase
protected circuit or 60A 380-415V 3 Phase + Neutral
protected circuit.
5. Make electrical connections inside IS40 Control
Module:
○ For 200-240V system, make electrical and
ground connections inside IS40 Control Module.
○ For 380-415V system, make electrical, neutral
and ground connections 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 13.1 to 13.4. If
the Proportioner was not configured at the factory,
then configure hoses as shown as shown in Chapter
16.9.5 Settings Screens: Display Settings.
13.1. From main menu, open Settings > Hose.
13.2. Select hose configuration.
13.3. Press Unpair Modems - Once completed press
Pair Modems - Ensure no other IntelliSpray
Machines are On when pairing modems.
13.4. Scan and select a recommended
communication frequency.
14. Purge A and B fluid sections (and hoses if
new or empty) to eliminate any air. See Chapter
15.6.2 Example 1: Initial System Bleed for detailed
instructions on first time system purging.
15. Follow the quick start instructions in Chapter 13 Quick
Start Guide to begin spraying.
NOTICE
The IS40 requires QuickHeat™ hoses for operation. Do not substitute QuickHeat™ hoses with other hose brands.
WARNING
Installation of the IS40 exposes installers to high voltages and high fluid pressures. Sever injury or death can result
from incorrect installation or installation techniques.
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EN EN12 INSTALLATION
12.1 INSTALLATION PROCEDURE
STEP 1. UNPACK THE UNIT
The IS40 Proportioner is shipped securely mounted to
a shock-absorbing dual-layer pallet. Screws are used
to secure the base of the unit to the pallet. A dual layer
cardboard cover, enclosure, and heavy duty plastic bag
protects the unit during shipping and storage.
After the cardboard covers and top sheet are removed,
put the pallet with the IS40 near the desired location for
installation. Leave adequate room to work around the unit
when it is removed from the shipping pallet.
Remove the four screws (1) that keep the IS40 attached
to the pallet. Lift the unit off the pallet by the tubular frame
members, and use ramps or blocks to slide or walk unit
down to floor level as needed.
STEP 2. PUT IN PREFERRED LOCATION
Slide, lift, or walk the unit into the desired location. Slide
the unit on plastic or cardboard sheets to position the
IS40. Keep adequate room behind, above, and beside the
unit to route the power cable and supply hoses.
STEP 3. SECURE THE UNIT
If the IS40 is to be used in a mobile of seismic
environment, the frame must be secured to a rigid floor
and wall using 5/16 (or larger) grade 8 fasteners and
washers.
The IS40 frame has integral floor and wall mounting
brackets for this purpose.
Use eight bolts or lag screws to secure to the flooring,
and four to secure the unit to the wall. Additional support
members, through-wall bolts, and external braces may be
required depending on the wall's strength.
STEP 4. TURN OFF ELECTRICAL POWER
Verify the IS40 is on a dedicated 80A 200-240V 3-Phase
or 60A 380-415V 3-Phase + Neutral protected circuit.
Make sure that the supply branch circuit is turned off and
appropriate lock-out-tag-out safety measures are in place.
This prevents personnel from accidentally energizing the
circuit during installation.
WARNING
It is the installers responsibility to properly secure the
IS40 in position to prevent movement or tipping in use
or transportation. Severe injury or death may result if
the unit is not secured in place.
Floor mounting brackets
on frame
Wall mounting
bracket on frame
WARNING
The IS40 weighs approximately 585 lbs. Use caution
to prevent unit tip-over and injury to the installers.
1
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EN EN 12 INSTALLATION
STEP 5. MAKE ELECTRICAL CONNECTIONS
Confirm the IS40 rotary disconnect switch is in the OFF
(O) position.
Open the Control Module by rotating the upper and lower
front cover latches on the front of the cabinet to the open
(vertical) position.
Insert appropriately rated 4 conductor power cord through
the M40 X 1.5 cable gland provided with each IS40
(suitable for 22mm to 32mm cable diameters).
Tighten the gland nut to secure the cable. A 2/4 SOOW
power cable is suitable for most installations, but installers
are responsible for selecting the proper cable size and
insulation based on installation configuration, cable
length, and environmental conditions.
Connect the power cord phase wires to the power switch
module inside the Control Module using an M4 hex key
torqued to 55 in-lb. Connection order is arbitrary.
Connect the power cord ground wire to the panel ground
lug with an M6 hex key torqued to 35 in-lb. Note: From
SN 1094 and after, the ground lug was moved below the
main terminal block and is labeled.
After the electrical connections are completed, close and
latch the Control Module cover.
INTERIOR CONNECTION DESCRIPTION
1. Front Cover Latches
2. M40 x 1.5 Cable Gland
3. Power Switch
4. Ground Wire Lug (35 in-lb)
5. Power Connections (55 in-lb)
V
1
2
3
4
5
WARNING
The installer is responsible for selecting the power
cable or wire that has the appropriate ampacity and
environmental ratings for the IS40 system. The use
of undersized power cables or wires can result in
electrical shorts and/or fire.
WARNING
The installer is responsible assuring power and ground
connections are secure and conductors are not
damaged. Loose or damaged connections can lead
to fire, serious equipment and/or property damage,
physical injury or death.
WARNING
Make sure the electric power is turned off to the IS40
before the electrical connections are made, or when
the Control Module is open.
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EN EN12 INSTALLATION
STEP 6. QUICKHEAT HOSE CONNECTION
Remove Master Modem cover by removing x2 M5 screws
(Item 1). Remove upper and lower hose clamp bolts and
outer clam shells. Set the Master modem in place in its
bracket. Note: using zip ties can help to hold the modem
in place when attaching hoses.
Using the flats method described in the QuickHeat™
Hose Manual Connect the A and B jumper hoses to
the respective master modem fluid connections. The A
and B fluid connections use JIC 5 and JIC 6 fittings,
respectively, and are color coded (A-side red, B-side
blue) to prevent cross-connecting.
Do not overtighten as damaged fluid fittings may require
a complete hose section replacement. Apply spray-gun
grease to the A side JIC threads for easier removal if
service is required.
Secure the modem into its retention bracket with the
upper and lower hose clamps. Tighten the retention bolts
to 15 lb-ft. Plug in the A and B heater power plugs to
their respective mating connectors (each is labeled by
zone and side). No tools are required.
Connect the hose DC power and communication cables
to their respective sockets on the side of the IS40. Take
care to align the connectors in their keyed position, insert,
and then tighten the retention ring. No tools are required.
Connect the gun air hose (contained in the QuickHeat
Hose assembly) to the rig air supply with a 1/4 type M
quick disconnect. Use cable zip ties to secure electrical
cables to the hoses. (This is not required, but helps keep
the electrical cables under the master modem cover).
Reinstall the Master Modem cover onto its bracket.
Refer to the QuickHeat Hose manual for more detailed
instructions.
QUICKHEAT HOSE CONNECTION DESCRIPTION
1. Master Modem Cover M5 Screws
2. Upper Hose Clamp (torque to 15 lb-ft)
3. Master Modem Bracket
4. Master Modem
5. A/B Hose Heater Power Connectors
6. A/B Jumper Hose Connectors
7. Lower Hose Clamp (torque top 15 lb-ft)
8. Hose Communication
9. Hose 24V DC Power
1
2
3
4
7
5
6
8 9
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EN EN 12 INSTALLATION
STEP 7. FLUID SUPPLY AND RECIRCULATION
CONNECTIONS
Begin with either the A or B fluid module, and loosen
the M4 button head screws that holds the module cover
to the pump module.
Pull the cover forward and over the valve handle to
remove. Make sure the recirculation handle is fully down
and aligned to the slot in the cover.
Loosen the two 5/16 socket head captive screws as
shown. Pull the spring-loaded locking pin on the outside
of the module.
Slide the module forward using the front handle to the 1st
or 2nd service position (indicated by holes for the locking
pin to engage). This gives easier access to connect the
recirculation and supply lines.
Connect the supply line to the male JIC 12 inlet fitting on
the corresponding Fluid Module. Use installation kit part
number 341133 (included with IS40) with 90˚ 3/4 sweep,
swivel fittings, and ball valve for easier installation (shown
on next page).
Make sure to connect the corresponding supply hose
to the right module (A to A, B to B)!
CONNECTION DESCRIPTION
1. M6 Cover Screws (two per module)
2. 5/16 Captive Socket Head Cap Screw
3. A Side Locking Pin (pull to release)
4. Fluid Supply Hose Fitting (3/4 JIC 12)
5. Recirculation Hose Fitting (JIC 5 A, JIC 6 B)
1
2
3
Pull A side locking pin, then
pull on front handle to slide
module into servicing position.
4
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EN EN12 INSTALLATION
Connect the recirculation line to the corresponding
module (JIC 5 on A module, JIC 6 on B module).
If required, use installation kit PN 341133 to connect to
1/4 NPT recirculation hoses.
Do not over tighten JIC fittings as this may damage
and require hose or fitting replacement. Applying spray
gun grease to the A-side JIC threads will allow easier
removal for service if required.
Pull the locking pin out, slide the module back to position,
engage the locking pin, and secure retention cap screw.
Repeat the previous steps on the other module (A
or B) to complete supply and recirculation hose
connections.
Replace module covers if removed and secure with M6
button head screws.
STEP 8. SET FLUID MODULE VALVES FOR
MATERIAL PURGE
Set both filter and recirculation valves (for each module)
in the spray position as shown in the figure.
1. Filter Valve Open (turn clockwise to spray position)
2. Spray (Gun) Position (valve points down)
STEP 9. CLOSE GUN MANIFOLD VALVE AND SPRAY
GUN REMOVAL
In preparation for purging the system or air, check to be
sure the material control valves on the gun manifold are
in the closed position and remove the spray gun from the
manifold.
STEP 10. FLUID SUPPLY LINES AND
DRUM PUMP PRESSURIZATION
Examine the drum pumps are verify they provide fluid
pressure to the IS40. Make sure that all ball valves on the
supply lines are in the open position.
The IS40 senses pressure at the inlets or each module.
An inlet pressure of 150–200 psi is usually adequate to
prevent cavitation of the gear pumps when the supply
(drum) pumps reverse direction. If low (or no) pressure
is detected the system will display an error message
that requires user intervention before the system can be
purged. Recommended air pressure on the drum pumps
(static and dynamic) should be as follows:
• 2:1 drum pump air pressure of 75 - 100 psi
• 3:1 drum pump air pressure of 50 - 70 psi
Inlet fluid pressure can be checked on the IS40 display
panel after the system is turned on.
21
5
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EN EN 12 INSTALLATION
STEP 11. ENERGIZE THE POWER CIRCUIT
Close any upstream breakers and/or disconnects to
provide electrical power to the IS40.
STEP 12. TURN ON THE IS40
Rotate the power switch on the side of the Control Module
clockwise to the ON (I) position. The IS40 will display a
startup screen while it performs internal system checks.
Once completed, the Spray Mode screen will be
displayed (30-60 seconds after powering on).
STEP 13. CONFIGURE FOR HOSE SETUP
If the Proportioner and Hoses were configured together
at the factory skip this step. If not, refer to the instructions
starting in Chapter 15.9.7 Settings Screens: Hose
Configuration to set hose configuration, pair hose
modems, and select communication frequency.
STEP 14. PURGE SYSTEM
To fill the IS40 and hoses with material, follow the
instructions in Chapter 15.6 Exchange Screen: Overview
for first time system purging.
STEP 15. START THE IS40
Refer to the quick start instructions in Chapter 13 Quick
Start Guide to begin using the IS40.
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EN EN12 INSTALLATION
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EN EN 13 QUICK START GUIDE
13 QUICK-START GUIDE
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
Chapter 15.12 Reports: Overview for additional steps
required when Job Reporting is turned on.
STEP 1. PRIOR TO START-UP
Before starting the IS40, remove all hose from the rack
and position for spraying. Make sure the drum pumps
are on, and the A and B fluid module valves are in the
proper position for spraying.
CONNECTION DESCRIPTIONS
1. Filter Valve Open (turn clockwise to spray position)
2. Spray (Gun) Position (pointed down)
STEP 2. START THE UNIT
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 Chapter 15.9.3 Settings Screens: System Status.
STEP 3. A-ISO and B-RES FLUID LEVELS
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.
Enter value, then press Enter and Save
Press to enter drum level.
21
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EN EN13 QUICK START GUIDE
STEP 4. PRESSURE AND TEMPERATURE SETPOINTS
Enter the desired pressure and temperature setpoints
using the on-screen + and - buttons.
STEP 5. UNIT WARM UP
Press the START button to begin system warm-up.
After the button has been pressed, it will change from
START to WARMING, then the button boundary will
change from solid white to flashing green to indicate the
system is in warm-up mode.
Once the center button changes from WARMING to
READY, then the pumps will automatically pressurize the
system to the desired setpoint.
STEP 6. GENERAL UNIT OPERATION
If required, spray out any cold material in the unheated
whip, then start spraying.
If drums are changed, enter the new fluid level and
continue spraying. (refer to STEP 3).
If errors occur, correct the issue, press the RESET
button, then the START button (refer to STEP 5).
When finished spraying, press the STOP button.
To power off the unit, rotate the power switch on the right
side of the control module ot the OFF position (indicated
by the character 0).
Indicates the system is in warm-up mode
NOTICE
If the IS40 detects a slow warmup in one of the hose
temperature sensors, the START button will change
to a flashing yellow WARMUP BYPASS button.
A button press will put the system into READY
mode. See Section 15.3.3 STEP 5. START THE
PROPORTIONER for more information about the
WARMUP BYPASS feature.
Indicates the system is ready to spray
Pressure setpoint
Press - to decrease
or + to increase B
temperature.
B-side temperature
setpoint
Press - to decrease
or + to increase A
temperature.
A-side temperature
setpoint
Press - to decrease
or + to increase
pressure.
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EN EN 15 OPERATION TIPS
14 OPERATION TIPS
• The system should always be turned off during
transportation.
• Remove and position all hose from the hose rack
before turning the system on. This avoids the
possibility of overheating the hose.
• Remove tight loops in the hose prior to pulling hose
into position to avoid hose kinking.
• Straighten sections of hose near modems to allow
best temperature feedback to unit.
• Do not drag the hose from the gun, whip, or modems.
Use care when moving the hose to avoid damage or
snagging of internal power cables.
• All air must be purged from wetted A side module
and hoses to avoid solidifying material in the lines.
• Do not pull on hose sections that are not in line-of-
sight to prevent tight loops and kinking.
• Do not heat hose without fluid to avoid damaging the
hose and causing leaks.
• Leave hose under positive pressure when not in use
to avoid reacting with the ambient environment.
• If two or more IntelliSpray™ systems are used
in close proximity ( JOB
REPORTS from the Main Menu.
The Job Report has a main summary page is followed
by 8 additional pages containing detailed information
about ambient conditions, materials, yield calculations,
sprayers, and equipment used on the job.
1. Job Header (printed on every page)
2. Job Conditions Summary (job conditions summary
including minimum, maximum, and average).
3. Application Summary (process parameters summary
including minimum, maximum, and average).
4. Material Input Summary (material conditions
summary including minimum, maximum, and
average).
5. Material Usage Summary
6. System performance summary
7. Yield calculation summary (if performed by user)
8. Previous (to view earlier reports).
9. Home (to return to the home screen).
10. Next (to move to the next screen).
11. Report Management (includes USB export, email,
and delete).
1
2
3
4
5
6
7
8 9 10 11
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EN EN15 DISPLAY SCREENS
15.13.4 JOB REPORTS: REPORT
MANAGEMENT
Each page of the on-screen Job Report contains a
section for Report Management. This section contains
buttons for navigating, exporting, ending, creating, and
deleting Job Reports.
Creates a new Job, or loads (continues) an existing Job.
Loading an existing Job allows the user to continue
logging information from a prior incomplete Jobs.
To Load an existing Job, select it from the pull-down
menu, then press Load.
The END JOB button is used at the end of Job.
If the user wishes to continue this job in the future they
should press NO.
Ending a Job prevent additional information to be added
to that Job Report.
The system will also prompt the user when they hit the
stop button.
If the user chooses to end a job the following dialogue
box appears, which allows the user to email the Job
Report and associated files.
See the next page for instructions on emailing or
exporting Job Reports.
1. Previous (to view previous Job Report page).
2. Home (returns to page 1 of the Job Report).
3. Next (to view the next page of the Job Report).
4. Job Name
5. Report Management (includes end job, USB export,
email, and delete).
6. Job Name (load a job from the menu).
7. New/Load (to create a new or load an existing job).
8. End of Job (ends job reporting).
9. End Job (to end job).
10. End Job and Email (to email job reports).
21 3
54
6
7
8
9
10
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EN EN 15 DISPLAY SCREENS
DELETE: Deletes a Job and information for that Job.
When the Delete button is pressed, a window will open
that allows the user to review and select the Job Report
to delete. Since this is a non-recoverable action, a
confirmation is required. This unit can store up to 200 Job
Reports. Once this limit is reached it will delete the oldest
Job Report automatically to create space for the next Job
Report.
EMAIL: If the EMAIL button is pressed the following
dialogue box appears. To email a job report, select the
Job to email from the drop-down window and press the
Attach Report button. Select the email recipient from the
pull down menu or enter it using the email icon button.
Add text to the email (optional) and press Send.
To enter a new email recipient, press the the email
icon button. Press Add New Email Here and use the
onscreen keyboard to enter the address. Press Add,
then Close. The new email recipient will now be
retained for future use. Up to 20 email addresses can be
stored.
Note: For email to work the Proportioner must be
equipped with a cellular modem (standard in North
America) and have an active SIM card with cellular data
plan. Email settings must also be properly configured
(see Chapter 16.9.1 Settings Screens: System
Information).
EXPORT PDF: The EXPORT PDF function copies
Job Reports to a USB memory stick inserted in the
IntelliSpray’s USB port on the side of the Control Module.
After pressing the EXPORT PDF button the following
menu appears. Select the Job to export from the drop-
down menu and press Attach. To copy all Job Reports to
the USB device, press Attach All.
1. Job Report (select to delete).
2. Delete Job (press to delete selected job).
3. Attach Report (press to attach selected report).
4. Job Reports (select from menu).
5. Email Call-Up (press to select from menu).
6. Email Recipient (select from menu).
7. Email Message Text Box
8. Send (press to send report).
9. Add New Email Address
10. Add (add email address).
11. Select Email To Delete (select from menu).
12. Close (press to close the window).
13. Attach (attach files to send to USB drive).
14. USB Drive (select the USB drive).
15. Attach All (press to attach all files to the USB drive).
1
2
10
12
11
9
14
15
13
4
8
6
7
5
3
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EN EN15 DISPLAY SCREENS
15.14 LANGUAGES
IntelliSpray Proportioners can display text in any of the
following languages:
• English (Factory Default)
• Spanish
• Chinese
• Greek
• German
• Polish
• Italian
• Dutch
• French
• Japanese
To change the setting, select the desired language from
the drop down menu.
Press on the language to change the displayed text.
1. LANGUAGE (press to display available languages).
2. LANGUAGE ICONS (select the desired language
icon from the menu).
1
2
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EN EN 15 DISPLAY SCREENS
15.15 VARIABLE RATIO OPERATION
3
4
AUTOMATIC KEY DETECTION
Automatic detection of the key:
Every 5 minutes the system scans if the key is detected.
Due to the system programming, if you use this method
to initially activate the Variable Ratio key it can take as
long as 7.5 minutes to be enabled, and depends on when
the key was plugged into the port.
5
(OPTIONAL FEATURE PN 347682)
15.15.1 ENABLE VARIABLE RATIO
To enable variable ratio, complete the following steps:
1. Plug in the Variable Ratio dongle (not shown).
2. Navigate to the Recipe screen: Menu –> Recipe
(not shown).
3. Navigate from there to the column that is labeled
RATIO and contains the arrow buttons.
4. License Key (click in the check box).
5. Variable Ratio will be enabled if the Variable Ratio
key is detected.
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EN EN15 DISPLAY SCREENS
15.15.2 ENABLE FIRST TIME
The events that will occur once Variable Ratio is enabled
for the first time:
1. The License Key check box on the Recipe screen
will change from unchecked...
2. ... to checked.
3. The Ratio Control indicator on the Recipe screen will
change from a red ...
4. ... to a green checkmark .
5. The Ratio Error will change from a blank state
(disabled)...
6. ... to a populated state (enabled).
3
1
4
2
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EN EN 15 DISPLAY SCREENS
7. If the Ratio Control field is disabled, it can only be
turned back on using the Ratio Control field.
8. To enable the Ratio Control, check the box next to
License Key, then press the License Key option to
reactivate the license key.
9. A dialog box will open on the Spray screen. It will
indicate if the Variable Ratio is on, and the A-ISO
and B-RES drums interfaces.
10. If there is anything other than a 1:1 ratio, disable the
ratio control (7) by unchecking the License Key box
(5). The system will automatically be reset to show
the 1:1 ratio.
7
8
9
B-RES
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EN EN15 DISPLAY SCREENS
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EN EN 16 SERVICING
16 SERVICING
The IS40™ Fluid Modules are designed for easy service.
Most components and assemblies are easily accessed
from the front of the Fluid Module and can be replaced in
several minutes if required with minimum tools and fluid
loss. Normal service of the Fluid Modules consists of the
following:
16.1 FLUID MODULE DEPRESSURIZATION
It recommended that the fluid modules only be fully
depressurized when performing maintenance on the fluid
module that requires breaking the fluid path.
1. Press the STOP button on the HMI screen.
2. Turn the power disconnect switch to the OFF (O)
position.
3. Turn off the material supply pumps.
4. Close the inlet ball valve and filter valves.
5. If a recirculation hose is connected to the high
pressure module, verify that the connections are
secure. If a recirculation hose is not connected, place
a container or bucket underneath the high pressure
module.
6. Slowly rotate the recirculation valve handle from the
vertical to the horizontal position.
7. Verify the pressure drop on the analog pressure
gauge on the high pressure manifold.
16.2 INLET FILTER SERVICING
Inlet Filter Service: The inlet filters on the IS40 prevent
solids from entering the Fluid Modules, hoses, and spray
gun. The IS40 alerts users when the inlet filters require
service. Pressure drop across each filter module can be
seen in the I/O screen. The following steps are taken
when filter maintenance is required.
1. Use a 7/8 socket or box head wrench and loosen the
filter cap 2 turns.
2. Let the pressurized fluid drip into the bucket.
3. Pull the filter assembly out of the filter manifold.
4. Slide the filter element off the filter body.
5. Clean the filter and filter body with a compatible
solvent (e.g. Brake Cleaner, TSL, Dynasol, DPM,
etc.).
6. Examine the O-ring for any tears, permanent set, or
damage and replace if necessary.
7. Apply ST1™ gun grease (or equivalent) to the O-ring
for reassembly.
8. Reinstall the filter element, but replace if damaged.
9. After residual material has drained from the filter
manifold, clean the internal threads with a compatible
solvent.
10. Put a light coat of ST1 gun grease (or equivalent) on
the internal manifold and filter body threads.
11. Insert the filter body and element into the filter
manifold.
12. Torque the filter body to the manifold at 40 ft-lb.
13. Open the inlet ball valve and the filter isolation valve.
14. Open upstream supply valves and turn on the supply
pumps.
15. Resume spray operation.
Power Switch
Filter Body:
Unscrew To Remove
Horizontal = Open
Vertical = Closed
Filter Element
(40 Mesh)
Rotate filter valves
counter clockwise
SAFETY
Wear proper personal protective equipment when
servicing the IS40.
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EN EN16 SERVICING
16.3 CHECK PUMP TSL LEVEL
Check Pump TSL Level: The gear pumps in each Fluid
Module include a chamber around the drive shafts that is
filled with TSL (Throat Seal Liquid) at the factory.
This prevents atmospheric moisture from migrating into
the shaft seals where it could react with Isocyanate in
the A-side pump, causing abrasive crystalline material
to form that may damage the shaft seal. The fluid also
lubricates the shaft seals on both A and B pumps.
Since the TSL and pump shaft are not exposed to
the environment (as in a piston pumps) loss of fluid is
unlikely, However, regular checking of TSL level should
be performed as follows:
1. Remove the captive fluid module retention screws
(2), pull the retention pin, and slide the module into
the second service position (second detent).
2. Remove the two module cover retention screws (1)
and slide the cover off the fluid module.
3. Locate the TSL fill port on top of the pump (3) and
remove the plug.
4. Check that the TSL fluid is up to bottom of the fill port.
If not, fill with additional TSL.
5. Replace the TSL fill plug.
6. Replace and secure the module cover.
7. Slide the fluid module back to the operating position
and secure the retention bolt.
TSL SERVICING COMPONENTS
1. Cover Screws (x2)
2. Retention Screw
3. TSL Fill Plug (upper)
4. TSL Drain Plug (lower)
4
1
2
3
NOTICE
If the TSL fluid is discolored (e.g. brown) it can indicate
a shaft seal leak. Before servicing the pump drain the
TSL from the lower port on the pump and replace it
with fresh fluid. If the problem persists the pump must
be replaced with a new or rebuilt unit.
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EN EN 16 SERVICING
16.4 BURST DISK REPLACEMENT
Burst Disk Replacement: As an additional safety
precaution against over-pressure conditions, Burst Disk
assemblies rated for 7000 psi are located on the back of
the A and B High Pressure Manifolds.
If the Burst Disk ruptures high pressure fluid is contained
by a cover and directed downward and away from other
equipment or users. Most fluids will not harm the Burst
Disk, but some B-side resins can be very caustic (pH
above 9) and can, over time, degrade the stainless-steel
element contained in the burst disk assembly and cause
failure at much lower fluid pressures. For this reason, the
burst disk assembly must be replaced annually.
If high pH B-side resins are used, replacement is
required monthly or quarterly.
The following steps describe the replacement procedure
for the Burst Disk assembly.
1. Relieve system pressure following the procedure in
section 16.1
2. For easier access (but not required), remove the Fluid
Module cover. (See section 16.2 for instruction).
3. For easier access, loosen the Fluid Module captive
retention screw, pull the spring loaded locking pin,
and slide the Fluid Module out until the locking pin
engages with the second stop. (See previous section
for instruction).
4. Place a pail or bucket under the High Pressure
Module to collect fluid.
5. Use a 7/8 socket wrench to loosen the Burst Disk
assembly two turns and let the remaining high
pressure fluid to drip into the collection container.
6. Fully remove the Burst Disk assembly with its O-ring.
7. After the High Pressure Manifold has drained, clean
the internal threads and apply ST1 gun grease (or
equivalent) to prevent seizing.
8. Apply grease to the threads and O-ring on the new
Burst Disk assembly (which includes a new O-ring).
9. Thread the new Burst Disk assembly into the
manifold and tighten to 25 ft-lbs.
10. Install the Fluid Module cover and secure the captive
retention screws.
11. Since some air will have entered the High Pressure
module, purge the system by using the Exchange
mode through the recirculation line.
Apply grease
to the threads
and O-ring
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EN EN16 SERVICING
16.4 FILTER MAINTENANCE
Air Filter Cleaning: A thermostatically controlled fan
in the IS40 Control Module pulls in outside cooling air
as needed through a reusable air filter in the bottom
of the front door. In typical use removal, cleaning, and
reinstallation is recommended every 3 months of use. If
the IS40 is exposed to particularly dusty environments
service should happen monthly.
The following steps describe removal, cleaning, and
installation of the reusable air filter.
1. Press the Stop button on the IS40 screen and turn
off power by rotating the power switch to the Off (O)
position.
2. Open the Control Module by rotating the door locks to
the open position.
3. Locate the air filter in the bottom of the Control
Module door and remove six socket head M5 button
screws and bracket holding the filter in place.
4. Remove the filter.
5. Use a shop vac or compressed air to remove dust
and debris from the filter, counter to the flow direction.
6. Soak the filter in warm soapy water, agitating
regularly. Rinse with warm water and repeat until the
wash water is clean.
7. Shake excess water off the filter and allow to dry
thoroughly.
8. Reinstall the filter in reverse order.
9. Close the Control Module door and secure door locks
in closed position.
FILTER MAINTENANCE DESCRIPTION
1. Door Locks (x2)
2. Power Switch (shown in Off position)
3. Air Filter and Bracket (behind door flange)
4. M4 Filter Screws (right side)
5. M4 Filter Screws (left side)
6. Filter Bracket
7. Filter
1
2
3
45
6
7
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EN EN 17 TROUBLESHOOTING
17 TROUBLESHOOTING
When an error occurs, the IS40 automatically enters the
STOP state and turns off power to heaters and motors.
If the system is in an error state, the user must eliminate
the error condition and press the RESET button before
restarting the system.
The Alarm Screen provides users with more information
on the error condition and recommended actions.
The following tables contain the same information that is
displayed for each error.
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
1 Emergency push button
is enabled.
Emergency stop button is
pressed.
Pull out emergency stop button on front of
machine.
2 Drive A Error. Drive Error FXXXX. Power cycle the system, and contact technical
service if the problem persists.
3 Drive B Error. Drive Error FXXXX. Power cycle the system, and contact technical
service if the problem persists.
4 Pressure Imbalance.
1. A/B pressure
difference exceeds
the max setpoint.
2. Gun filter is clogged.
3. Gun manifold is
closed.
4. Material viscosity is
different.
1. Verify that the gun manifold valves are
open.
2. Examine and clean/replace the gun filters.
3. Adjust the material temp setpoints to
balance any pressure differences.
4. Enable the AVC mode.
5. Increase the permitted pressure difference
in the Recipes Menu.
5 Material A Below Set
Point.
A material level below
error setpoint.
Add material or change drum, then update the
gallon amount.
6 Material B Below Set
Point.
B material level below
error setpoint.
Add material or change drum, then update the
gallon amount.
7 Ethercat Bus Error. Device communication is
lost.
Verify that all ethernet (green) cables are
properly connected to each port.
8 Drive A Overload
Shutdown. Drive is overloaded. Reduce the system pressure.
9 Drive B Overload
Shutdown. Drive is overloaded. Reduce the system pressure.
10 Drive A Amplifier Over
Temperature Shutdown. Drive is overheating. Reduce the system pressure.
11 Drive B Amplifier Over
Temperature Shutdown. Drive is overheating. Reduce the system pressure.
12 Drive A Motor
Shutdown Temperature. Motor is overheating. Reduce the system pressure.
13 Drive B Motor
Shutdown Temperature. Motor is overheating. Reduce the system pressure.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
14 Drive A Control
Voltage Error.
Incorrect DC voltage
supply.
Verify if the cabinet DC voltage supply is
providing 24VDC, and adjust the output if
required.
15 Drive B Control
Voltage Error.
Incorrect DC voltage
supply.
Verify if the cabinet DC voltage supply is
providing 24VDC, and adjust the output if
required.
16 Drive A Encoder Error. Motor Encoder Error.
1. Verify the encoder cable connection at drive
and fluid module.
2. Power cycle the system, and contact
technical service if the problem persists.
17 Drive B Encoder Error. Motor Encoder Error.
1. Verify the encoder cable connection at drive
and fluid module.
2. Power cycle the system, and contact
technical service if the problem persists.
18 Drive A Over Current
Error. Drive is overloaded. Reduce the system pressure.
19 Drive B Over Current
Error. Drive is overloaded. Reduce the system pressure.
20 Drive A Over Voltage
Error.
Incorrect AC supply
voltage.
Verifly for correct supply voltage per
configuration.
21 Drive B Over Voltage
Error.
Incorrect AC supply
voltage.
Verifly for correct supply voltage per
configuration.
22 Drive A Under Voltage
Error.
Incorrect AC supply
voltage.
Verifly for correct supply voltage per
configuration.
23 Drive B Under Voltage
Error.
Incorrect AC supply
voltage.
Verifly for correct supply voltage per
configuration.
24 Drive A Excessive
Deviation.
Pump and motor position
position error.
Verify the coupling is properly installed with
correct torque settings.
25 Drive B Excessive
Deviation.
Pump and motor position
position error.
Verify the coupling is properly installed with
correct torque settings.
26 Drive A
Communication Error.
Lost communication with
Drive A.
Verify that the system ethernet cables are
connected to the correct ports.
27 Drive B
Communication Error.
Lost communication with
Drive B.
Verify that the system ethernet cables are
connected to the correct ports.
28 Drive A Position Limit
Value Exceeded. Drive A limit exceeded. Power cycle the system, and contact technical
service if the problem persists.
29 Drive B Position Limit
Value Exceeded. Drive B limit exceeded. Power cycle the system, and contact technical
service if the problem persists.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
30 System Ratio Error.
1. Air in the lines.
2. Pump Failure.
1. Purge all the air from the supply lines,
proportioner, and hoses.
2. Verify the pump's efficiency and replace the
pump if necessary.
100 Insufficient Drum Pump
Pressure A.
1. A drum pump off.
2. A drum pump
pressure too low.
3. A inlet valve stuck or
closed.
4. Insufficient A
material Level.
5. Cold A material.
6. Minimum pressure
setting too low.
7. A inlet pressure
sensor failure.
1. Verify that the A drum pump is providing
100 -300 psi at the proportioner.
2. Verify the A supply line valves are open.
3. Examine the A drum material level.
4. Warm the A material to the manufacturer's
recommendations.
5. Lower the minimum pressure setting in the
Settings screen.
6. Examine the A inlet pressure sensor
connectors, and contact technical service if
the problem persists.
101
Excessive System
Pressure A Post-Gear
Pump.
1. A side pressure
exceeds maximum
system setpoint
2. A side gun manifold
valve turned off.
3. A side gun filter
clogged.
4. A post gear pump
pressure sensor
failure.
5. B recirculation valve
is open or stuck.
1. Lower the system pressure set point.
2. Raise the pressure error limit in the Recipes
screen.
3. Verify the A side gun manifold is in the
open position.
4. Clean or replace the A side gun filter.
5. Examine the A side outlet pressure
sensor connector.
6. Verify that the B side recirculation valve is
not stuck and is in the gun position.
103 Hose OverTemp A
End Modem.
1. Hose overheat due to
ambient conditions.
2. Heater cable
connected to the
incorrect section.
1. Let the hose cool (and/or purge fluid
through the hose).
2. Examine the hose power connections.
104 PreHeat OverTemp A.
1. Preheater A is too
hot.
2. Temperature sensor
failure.
1. Let the preheater (and/or purge fluid
through the preheater).
2. Examine the temperature sensor connector.
105 Filter Clog A.
1. Filter clogged.
2. Pressure drop error
settting too low.
3. Pressure sensor
failure.
1. Clean or replace the filter element.
2. Increase the maximum permitted pressure
drop in the Recipes screen.
3. Examine the inlet and outlet pressure
sensor connectors.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
106 Insufficient Preheat
Pressure A.
1. A drum pump off.
2. A drum pump
pressure too low.
3. A supply line, pre-
filter, and/or post-filter
valve closed.
4. Insufficient A
material Level.
5. Cold A material.
6. Minimum pressure
setting too low.
7. A inlet pressure
sensor failure.
8. Pressure sensor
failure.
9. A pre-filter or inlet
valve clogged.
10. A flow meter stuck.
1. Verify that the A drum pump is providing
100 -300 psi at the proportioner.
2. Verify that the A inlet and filter valves are
open.
3. Examine the A drum material level.
4. Warm the A material to the manufacturer's
recommendations.
5. Lower the minimum pressure error setting
in the Settings screen.
6. Examine the A pressure sensor
connectors.
7. Clean or replace the A inlet filter.
8. Remove the A filter inlet valve and
examine it for debris.
9. Remove A flow meter and check for solids
of debris.
107 Insufficient Filter
Pressure A.
1. A drum pump off.
2. A drum pump
pressure too low.
3. A supply line or pre-
filter valve closed.
4. Insufficient A
material Level.
5. Cold A material.
6. Minimum pressure
setting too low.
7. Pressure sensor
failure.
8. A pre-filter or inlet
valve logged.
1. Verify that the A drum pump is providing
100 -300 psi at the proportioner.
2. Verify that the A inlet and filter valves are
open.
3. Examine the A drum material level.
4. Warm the A material to the manufacturer's
recommendations.
5. Lower the minimum pressure error setting
in the Settings screen.
6. Examine the A pressure sensor
connectors.
7. Clean or replace the A inlet filter.
8. Remove the A filter inlet valve and
examine it for debris.
108 Excessive Drum Pump
Pressure A.
1. A drum pump
pressure too high.
2. Pressure sensor
failure.
3. A check valve leak.
1. Verify that the A drum pump is providing
100 -300 psi at the proportioner.
2. Increase the maximum inlet pressure
setting in the Settings screen.
3. Examine the A inlet pressure sensor
connector.
4. Examine the A side high-pressure check
valve and replace if necessary.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
109 Excessive System
Pressure A SMOSE.
1. A side pressure
exceeds maximum
system setpoint.
2. A side gun manifold
valve turned off.
3. A side gun filter
clogged.
4. B side recirculation
valve in open
(recirculation) position
5. Hose pressure sensor
not calibrated.
6. Hose pressure sensor
failure.
1. Lower the pressure set point.
2. Raise the pressure error limit in the Recipes
screen.
3. Verify the A side gun manifold is in the
open position.
4. Clean or replace the A side gun filter.
5. Examine that the B side recirculation
valve is in the hose (gun) position
6. Verify the hose calibration (see Hose
Calibration in the System Screen).
110 A Flow Meter Error. Flow meter failure. Examine the A flow meter and the connector.
111 A TRTD Body Top
Error. Sensor failure. Examine the RTD sensor and connector.
112 A PreHeat RTD Body
Bottom Error. Sensor failure. Examine the RTD sensor and connector.
113 A PreHeat RTD In
Error. Sensor failure. Examine the RTD sensor and connector.
114 A PreHeat RTD Out
Error. Sensor failure. Examine the RTD sensor and connector.
115 A Pre-Filter Pressure
Sensor Error.
1. Excessive Pressure.
2. Pressure below zero.
3. Sensor failure.
1. Examine the check valve and replace if not
holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
116 A Post-Filter Pressure
Sensor Error.
1. Excessive Pressure.
2. Pressure below zero.
3. Sensor failure.
1. Examine the check valve and replace if not
holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
117 A Pre-Gear Pump
Pressure Sensor Error. Sensor failure.
1. Examine the check valve and pressure
sensor and replace if not holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
118 A Post-Gear Pump
Pressure Sensor Error. Sensor failure.
1. Verify pressure reading matches the analog
pressure gauge.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
119 Hose UnderTemp A
Middle 1 Modem.
1. Heater cable
disconnected or
connected to the
incorrect section.
2. Hose heater wire
failure.
Examine the hose power connections.
120 Hose OverTemp A
Middle 1 Modem.
1. Hose overheat due to
ambient conditions.
2. Heater cable
connected to the
incorrect section.
1. Let the system cool and/or purge the
material.
2. Examine the heater cable connections.
200 Insufficient Drum Pump
Pressure B.
1. B drum pump off.
2. B drum pump
pressure too low.
3. B inlet valve stuck or
closed.
4. Insufficient B
material Level.
5. Cold B material.
6. Minimum pressure
setting too low.
7. B inlet pressure
sensor failure.
1. Verify that the B drum pump is providing
100 -300 psi at the proportioner.
2. Verify that the B supply line valves are
open.
3. Examine the B drum material level.
4. Warm the B material to the manufacturer's
recommendations.
5. Lower the minimum pressure setting in the
Settings screen.
6. Examine the B inlet pressure sensor
connectors, and contact technical service if
the problem persists.
201
Excessive System
Pressure B Post-Gear
Pump.
1. B side pressure
exceeds maximum
system setpoint.
2. B post gear pump
pressure sensor
failure.
1. Lower the system pressure set point.
2. Raise the system pressure error limit in the
Recipes screen.
3. Examine the B side outlet pressure
sensor connector.
202 Hose UnderTemp B
End Modem.
1. Heater cable
disconnected or
connected to the
incorrect section
2. Hose heater wire
failure.
1. Examine the hose power connections.
Contact technical service if the problem
persists.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
203 Hose OverTemp B
End Modem.
1. Hose overheat due to
ambient conditions.
2. Heater cable
connected to the
incorrect section.
1. Let the hose cool (and/or purge fluid
through the hose).
2. Examine the hose power connections.
204 PreHeat OverTemp B.
1. Preheater B too hot.
2. Temperature sensor
failure.
1. Let the preheater cool (and/or purge fluid
through preheater).
2. Examine the temperature sensor connector.
205 Filter Clog B.
1. Filter clogged.
2. Pressure drop error
settting too low.
3. Pressure sensor
failure.
1. Clean or replace the filter element.
2. Increase the maximum permitted pressure
drop in the Recipes screen.
3. Examine the inlet and outlet pressure
sensor connectors.
206 Insufficient Preheater
Pressure B.
1. B drum pump off.
2. B drum pump
pressure too low.
3. B supply line, pre-
filter, and/or post-filter
valve closed.
4. Insufficient B
material Level.
5. Cold B material.
6. Minimum pressure
setting too low.
7. B inlet pressure
sensor failure.
8. Pressure sensor
failure.
9. B pre-filter or inlet
valve logged.
10. B flow meter stuck.
1. Verify that the B drum pump is providing
100 -300 psi at the proportioner.
2. Verify the B inlet and filter valves are
open.
3. Examine the B drum material level.
4. Warm the B material to the manufacturer's
recommendations.
5. Lower the minimum pressure error setting
in the Settings screen.
6. Examine the B pressure sensor
connectors.
7. Clean or replace the B inlet filter.
8. Remove the B filter inlet valve and
examine it for debris.
9. Remove the B flow meter and examine it
for solids of debris.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
207 Insufficient Filter
Pressure B.
1. B drum pump off.
2. B drum pump
pressure too low.
3. B supply line or pre-
filter valve closed.
4. Insufficient B
material Level.
5. Cold B material.
6. Minimum pressure
setting too low.
7. Pressure sensor
failure.
8. B pre-filter or inlet
valve logged.
1. Verify that the B drum pump is providing
100-300 psi at the proportioner.
2. Verify the B inlet and filter valves are
open.
3. Examine the B drum material level..
4. Warm the B material to the manufacturer's
recommendations.
5. Lower the minimum pressure error setting
in the Settings screen.
6. Examine the B pressure sensor
connectors.
7. Clean or replace the B inlet filter.
8. Remove the B filter inlet valve and
examine it for debris.
208 Excessive Drum Pump
Pressure B.
1. B drum pump
pressure too high.
2. Pressure sensor
failure.
3. B high-pressure
check valve leak.
1. Examine that the B pump is pressurized
to provide 100-300 psi at the system.
2. Examine the 'B inlet pressure sensor
connector.
3. Verify or replace the B side high-pressure
check valve.
209 Excessive System
Pressure B SMOSE.
1. B drum pump
pressure too high.
2. Pressure sensor
failure.
3. B check valve leak.
1. Verify that the B drum pump is providing
100 -300 psi at the proportioner.
2. Increase the maximum inlet pressure
setting in the Settings screen.
3. Examine the B inlet pressure sensor
connector.
4. Verify or replace the B side high-pressure
check valve.
5. Examine that the B side recirculation
valve is in the hose (gun) position.
6. Verify the hose calibration (see Hose
Calibration in the System Screen).
210 B Flow Meter Error. Flow meter failure. Examine the B flow meter and the connector.
211 B PreHeat RTD Body
Top Error. Sensor failure. Examine the RTD sensor and connector.
212 B PreHeat RTD Body
Bottom Error. Sensor failure. Examine the RTD sensor and connector.
213 B PreHeat RTD In
Error. Sensor failure. Examine the RTD sensor and connector.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
214 B PreHeat RTD Out
Error. Sensor failure. Examine the RTD sensor and connector.
215 B Pre-Filter Pressure
Sensor Error.
1. Excessive Pressure.
2. Pressure below zero.
3. Sensor failure.
1. Examine the check valve and replace if not
holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
216 B Post-Filter Pressure
Sensor Error.
1. Excessive Pressure.
2. Pressure below zero
3. Sensor failure.
1. Examine the check valve and replace if not
holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
217 B Pre-Gear Pump
Pressure Sensor Error.
1. Excessive Pressure.
2. Pressure below zero.
3. Sensor failure.
1. Examine the check valve and replace if not
holding pressure.
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
218 B Post-Gear Pump
Pressure Sensor Error. Sensor failure.
1. Verify pressure reading matches the analog
pressure gauge
2. Examine for cavitation.
3. Examine the connector.
4. Replace the sensor.
219 Hose UnderTemp B
Middle 1 Modem.
1. Heater cable
disconnected or
connected to the
incorrect section.
2. Hose heater wire
failure.
Examine the hose power connections.
220 Hose OverTemp B
Middle 1 Modem.
1. Hose overheat due to
ambient conditions.
2. Heater cable
connected to the
incorrect section.
1. Let the system cool and/or purge the
material.
2. Examine the heater cable connections.
300 SMOSE MM - Yamar
chip failed to initialize. Hardware failure. Cycle the power.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
301 SMOSE MM - No PLC
packets received.
1. Frequency setting not
optimal.
2. Interference from
other nearby systems.
3. Modems not paired
correctly.
4. Incorrect hose
configuration setting.
5. Hardware failure.
1. Reposition the hose (uncoil fully).
2. Examine the hose configuration (see the
Hose Configuration screen).
3. Pair, scan, and set the hose frequencies
(see the Hose Configuration screen).
302
SMOSE MM - Timeout
waiting for Tx complete
Interrupt.
Hardware failure. Cycle the power.
303
SMOSE MM - Multiple
master modems
detected on RF link.
1. Multiple systems
in close proximity
operating on the same
frequency.
2. Modems not paired
correctly.
1. Move one system to a different frequency
(see the Hose Configuration screen).
2. Pair the modems (see the Hose
Configuration screen).
304
SMOSE MM -
Arbitration lost (bus may
be shorted to GND or
VDD.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
305
SMOSE MM - No ACK
from device (Verify i2C
address for device is set
correctly).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
306 SMOSE MM - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
307
SMOSE MM - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
308
SMOSE MM - No
pressure data from
sensor (i2C read
failure).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
309 SMOSE MM - Hose A
pressure out of range.
Pressure sensor out of
calibration.
Calibrate the sensor (see the Hose
Configuration screen).
310 SMOSE MM - Hose B
pressure out of range.
Pressure sensor out of
calibration.
Calibrate the sensor (see the Hose
Configuration screen).
311
SMOSE MM - No
Temperature data
from sensor (i2C read
failure).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
312
SMOSE MM - Hose
A temperature out of
range.
Hardware failure. Cycle the power.
313
SMOSE MM - Hose
B temperature out of
range
Hardware failure. Cycle the power.
314 SMOSE MM - Event
Memory Pool is empty. Firmware error. Cycle the power. Contact technical service and
enable limp mode.
315
SMOSE MM - Flash
Parameter Storage
system error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
316 SMOSE MM - Error
during DMA transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
317
SMOSE MM - EtherCAT
chip failed to initialize
End and Mid Modems:
Not Applicable.
Hardware failure. Cycle the power.
318
SMOSE MM - EtherCAT
no Network link End
and Mid Modems Not
Applicable.
1. No network
connection between
HMI and Main
modem.
2. Hardware Failure.
1. Examine the network connection to the
main modem.
2. Cycle the power.
319
SMOSE MM - Other
uncategorized error
condition.
Hardware failure. Cycle the power.
320
SMOSE MM -
Arbitration lost (bus may
be shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
321
SMOSE MM - No ACK
from device (Verify i2C
address for device is set
correctly).
1. Bad connection
between modem A
and B sides.
2. Hardware failure.
1. Verify that the connection contacts are
clean and secure between the A and B
sides of the modem.
2. Cycle the power.
322 SMOSE MM - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
323
SMOSE MM - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
324
SMOSE MM -
Arbitration lost (bus may
be shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
325
SMOSE MM - No ACK
from device (Verify i2C
address is correct).
1. Bad connection
between modem A
and B sides.
2. Hardware failure.
Verify that the connection contacts are clean
and secure between the A and B sides of
the modem.
326 SMOSE MM - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power
327
SMOSE MM - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
400 SMOSE M1 - Yamar
chip failed to initialize. Hardware failure. Cycle the power.
401 SMOSE M1 - No PLC
packets received.
1. Frequency setting not
optimal.
2. Interference from
other nearby systems.
3. Modems not paired
correctly.
4. Incorrect hose
configuration setting.
5. Hardware failure.
1. Reposition the hose (uncoil fully).
2. Examine the hose configuration (see the
Hose Configuration screen).
3. Pair, scan, and set the hose frequencies
(see the Hose Configuration screen).
402
SMOSE M1 - Timeout
waiting for Tx complete
Interrupt.
Hardware failure. Cycle the power.
403
SMOSE M1 - Multiple
master modems
detected on RF link.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
404
SMOSE M1 - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
405
SMOSE M1 - No ACK
from device (Verify i2C
address for device is set
correctly).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
406 SMOSE M1 - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
407
SMOSE M1 - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
408
SMOSE M1 - No
pressure data from
sensor.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
409 SMOSE M1 - Hose A
pressure out of range.
Pressure sensor out of
calibration. Calibrate the sensor.
410 SMOSE M1 - Hose B
pressure out of range.
Pressure sensor out of
calibration. Calibrate the sensor.
411
SMOSE M1 - No
Temperature data from
sensor.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
412
SMOSE M1 - Hose
A temperature out of
range.
Hardware failure. Cycle the power.
413
SMOSE M1 - Hose
B temperature out of
range.
Hardware failure. Cycle the power.
414 SMOSE M1 - Event
Memory Pool is empty. Firmware issue. Cycle the power.
415
SMOSE M1 - Flash
Parameter Storage
system error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
416 SMOSE M1 - Error
during DMA transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
417
SMOSE M1 - EtherCAT
chip failed to initialize.
End and Mid Modems:
Not Applicable.
Hardware failure. Cycle the power.
418
SMOSE M1 - EtherCAT
no Network link. End
and Mid Modems Not
Applicable.
1. No network
connection between
HMI and Main
modem.
2. Hardware Failure.
1. Examine the network connection to the
main modem.
2. Cycle the power.
419
SMOSE M1 - Other
uncategorized error
condition.
Hardware failure. Cycle the power.
420
SMOSE M1 - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides
1. Examine the modem connection cable.
2. Cycle the power.
421 SMOSE M1 - No ACK
from device.
Bad connection between
modem A and B sides
1. Examine the modem connection cable.
2. Cycle the power.
422 SMOSE M1 - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
423
SMOSE M1 - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
424
SMOSE M1 - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
425 SMOSE M1 - No ACK
from device.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
426 SMOSE M1 - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
427
SMOSE M1 - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
600 SMOSE ME - Yamar
chip failed to initialize. Hardware failure. Cycle the power.
601 SMOSE ME - No PLC
packets received.
1. Frequency setting not
optimal.
2. Interference from
other nearby systems.
3. Modems not paired
correctly.
4. Incorrect hose
configuration setting.
5. Hardware failure.
1. Reposition the hose (uncoil fully).
2. Examine the hose configuration (see the
Hose Configuration screen).
3. Pair, scan, and set the hose frequencies
(see the Hose Configuration screen).
602
SMOSE ME - Timeout
waiting for Tx complete
Interrupt.
Hardware failure. Cycle the power.
603
SMOSE ME - Multiple
master modems
detected on RF link.
1. Multiple systems
in close proximity
operating on the same
frequency.
2. Modems not paired
correctly.
1. Move one system to a different frequency.
2. Pair the modems.
604
SMOSE ME - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Move one system to a different frequency.
2. Pair the modems.
605
SMOSE ME - No ACK
from device (Verify i2C
address for device is set
correctly).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN 17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
606 SMOSE ME - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
607
SMOSE ME - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
608
SMOSE ME - No
pressure data from
sensor (i2C read
failure).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
609 SMOSE ME - Hose A
pressure out of range.
Pressure sensor out of
calibration. Calibrate the sensor.
610 SMOSE ME - Hose B
pressure out of range.
Pressure sensor out of
calibration. Calibrate the sensor
611
SMOSE ME - No
Temperature data
from sensor (i2C read
failure).
1. Bad connection
between modem A
and B sides.
2. Hardware failure.
Verify that the connection contacts are clean
and secure between the A and B sides of
the modem.
612
SMOSE ME - Hose
A temperature out of
range.
Hardware Failure. Cycle the power.
613
SMOSE ME - Hose
B temperature out of
range.
Hardware Failure. Cycle the power.
614 SMOSE ME - Event
Memory Pool is empty. Firmware Failure. Cycle the power.
615
SMOSE ME - Flash
Parameter Storage
system error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
616 SMOSE ME - Error
during DMA transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
617
SMOSE ME - EtherCAT
chip failed to initialize
End and Mid Modems:
Not Applicable.
Hardware failure. Cycle the power.
618
SMOSE ME - EtherCAT
no Network link End
and Mid Modems Not
Applicable.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
619
SMOSE ME - Other
uncategorized error
condition.
Hardware failure. Cycle the power.
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EN EN17 TROUBLESHOOTING
17.1 SYSTEM ERRORS
Error
No. Alarm Description Condition Action
620
SMOSE ME - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
621
SMOSE ME - No ACK
from device (Verify i2C
address for device is set
correctly.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
622 SMOSE ME - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
623
SMOSE ME - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
624
SMOSE ME - Arbitration
lost (bus may be
shorted to GND or
VDD).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
625
SMOSE ME - No ACK
from device (Verify i2C
address is correct).
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
626 SMOSE ME - Timeout
during i2C data transfer.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
627
SMOSE ME - Other
errors: OverUnderRun,
DMA Error or Bus Error.
Bad connection between
modem A and B sides.
1. Examine the modem connection cable.
2. Cycle the power.
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EN EN 18 MAINTENANCE
18 MAINTENANCE
18.1 REGULAR MAINTENANCE
PROCEDURES AND RECOMMENDATIONS
Material Purge
After a job is completed, remember to thoroughly purge
the system. Failure to do so can cause clogs, leaks, or
cross-contamination of materials when the system is
disassembled for servicing.
Regular Inspection
Continuous use or lack of use of the system can cause
a system malfunction. Do regular interval system
inspections as shown at the table below.
MAINTENANCE INTERVALS
Frequency Description Inspection Method
DAILY SYSTEM FLUSHED WITH SOLVENT VISUAL
DAILY CHECK FOR LEAKS VISUAL
DAILY CLEAN SPRAY GUNS VISUAL
DAILY CHECK ALARM HISTORY VISUAL
DAILY CHECK FOR MATERIAL SUPPLY VISUAL
MONTHLY CHECK FILTER BODY AND MESH SCREEN FOR CLOGS VISUAL
MONTHLY CHECK ALL HOSES FOR KINKS AND WEAR VISUAL
MONTHLY PERFORM LOW PRESSURE MODULE CALIBRATION
CHECK
COMPARE THE ANALOG
PRESSURE INDICATOR WITH
THE HMI PRESSURE INDICATION
MONTHLY PERFORM HIGH PRESSURE MODULE CALIBRATION
CHECK
COMPARE THE ANALOG
PRESSURE INDICATOR WITH
THE HMI PRESSURE INDICATION
MONTHLY PERFORM PUMP MODULE CALIBRATION CHECK
COMPARE THE ANALOG
PRESSURE INDICATOR WITH
THE HMI PRESSURE INDICATION
MONTHLY PERFORM PUMP I/O MODULE CALIBRATION CHECK
COMPARE THE ANALOG
PRESSURE INDICATOR WITH
THE HMI PRESSURE INDICATION
MONTHLY CHECK FLUID MODULE OPERATION TRIGGER MANUALLY OR FROM
HMI
MONTHLY CHECK RECIRCULATION VALVE OPERATION CHECK MANUALLY
MONTHLY CLEAN FLUID MODULES AND CHECK VALVES & SEALS DISASSEMBLE
MONTHLY CHECK A/B FLUID HOSES FOR MATERIAL BUILDUP DISASSEMBLE
AS NEEDED REBUILD FLUID MODULES DISASSEMBLE
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EN EN18 MAINTENANCE
18.2 FLUID MODULE
10
6
8
14
11
4
2
1
3
15
13
7
16
5
17
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EN EN 18 MAINTENANCE
18.2 FLUID MODULE ITEMS
Item P/N Description Qty
(Per Module)
1
341000 A SIDE FLUID MODULE
1
341001 B SIDE FLUID MODULE
2
341005 KIT, A FLUID MOD COVER
1
341019 KIT, B FLUID MOD COVER
3 - SCREW, BHCS, M6 x 1.0 x 12 LG, SS 2
4 341007 ASSEMBLY, HEATER, MODULAR, POPULATED 1
5 -
ASSEMBLY, MOTOR & PUMP MOUNT, SIDE A
1
ASSEMBLY, MOTOR & PUMP MOUNT, SIDE B
6 - WELDMENT, BRACKET, MANIFOLD, HP 1
7 - SCREW SHCS M6 x 1.0 x 10 LG SS 5
8
347705 A SIDE HIGH PRESSURE MODULE
1
347697 B SIDE HIGH PRESSURE MODULE
9 - SOCKET HEAD CAP SCREW, M6 x 1.0 x 30 LG, SST 2
10 341048 ASSEMBLY, ELECTRIC ENCLOSURE 1
11 -
A SIDE PUMP MODULE FRAME (INCLUDES 15)
1
B SIDE PUMP MODULE FRAME (INCLUDES 15)
12 - SOCKET HEAD CAP SCREW, M6 x 1.0 x 8 LG, FLANGE, BO 2
13 - SOCKET HEAD CAP SCREW. M8 x 12 LG, FLANGE. BO 2
14 - SCREW, HEX M6 x 1.0 x 14 LG 8
15 - CAPTIVE SCREW. M10 x 1.5 x 40 mm, SST 2
16
347593 HANDLE KIT, RED RECIRCULATION A VALVE
1
347664 HANDLE KIT, BLUE RECIRCULATION B VALVE
17 - SKIN, PUMP MODULE, SHORT 1
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EN EN18 MAINTENANCE
18.3 LOW-PRESSURE MODULE
Note: Installation kit PN 341133 includes 90° sweeps
(x2), ball valves (x2), and JIC to NPT fittings for
recirculation line fittings on high pressure manifolds.
32
26
1
14
3
5
2
13
17
18
33 19
20 5
16
24 25
34
1621
20
22
27
13
28
30
29
27
12
11
10
6
4
31
15
9
8
34
7
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EN EN 18 MAINTENANCE
18.3 LOW PRESSURE MODULE
Item P/N Description Qty
(Per Module)
1 341007 ASSEMBLY, HEATER MODULE POPULATED 1
2 - SCREW, M6 x 55MM, SCHS, SS 5
3 341016 VALVE, CARTRIDGE, POPPET, 2-WAY 2
4 340981 O-RING, X-PROFILE 2
5 341031 O-RING, CARTRIDGE VALVE SEAL O-RING 2
6 341133 INSTALLATION KIT (INCLUDES, 7, 9 x1, 10, and 11 x2) 1
7 341050 FILTER, CAP (INCLUDES 9) 1
8 341051 ASSEMBLY, INLET FILTER 1
9 340992 O-RING, FILTER CAP (2 PACK) 6
10 341045 FILTER, BODY 1
11
341027 SCREEN, FILTER, 40 MESH (10 PACK)
2
341028 SCREEN, FILTER, 40 MESH (50 PACK)
12
340991 O-RING, FILTER BODY (2 PACK)
1
341029 O-RING, FILTER BODY (10 PACK)
13 347507 O-RING, PRESSURE SENSOR (4 PACK) 4
14 341057 KIT, SENSOR, PRESSURE, 500 PSI (INCLUDES 13) 3
15 341047 KIT, MANIFOLD FILTER (INCLUDES 4 AND 34) 1
16 347504 ASSEMBLY, INLET FITTING 1
17 - SCREW, SCHS, M8 x 70 MM, SS 4
18 341078 FLOW METER, (INCLUDES 33 QTY 2, AND CABLE) 1
19 347477 SENSOR, TEMPERATURE, VITON EXT, SHORT 1
20 347506 SEAL KIT, TEMP SENSOR (2 PACK) 2
21 341102 MANIFOLD, FLOWMETER 1
22 341099 KIT SENSOR, TEMP, LONG (INCLUDES 20 QTY 1) 1
23 341103 SEAL, PUMP UNION NIPPLE 4
24 347574 NUT, UNION 2
25 341002 UNION BSPP, END FACE, FLAT 2
26 341048 ASSEMBLY, FLUID MODULE I/O 1
27 - SCREW, SHCS, M6 x 12,THREADLOK 6
28 - CONNECTOR, POWER, HARTING, MALE 1
29 - M4 x 0.7 MM - 12 MM, SHCS 4
30 - 18-8 SOCKET SCREW 30MM LONG 6
31 347569 THERMAL FUSE 1
32 341006 ASSEMBLY, HEATER MODULE 1
33 341095 O-RING, FLOW METER (2 PACK) 2
34 341096 O-RING, FILTER AND FLUID MODULE MANIFOLDS (4 PACK) 4
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EN EN18 MAINTENANCE
18.4 PUMP MODULE
1
14
15
12
13
16
9
8
17
74
5
6
2
6
5
7
10
4
11
3
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EN EN 18 MAINTENANCE
18.4 PUMP MODULE
Item P/N Description Qty
(Per Module)
1 -
ASSEMBLY, PUMP AND MOTOR A SIDE
1
ASSEMBLY, PUMP AND MOTOR B SIDE
2 347666 KIT, PUMP ASSEMBLY (INCLUDES 3, 4 x2, 5 x2, 6 x2, 7 x2, 8, 9 x6, AND 10) 1
3 347545 GEAR, DOSING PUMP, 7.3 PTFE KIN 1
4 347572 O-RING, PUMP UNIONS (2PK) 2
5 341196 UNION END, SLOTTED FACE 2
6 341103 SEAL, PUMP UNION NIPPLE 2
7 347571 PLUG, TSL CHAMBER, LOWER OR UPPER 2
8 - PLATE, PUMP MOUNT 1
9 - M6 x 1.0 x 16 mm THRD LOCK SHCSB 6
10 341040 KIT COUPLING MOTOR PUMP (INCL 11, 12, 13) 1
11 - SHAFT COUPLER, PUMP 1
12 - SHAFT COUPLER, SPIDER 1
13 - SHAFT COUPLER, MOTOR 1
14
341034 KIT, MOTOR, A SIDE (INCLUDES 15)
1
341035 KIT, MOTOR, B SIDE (INCLUDES 15)
15 - SOCKET HEAD CAP SCREW, M10 x 1.5 x 35 LG, FLANGE, BO 4
16 - ASSEMBLY, MACHINED MOTOR & PUMP MOUNT 1
17 - SOCKET HEAD CAP SCREW, M8 x 12 LG, FLANGE, BO 4
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EN EN18 MAINTENANCE
18.5 HIGH-PRESSURE MODULE
1
22
6
7
18
19
20
2
3
4
5
13
21
13
14
10
9
24
23
17
15
11
12
8
13
16
26
27
25
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EN EN 18 MAINTENANCE
18.5 HIGH PRESSURE MODULE
Item P/N Description Qty
(Per Module)
1 347705
347697
A SIDE HIGH PRESSURE MANIFOLD ASSEMBLY
B SIDE HIGH PRESSURE MANIFOLD ASSEMBLY 1
2 347593
347664
HANDLE KIT, RED RECIRCULATION A VALVE (INCLUDES 3, 4, 5, 22)
HANDLE KIT, BLUE RECIRCULATION B VALVE (INCLUDES 3, 4, 5, 22) 1
3 347592 NUT, RECIRCULATION VALVE 1
4 - HANDLE, RED RECIRC VALVE (A SIDE)
HANDLE, BLUE RECIRC VALVE (B SIDE) 1
5 347590 SPRING, RECIRCULATION VALVE 1
6 347581 GAUGE, PRESSURE 0-3000 PSI 1
7 347582 BUSHING 1
8 - MANIFOLD, HIGH PRESSURE 1
9 347507 O-RING, PRESSURE SENSOR (4 PACK) 4
10 341058 KIT, HP SENSOR, 0-5000 PSI (INCLUDES 9 QTY 1) 1
11 347587 SPACER, CHECK VALVE NOSE (1 PACK) 1
12 347586 O-RING, CHECK VALVE NOSE (1 PACK) 1
13 347505 O-RING, INLET FITTING, FILTER MODULE, FLOWMETER, PREHEATER,
BURST DISK, CHECK VALVE, RECIRCULATION VALVE (8 PACK) 1
14 347584 BURST DISK (INCLUDES 13 QTY 1) 1
15 - WELDMENT BRACKET, MANIFOLD, PUMP OUTLET 1
16 347457 KIT, CHECK VALVE (INCLUDES 11, 12, 13) 1
17 - SCREW, HEX M6 x 1.0 x 14 LG 8
18 347589
347663
JIC 5 MALE TO 3/8 NPT MALE, A SIDE (INCLUDES 19 QTY 1)
JIC 6 MALE TO 3/8 NPT MALE, B SIDE (INCLUDES 19 QTY 1) 2
19 347588 O-RING, HOSE AND RECIRCULATION JIC S & JIC 6 (2 PACK) 2
20 - JIC 5 MALE TO 3/8 NPT MALE, A SIDE
JIC 6 MALE TO 3/8 NPT MALE, B SIDE 2
21 347580 VALVE, RECIRCULATION (INCLUDES 13 QTY 1, 29) 1
22 - CAP, RECIRCULATION HANDLE 1
23 341002 UNION END, FLAT 1
24 341103 SEAL, PUMP UNION NIPPLE 1
25 341111 KIT, HP MANIFOLD PLUG (INCLUDES 26, 27) 1
26 341110 O-RING, HIGH PRESSURE PLUG (2 PACK) 1
27 341109 PLUG, HP MANIFOLD 1
28 341038
341039
KIT, VALVE RECIRCULATION ASSEMBLY, RED (INCLUDES 2, 3, 4, 21, AND
29)
KIT, VALVE RECIRCULATION ASSEMBLY, BLUE (INCLUDES 2, 3, 4, 21, AND
29)
1
29 341041 KIT, RECIRCULATION VALVE, O-RING 1
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EN EN18 MAINTENANCE
18.6 PUMP I/O MODULE
1
4
15
3
2
14
18
19
20
16
17
11
6
5
8
7
10
9
12
13
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EN EN 18 MAINTENANCE
18.6 PUMP I/O MODULE
Item P/N Description Qty
(Per Module)
1 341048 ASSEMBLY, FLUID MODULE I/O 1
2 - M4 x 0.7MM - 12MM, SHCS 4
3 - CONNECTOR, POWER, HARTING, MALE 1
4 - WELDMENT, PANEL PUMP MODULE 1
5 - SEALCON GLAND, PG7, GREY 2
6 - SEALCON PG7 NUT, GREY 2
7 - SEALCON GLAND, PG11, GREY 1
8 - SEALCON PG11 NUT, GREY 1
9 - SEALCON GLAND, PG16, 4 x 4 2
10 - SEALCON PG16 NUT, GREY 2
11 341024 24V ENCODER 1
12 341023 4 CHANNEL RTD INPUT 1
13 341022 ETHERCAT 4 CHANNEL ANALOG INPUT 1
14 - DIN RAIL 1
15 - TERMINAL BLOCK ASSEMBLY 1
16 - SCREW, SHCS, M3 x 0.5 x 16 BA 6
17 341082 CABLE M8-M8 0.2M CAT 2
18 341084 CABLE M12-M8 0.4M ECAT 1
19 341091 CABLE M8-FL 0.5M POWER 1
20 - CABLE M8-M8 STRAIGHT 0.2M 2
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EN EN18 MAINTENANCE
18.7 FLUID MODULE O-RINGS AND SEALS
2
43
5
6
1
18
8
7
17
2
9
9
1
12
3
13
15
14
3
10
9
9
10
11
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EN EN 18 MAINTENANCE
18.7 FLUID MODULE O-RINGS AND SEALS
Item P/N Description Qty (Per Module)
1 347507 O-RING, PRESSURE SENSOR (4 PACK) 4
2 341096 O-RING, FILTER AND FLOW METER MANIFOLDS (4 PACK) 4
3 347505 O-RING, VARIOUS LOCATIONS (8 PACK) 6
4 340991
341029
O-RING, FILTER BODY (2 PACK)
O-RING, FILTER BODY (10 PACK ) 1
5 340981 O-RING X PROF 2MM x 21MM BUNA-N 2
6 341031 KIT SEAL CART VALVE (2 PACK) 2
7 341095 O-RING, FLOW METER (2 PACK) 2
8 347506 SEAL, TEMPERATURE SENSOR (2 PACK) 2
9 341103 SEAL, PUMP UNION NIPPLE 4
10 347572 O-RING, PUMP UNION (2 PACK) 2
11 341041 KIT VALVE RECIRCULATION O-RING 1
12 347588 O-RING, HOSE AND RECIRCULATION JIC 5 & JIC 6 (2 PACK) 2
13 347586 O-RING CHECK VALVE NOSE (1 PACK) 1
14 347587 SPACER, CHECK VALVE NOSE (1 PACK) 1
15 341110 O-RING, PLUG 1
16 341093 O-RING, INLET FITTING 1
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EN EN18 MAINTENANCE
18.8 IS40 CONTROL MODULE ENCLOSURE
1
26
27
28
29
30
23
2
17
19
13
34
32
11
12
35
36
33
10
9
6
3
21
24
25
22
31
7
8
18
16
15
12
11
14
20
37
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EN EN 18 MAINTENANCE
18.8 IS40 CONTROL MODULE-ENCLOSURE
Item P/N Description Qty (Per Module)
1 - CONTROL MODULE COVER ASSEMBLY 1
2 341025 15IN HMI WITH CODESYS 1
3 - IS40 DOOR - WELDMENT ASSY 1
6 - M5 x 0.8 x 14MM BHCS 316 SS 14
7 - M5, 18-8 SS WASHER 14
8 - M6X0.8 18-8 SS NYLON LOCK NUT 14
9 - BUTTON HEAD CAP SCREWS, SST 10
10 - IS40 ENCLOSURE - FILTER BRACKET 1
11 341026 FILTER CUSTOM 4 x 6 7/8 x 1/2 1
12 347598 E-STOP KIT (INCL. CONTACTORS) 1
13 - LOW DENSITY PVC BLK 1/4 x 3/4 x 50FT 105.4 IN
14 - M5 EXTERNAL TOOTH LOCK WASHER 1
15 - POWER CORD GLAND 1
16 - SUPER GRIP CABLE TIE MOUNT 0.91 NYLON 6.6 1
17 - CELLULAR MODEM 1
18 - BALL STUD MOUNTING BRACKET FOR GAS SPRING 1
19 - M5 x 0.8 x 10MM BHCS 11
20 - GAS SPRING, #15 1
21 - IS40 ENCLOSURE - THERMO COVER 1
22 - COVER LOCK ASSEMBLY 2
23 - EMI CAGE 1
24 - CONTROL MODULE FRAME 1
25 347609 DOOR HINGE ASSY 2
26 347615 CONTROL MODULE FAN ASSY 1
27 347613 CELLULAR ANTENNA 1
28 347612 POWER CORD GLAND 1
29 347611 USB KIT 1
30 341059
347702
KIT ROTARY AC DISCONNECT (200V PROPORTIONER)
DISCONNECT KIT, 3PH+N, 600V, 100A (400V PROPORTIONER) 1
31 - IS40 SMOSE COVER 1
32 - SCREW, SMOSE COVER 2
33 - IS40 SMOSE CLAMP (INCLUDES BRACKET) 1
34 - IS40 SMOSE CLAMP TOP PLATE 2
35 - M10 FLANGE HEAD CAP SCREW 2
36 - SMOSE CLAMP BLOCK 4
37 341015 50AMP SSR WITH THERMOPAD 3
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EN EN18 MAINTENANCE
18.9 IS40 CONTROL MODULE CONTROL
PANEL 200V-240V
23
3020212191816
15
14
17
1133
4
5
6
29
7
8
9
10
11
12
35
34
24
2
28 33 25 26
37
27
31
32
22
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EN EN 18 MAINTENANCE
18.9 IS40 CONTROL MODULE 200V-240V CONTROL PANEL
Item P/N Description Qty
(Per Module)
1 - BACKPANEL - ELECTRICAL MAIN 1
2 - AB TERMINAL END ANCHOR 8
3 347600 TERMINAL BLOCK GROUND AND BARRIER 1
4 - A/B TERMINAL END BLOCK 2
5 - PUSH IN TERMINAL BLOCK, 5 POLE 4
6 - A/B DIST BLOCK, 5PL, RED 2
7 - BUS END CAP 1
8 341018 ECAT JUNCTION 2CH 1
9 341021 ECAT DIGITAL OUTPUT 16CH 1
10 341020 ECAT DIGITAL INPUT 8CH 1
11 341017 ECAT COUPLER 1
12 340993 TERMINAL BLOCK RELAY 1
13 340979 THERMOSTAT 1
14 341081 CIRCUIT BREAKER WITH TERMINAL BLOCK 5AMP 2
15 341079 CIRCUIT BREAKER WITH TERMINAL BLOCK 1AMP 2
16 341080 CIRCUIT BREAKER WITH TERMINAL BLOCK 3AMP 2
17 - ETA 10PLUS TB BUSBAR 12P 5
18 347623 24V POWER SUPPLY 1
19 340982 CIRCUIT BREAKER 6A/2P C TRIP 1
20 340980 CONTACTOR, 24V COIL, 43AMP 2
21 - CONTACT FRONT MOUNT 1
22 - POWER DISTRIBUTION BLOCK 1 IN 4 OUT 3
23 340983 2PH CB 50AMP C CURVE 2
24 347631 HOSE HEAT GFCI 15A 4
25 341055 KIT 18A DRIVE WITH FIRMWARE 1
26 341056 KIT 54A DRIVE WITH FIRMWARE 1
27 - GROUND LUG 1/0-8AWG 1
28 - GROUND BAR 1
29 347714 CIRCUIT BREAKER ELECTRONIC 1P 1
30 - M4 SPLIT WASHER, 18-8 SS 4
31 - M8 EXTERNAL TOOTH LOCKWASHER 1
32 - M8 x 1.25 x 15MM HEX HEAD BOLT 1
33 - SHCS, M5 x 20, 18-8 2
34 347678 HOSE COMM RESET REPLACEMENT KIT 1
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EN EN18 MAINTENANCE
18.9 IS40 CONTROL MODULE CONTROL
PANEL 200V-240V
23
3020212191816
15
14
17
1133
4
5
6
29
7
8
9
10
11
12
35
34
35
24
2
28 33 25 26
37
27
31
32
22
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EN EN 18 MAINTENANCE
18.9 IS40 CONTROL MODULE 200V-240V CONTROL PANEL
Item P/N Description Qty
(Per Module)
35 347645 HOSE RESET RELAY 1
36 347688 FERRITE 260 OHM 2
37 - IS40 CE CAGE - ASSEMBLY 1
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EN EN18 MAINTENANCE
18.10 IS40 CONTROL MODULE CONTROL
PANEL 380V-415V
28
253233242322
21
20
19
1347
6
8
9
10
11
12
13
14
15
17
18
29
31
36 42 37 38
47
35
43
44
34
30
16
2 26 27
39
40
41
5
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EN EN 18 MAINTENANCE
18.10 IS40 CONTROL MODULE 380V-415V CONTROL PANEL
Item P/N Description Qty
(Per Module)
1 - BACKPANEL - ELECTRICAL MAIN 1
2 - TERMINAL END BLOCK 8
3 340979 THERMOSTAT NO 77-95 DEG F 1
4 - TERMINAL END BLOCK 2
5 - PUSH IN TERMINAL BLOCK, 5 POLE 4
6 - DISTRIBUTION BLOCK, 5PL, RED 2
7 - JUMPER, 4 PLACE, BLUE 1
8 - JUMPER 2 PLACE RED 1
9 347714 CIRCUIT BREAKER ELECTRONIC 1P 1
10 - BECKHOFF BUS END CAP 1
11 341018 2 PORT ETHERCAT JUNCTION 1
12 341021 16 CHANNEL OUTPUT MODULE 1
13 341020 8 CHANNEL INPUT MODULE 1
14 341017 ETHERCAT COUPLER 1
15 340993 RELAY DPDT 24VDC COIL 3
16 - TERMINAL BLOCK JUMPER, 8 POLE, BLUE .5
17 347645 HOSE RESET RELAY 1
18 347678 HOSE COMM RESET REPLACEMENT KIT 1
19 - ETA 10PLUS TB BUSBAR, 12P 2
20 341081 CIRCUIT BREAKER WITH TERMINAL BLOCK 5A 2
21 341079 CIRCUIT BREAKER WITH TERMINAL BLOCK 1AMP 2
22 341080 CIRCUIT BREAKER WITH TERMINAL BLOCK 3AMP 1
23 347623 24V POWER SUPPLY 1
24 347679 CIRCUIT BREAKER, 6A, 1 POLE 1
25 340987 CIRCUIT BREAKER 60A/3P C TRIP 1
26 347685 CIRCUIT BREAKER, 10A, 3 POLE 1
27 347706 CIRCUIT BREAKER, 20A, 3 POLE 1
28 347707 CIRCUIT BREAKER, 1 POLE, 50A 2
29 347683 GFCI 16A 1 POLE 4
30 347681 NEUTRAL DISTRIBUTION BLOCKS 5
31 347704 GROUND TERMINAL BLOCKS 2
32 340980 CONTACTOR, 24V COIL 43AMP 2
33 - CONTACT FRONT MOUNT 1
34 347703 DISTRIBUTION BLOCK, 1 POLE, 115A, 8 POSITION 3
35 - GROUND LUG 1/0-8AWG 1
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EN EN18 MAINTENANCE
18.10 IS40 CONTROL MODULE CONTROL
PANEL 380V-415V
28
253233242321
22
20
19
1347
6
8
9
10
11
12
13
14
15
17
18
29
31
36 42 37 38
47
35
43
44
34
30
16
2 26 27
39
40
41
5
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EN EN 18 MAINTENANCE
18.10 IS40 CONTROL MODULE 380V-415V CONTROL PANEL
Item P/N Description Qty
(Per Module)
36 - GROUND BAR 1
37 347687 SERVO DRIVE, 18AMP 400V 1
38 341056 KIT 54A DRIVE WITH FIRMWARE 1
39 347686 LINE FILTER, 30A, CHASSIS MOUNT 1
40 - M4 x .7 x 10 mm EW TRUSS PHIL SCREW 4
41 - M4 SPLIT WASHER, 18-8 SS 8
42 - SHCS, M5 x 20, 18-8 2
43 - M8 x 1.25 x 20MM HEX BOLT 1
44 - M8 EXTERNAL TOOTH LOCKWASHER 1
45 347688 FERRITE 260 OHM (Not Shown) 4
46 - SCREW SHC, M4 x 16, SST (Not Shown) 4
47 - IS40 CE CAGE - ASSEMBLY 1
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EN EN18 MAINTENANCE
IS40 CONTROL MODULE
Cable No. P/N Description Qty
CBL2007 347633 A-ISO ZONE 1 HOSE HEAT 1
CBL2010 347634 B-RES ZONE 1 HOSE HEAT 1
CBL2014 347635 A-ISO ZONE 2 HOSE HEAT 1
CBL2017 347636 B-RES ZONE 2 HOSE HEAT 1
CBL3017 347637 HOSE MASTER MODEM POWER 1
CBL4004 347638 HOSE MASTER MODEM COMMUNICATION 1
CBL4208 - BEACON LIGHT (INCLUDED IN 347483) 1
CBL4401 347640 A SIDE MASTER COMMUNICATION 1
CBL4404 347641 B SIDE MASTER COMMUNICATION 1
CBL5020 347642 HMI TO BUS COUPLER COMMUNICATION 1
CBL5505 347643 ANTENNA ExTENSION CABLE 1
CBL5514 347644 ROUTER TO HMI COMMUNICATION 1
CBL5517 - CELLULAR ROUTER (INCLUDED WITH ITEM 207) 1
CBL6007 347646 A SIDE MOTOR ENCODER 1
CBL6017 347647 A SIDE MOTOR POWER 1
CBL6027 347648 A SIDE DRIVE TO PUMP COMMUNICATION 1
CBL7007 347649 B SIDE MOTOR ENCODER 1
CBL7017 347650 B SIDE MOTOR POWER 1
CBL7027 347651 B SIDE DRIVE TO PUMP COMMUNICATION 1
CBL9003 341084 CABLE M12-M8 0.4M ECAT 2
CBL9010 - THERMO-OVERLOAD 2
CBL9506 347655 ENCODER BULKHEAD 2
CBL9609 - HEATER TEMP SENSOR (INCLUDED WITH ITEM 4) 2
CBL9614 347657 INLET FLUID TEMP 2
CBL9619 347658 PREHEATER OUT TEMP 2
CBL9704 347659 PRE-FILTER PRESSURE 2
CBL9709 347660 POST-FILTER PRESSURE 2
CBL9714 347661 PRE-GEAR PUMP PRESSURE 2
CBL9719 347662 POST GEAR PUMP PRESSURE 2
18.11 IS40 CABLES
REFER TO WIRING DIAGRAMS FOR CBL NUMBER
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EN EN 18 MAINTENANCE
18.12 IS40 ACCESSORIES AND KITS
P/N Description
310-8030 SCREEN PROTECTOR KIT, 15
342491 JUMPER HOSE, A SIDE
342492 JUMPER HOSE, B SIDE
347432 SUPPLY A/B JUMPER HOSE KIT
347674 INTELLISPRAY ETHERNET IP GATEWAY
347675 INTELLISPRAY PROFINET GATEWAY
347676 INTELLISPRAY MODBUS TCP GATEWAY
347677 INTELLISPRAY ETHERCAT GATEWAY
347682 VARIABLE RATIO SOFTWARE KEY
347708 PUMP REBUILD KIT
341133 KIT FLUID INSTALLATION
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EN EN18 MAINTENANCE
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EN EN 19 SCHEMATICS
WIRE GAUGE (UNLESS NOTED) USE MIN 75 DEGREE C COPPER WIRE
American Wire Gauge
(AWG)
Diameter
(Inches)
Cross Sectional Area
(mm2) Ampacity (75° C Copper)
3 0.2292 26.65 100
4 0.2043 21.14 85
6 0.162 13.29 65
8 0.1285 8.36 52
10 0.1019 5.26 30
12 0.0808 3.31 20
14 0.0641 2.08 15
16 0.0508 1.31 10
18 0.0403 0.82 7
20 0.0320 0.52 5
22 0.0253 0.33 3
FERRULES TO BE USED ON ALL WIRES (UNLESS NOTED)
Wire Reference Description
BLACK UNGROUNDED LINE VOLTAGE
WHITE UNGROUNDED DC VOLTAGE
WHITE/BLUE GROUNDED DC COMMON
GREEN/YELLOW GROUND
19 ELECTRICAL SCHEMATICS
19.1 ELECTRICAL DIAGRAMS 200V-240V
WIRE REFERENCE COLOR
BLK Black
WHT White
BLU Blue
RED Red
GRN Green
ORG Orange
BRN Brown
YLW Yellow
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EN EN19 SCHEMATICS
WIRE REFERENCE COLOR
RED_GRY RED WITH GREY STRIPE
GRY_RED GREY WITH WHITE STRIPE
WHT_BRN WHITE WITH BROWN STRIPE
BRN_WHT BROWN WITH WHITE STRIPE
WHT_GRY WHITE WITH GREY STRIPE
GRY_WHT GREY WITH WHITE STRIPE
RED_BLU RED WITH BLUE STRIPE
BLU/RED BLUE WITH RED STRIPE
RED/ORG RED WITH ORANGE STRIPE
ORG/RED ORANGE WITH RED STRIPE
RED/GRN RED WITH GREEN STRIPE
GRN_RED GREEN WITH RED STRIPE
BRN_RED BROWN WITH RED STRIPE
RED_BRN RED WITH BROWN STRIPE
WHT_GRN WHITE WITH GREEN STRIPE
GRN_WHT GREEN WITH WHITE STRIPE
WHT_BLU WHITE WITH BLUE STRIPE
BLU_WHT BLUE WITH WHITE STRIPE
WHT_ORG WHITE WITH ORANGE STRIPE
ORG_WHT ORANGE WITH WHITE STRIPE
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EN EN 19 SCHEMATICS
CROSS
WIRE CONNECTION
WIRE
LEGEND DESCRIPTIONS
NUMBERING CODE
XX???? = COMPONENT TYPE
??XX?? = SHEET
????XX = COLUMN
CORE IDENTIFIER
CABLE NUMBER
COLORCBL????
WIRE NUMBER
TERMINAL BLOCK
????
TB???
NORMALLY OPEN
PUSHBUTTON
PB????
NORMALLY CLOSED
PUSHBUTTON
PB????
FUSE WITH
RATING
??A
FU????
WITH RATING
FUSED DISCONNECT
DS????
??A
??A
WITH RATING
CIRCUIT BREAKER
CB????
RELAY COIL
CONTROL
CR????
CONTACT
NORMALLY OPEN
CONTROL RELAY
CR????
CONTACT
NORMALLY CLOSED
CONTROL RELAY
CR????
SOL????
SOLENOID
LIMIT SWITCH
NORMALLY CLOSED
LS????
PRESSURE SWITCH
NORMALLY OPEN
PS????OX
SELECTOR SWITCH
NORMALLY OPEN
SS????
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EN EN19 SCHEMATICS
N
O
TE
:
C
U
ST
O
M
ER
S
U
PP
LI
ED
4
00
VA
C
, 8
0A
M
P,
3
PH
, 6
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Z
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SE
7
5
D
EG
R
EE
C
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W
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N
LYDS1001 DISTRIBUTION BLOCKS
**
N
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TE
**
U
SE
S
PA
D
E
TE
R
M
IN
AL
S
O
N
A
LL
F
IL
TE
R
C
O
N
N
EC
TI
O
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S
01
6A
PO
W
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S
UP
PL
Y
24
VD
C
10
AM
P
CB
10
17
MA
IN
S
CO
NT
AC
TO
R
HE
AT
ER
CR
30
30
PU
MP
A
CB
10
01
10
A
PU
MP
B
CB
10
05
20
A
10
01
C
to
60
01
10
02
C
to
60
02
10
03
C
to
60
03
10
05
to
70
01
10
06
to
70
02
10
07
to
70
03
10
17
to
30
01
10
04
to
30
02
MA
IN
S
CO
NT
AC
TO
R
A/
B
PU
MP
CR
30
27
DI
SC
ON
NE
CT
MA
IN
DS
10
01
10
0A
HE
AT
ER
S
CB
10
09
TB
10
04
TB
10
04
FL
T1
00
1
LIN
E F
ILT
ER
30
A
60
A
10
09
A
to
20
01
10
09
A
to
20
10
10
10
A
to
20
04
10
10
A
to
20
14
10
11
A
to
20
07
10
11
A
to
20
17
10
04
to
20
05
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BL
K_
3A
W
G
BL
K_
3A
W
G
BL
K_
3A
W
G
BL
K_
6A
W
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
14
AW
G
BL
K_
14
AW
G
BL
K_
14
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
12
AW
G
BL
K_
8A
W
G
BL
K_
14
AW
G
BL
K_
14
AW
G
BL
U
_1
4A
W
G
BL
K_
6A
W
G
N
EU
TR
AL
BL
U
_6
AW
G
BL
K_
10
AW
G
BL
K_
10
AW
G
BL
K_
10
AW
G
BL
K_
10
AW
G
BL
K_
10
AW
G
BL
K_
10
AW
G
BL
K_
6A
W
G
BL
K_
6A
W
G
BL
K_
6A
W
G
BL
K_
6A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
10
17
10
09
A
10
01
10
02
10
03
10
05
10
06
10
07
10
09
10
04
10
01
A
10
02
A
10
03
A
10
11
10
10
A
10
11
A
10
10
10
01
B
10
02
B
10
03
B
10
01
C
10
02
C
10
03
C
10
04
10
01
10
01
10
01
10
02
10
03
10
09
A
10
10
A
10
11
A
10
04
10
01
B
10
02
B
10
03
B
10
02
10
03
N
ot
e
1:
D
o
no
t u
se
F
er
ru
le
s
fo
r w
ire
s
go
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g
in
to
D
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1
(S
ee
N
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e
1)
(S
ee
N
ot
e
1)
(S
ee
N
ot
e
1)
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EN EN 19 SCHEMATICS
01
T1
L150
AM
P
A
HO
SE
S1
SS
R4
21
7
16
A/
30
m
a R
CB
O
SE
CT
IO
N
1
A
HO
SE
CB
20
07
T1
L150
AM
P
B H
OS
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1
SS
R4
21
9
16
A/
30
m
a R
CB
O
SE
CT
IO
N
1
B H
OS
E
CB
20
10
T1
L150
AM
P
A
HO
SE
S2
SS
R4
22
0
16
A/
30
m
a R
CB
O
SE
CT
IO
N
2
A
HO
SE
CB
20
14
T1
L150
AM
P
B H
OS
E S
2
SS
R4
22
2
16
A/
30
m
a R
CB
O
SE
CT
IO
N
2
B H
OS
E
CB
20
17
50
A
PR
E-H
EA
T A
CB
20
01
50
A
PR
E-H
EA
T B
CB
20
04
T1
L150
AM
P
PR
E-H
EA
T B
SS
R4
21
6
20
01
A
to
61
18
20
04
A
to
71
18
1
CB
L2
00
7
2 GR
N
1
CB
L2
01
0
2 GR
N
1
CB
L2
01
4
2 GR
N
1
CB
L2
01
7
2 GR
N
GN
D2
00
9
GN
D2
01
2
GN
D2
01
6
GN
D2
01
9
T1
L150
AM
P
PR
E-H
EA
T A
SS
R4
21
4
GN
D2
00
9A
GN
D2
01
2A
GN
D2
01
6A
GN
D2
01
9A
10
04
to
71
19
10
04
to
61
19
10
09
A
fro
m
10
09
10
10
A
fro
m
10
11
10
04
fro
m
10
15
10
09
A
fro
m
10
10
10
10
A
fro
m
10
12
10
11
A
fro
m
10
14
10
11
A
fro
m
10
13
TB
10
04
TB
10
04
TB
10
04
TB
10
04
TB
10
04
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
14
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G
BL
K_
14
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BL
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14
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BL
K_
8A
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G
BL
K_
8A
W
G
BL
K_
8A
W
G
20
01
20
04
20
07
20
10
20
01
A
20
04
A
20
07
A
20
10
A
20
14
20
14
A
20
17
20
17
A
10
09
A
10
10
A
10
09
A
10
10
A
10
11
A
10
11
A
20
08
20
11
20
15
20
18
Zo
ne
1
A
R
ed
C
lip
Zo
ne
1
B
Bl
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C
lip
Zo
ne
2
A
R
ed
C
lip
Zo
ne
2
B
Bl
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C
lip
10
04
10
04
10
04
10
04
10
04
10
04
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EN EN19 SCHEMATICS
N
ot
e:
A
ll
un
m
ar
ke
d
D
C
w
ire
s
to
b
e
18
AW
G
1
01
26
10
A
PU
LS
CP
10
.24
1
24
VD
C
PO
W
ER
S
UP
PL
Y
PW
S3
00
6
(M
P1
)
L
N
GN
D
+
+
-
-
GN
D3
00
6
GN
D3
01
0
5A
(M
P1
)
SE
RV
O
DR
IV
ES
24
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C
TO
CB
30
13 5A
(M
P1
)
PL
C/
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I
24
VD
C
TO
CB
30
15 1A
(M
P1
)
CO
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G
FA
N
24
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C
TO
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EN EN19 SCHEMATICS
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EN EN19 SCHEMATICS
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GR
N
BR
N
CB
L9
70
9
GR
N
BR
N
CB
L9
71
4
GR
N
BR
N
CB
L9
71
9
GR
N
fro
m
96
02
fro
m
96
25
CB
L9
60
2
CB
L9
62
6
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
m
A
m
A
m
A
m
A
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EN EN 19 SCHEMATICS
WIRE GAUGE (UNLESS NOTED) USE MIN 75 DEGREE C COPPER WIRE
American Wire Gauge
(AWG)
Diameter
(Inches)
Cross Sectional Area
(mm2) Ampacity (75° C Copper)
3 0.2292 26.65 100
4 0.2043 21.14 85
6 0.162 13.29 65
8 0.1285 8.36 52
10 0.1019 5.26 30
12 0.0808 3.31 20
14 0.0641 2.08 15
16 0.0508 1.31 10
18 0.0403 0.82 7
20 0.0320 0.52 5
22 0.0253 0.33 3
FERRULES TO BE USED ON ALL WIRES (UNLESS NOTED)
Wire Reference Description
BLACK UNGROUNDED LINE VOLTAGE
WHITE UNGROUNDED DC VOLTAGE
WHITE/BLUE GROUNDED DC COMMON
GREEN/YELLOW GROUND
19.2 ELECTRICAL DIAGRAMS 380V-400V
WIRE REFERENCE COLOR
BLK Black
WHT White
BLU Blue
RED Red
GRN Green
ORG Orange
BRN Brown
YLW Yellow
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EN EN19 SCHEMATICS
WIRE REFERENCE COLOR
RED_GRY RED WITH GREY STRIPE
GRY_RED GREY WITH WHITE STRIPE
WHT_BRN WHITE WITH BROWN STRIPE
BRN_WHT BROWN WITH WHITE STRIPE
WHT_GRY WHITE WITH GREY STRIPE
GRY_WHT GREY WITH WHITE STRIPE
RED_BLU RED WITH BLUE STRIPE
BLU/RED BLUE WITH RED STRIPE
RED/ORG RED WITH ORANGE STRIPE
ORG/RED ORANGE WITH RED STRIPE
RED/GRN RED WITH GREEN STRIPE
GRN_RED GREEN WITH RED STRIPE
BRN_RED BROWN WITH RED STRIPE
RED_BRN RED WITH BROWN STRIPE
WHT_GRN WHITE WITH GREEN STRIPE
GRN_WHT GREEN WITH WHITE STRIPE
WHT_BLU WHITE WITH BLUE STRIPE
BLU_WHT BLUE WITH WHITE STRIPE
WHT_ORG WHITE WITH ORANGE STRIPE
ORG_WHT ORANGE WITH WHITE STRIPE
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EN EN 19 SCHEMATICS
CROSS
WIRE CONNECTION
WIRELEGEND DESCRIPTIONS
NUMBERING CODE
XX???? = COMPONENT TYPE
??XX?? = SHEET
????XX = COLUMN
CORE IDENTIFIER
CABLE NUMBER
COLORCBL????
WIRE NUMBER
TERMINAL BLOCK
????
TB???
NORMALLY OPEN
PUSHBUTTON
PB????
NORMALLY CLOSED
PUSHBUTTON
PB????
FUSE WITH
RATING
??A
FU????
WITH RATING
FUSED DISCONNECT
DS????
??A
??A
WITH RATING
CIRCUIT BREAKER
CB????
RELAY COIL
CONTROL
CR????
CONTACT
NORMALLY OPEN
CONTROL RELAY
CR????
CONTACT
NORMALLY CLOSED
CONTROL RELAY
CR????
SOL????
SOLENOID
LIMIT SWITCH
NORMALLY CLOSED
LS????
PRESSURE SWITCH
NORMALLY OPEN
PS????OX
SELECTOR SWITCH
NORMALLY OPEN
SS????
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EN EN19 SCHEMATICS
N
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TE
:
C
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ST
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M
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S
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PP
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4
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01
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CR
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TB
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10
10
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A
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14
10
11
A
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20
07
10
11
A
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17
10
04
to
20
05
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BL
K_
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10
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10
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B
10
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B
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B
10
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C
10
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C
10
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C
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01
10
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10
02
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03
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10
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A
10
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EN EN 19 SCHEMATICS
3 PHASE BUS BAR (CONNECT TO L1 AND L2 ONLY)
L2
L1
01
T1
L1
42
17
50
AM
P
A H
OS
E
S1
SS
R4
21
7
SE
CT
IO
N
1
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07
15
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42
19
50
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1
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9
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1
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10
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FI
T1
L1
42
20
50
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P
A H
OS
E
S2
SS
R4
22
0
SE
CT
IO
N
2
A H
OS
E
CB
20
14
15
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30
ma
G
FI
T1
L1
42
22
50
AM
P
B
HO
SE
S
2
SS
R4
22
2
SE
CT
IO
N
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B
HO
SE
CB
20
17
PR
E-
HE
AT
A
CB
20
01
PR
E-
HE
AT
B
CB
20
04
50
A
50
A
15
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30
ma
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FI
T1
L1
42
16
50
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P
PR
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HE
AT
B
SS
R4
21
6T1
L1
42
14
50
AM
P
PR
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HE
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A
SS
R4
21
4
10
09
A
fro
m
10
09 10
10
A
fro
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10
10 10
11
A
fro
m
10
11
20
01
A
to
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18
20
02
to
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19
20
04
A
to
71
18
20
05
to
71
19
GN
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01
9
GN
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01
6
GN
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01
2
GN
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00
9
1
CB
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00
7
2 GR
N
1
CB
L2
01
0
2 GR
N
1
CB
L2
01
4
2 GR
N
1
CB
L2
01
7
2 GR
N
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
8A
W
G
BL
K_
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20
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10
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20
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20
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17
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20
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A
10
11
A
10
09
A
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EN EN19 SCHEMATICS
1
01
26
10
A
PU
LS
CP
10
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1
24
VD
C
PO
W
ER
S
UP
PL
Y
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00
6
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23
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0
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17
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18
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10
18
30
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25
30
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29 30
19
A
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03
30
21
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07
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23
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02
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03
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27
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26
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15
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09
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10
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,41
13
MA
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46
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48
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7
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30
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19
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27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
W
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EN EN 19 SCHEMATICS
01
26
PL
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20
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4
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01
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
EK1100
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EN EN19 SCHEMATICS
N
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02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
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EN EN 19 SCHEMATICS
01
26
0V
DC
to
44
01
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EN EN19 SCHEMATICS
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EN EN 19 SCHEMATICS
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EN EN19 SCHEMATICS
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EN EN 19 SCHEMATICS
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EN EN19 SCHEMATICS
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EN EN 20 REMOTE ACCESS
Click here for Simplified Interface
Click here for Full Interface
20 REMOTE ACCESS
Remote access to IntelliSpray™ systems is via the
IntelliSpray Cloud (ISC) which acts as a virtual gateway
to all systems accessible to registered users. The ISC
URL (web address) is provided when purchasing an
IntelliSpray Proportioner. Remote access to IntelliSpray
systems is a simple two step process that requires a
computer, tablet, or phone equipped with a web browser.
IntelliSpray Authorized Service Providers and/or trained
Rig Administrators provide username and password
access to both the ISC and individual IS40s™. Users or
Rig Owners can also disable or enable Remote Access
from the System Settings screen on the IS40. Instructions
for ISC Administrators is contained in the document
IntelliSpray Cloud Administrator Instructions.
Note: To support remote service (including remote
software upgrades), all IntelliSpray systems are factory
configured to allow access by IntelliSpray Service
Engineers and/or Authorized Service Providers.
STEP 1. Select IS40 IntelliSpray Cloud
An example of the ISC gateway shown in a standard
browser is shown in the following figure.
Each device has a unique Serial Number (SN) that is
loaded at the factory and corresponds to the serial tag
inside the Control Module and the SN shown at the top of
all display screens and in the System Status screen.
The Organization column shows the primary service
provider (generally a Distributor).
The Group column generally refers to the rig owner and
the Description column is a free-form field to identify a
specific IS40 (e.g. by rig name as shown below).
The Status column indicates which systems are online,
and if any remote users are connected to the machine.
STEP 2. Open IS40 Connection
Clicking on a Device in the first column creates a secure
connection to that system, and allows the user to select
either a full interface or a simplified interface.
When using the full interface, the remote user is seeing
and using the actual IntelliSpray screens via a Virtual
Network Connection (VNC icon).
The simplified interface (HTTPS icon) is a direct peer-to-
peer interface that allows monitoring and/or controlling
the primary functions of the system.
Click Device to select IS40
A2Z Spray Foam FOAM DIST. RIG 1
A2Z Spray Foam FOAM DIST. RIG 2
A2Z Spray Foam FOAM DIST. RIG 3
A2Z Spray Foam FOAM DIST. RIG 4
A2Z Spray Foam FOAM DIST. RIG 5
A2Z Spray Foam FOAM DIST. RIG 6
A2Z Spray Foam FOAM DIST. RIG 7
IntelliSpray CLOUD
Powered by Corvina
IS40
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EN EN20 REMOTE ACCESS
Full Interface (VNC) access on the phone
Simplified Interface (HTTPS) remote access on
the computer, phone, or tablet
Each IntelliSpray Proportioner is factory equipped with
an internal cellular modem that enables remote access
for operating, monitoring, updating, and/or servicing the
system.
Access by registered users (see previous page) is via
any computer, phone, or tablet equipped with a standard
browser (e.g. Edge, Chrome, Safari).
The cellular modem also allows users to email Job
Reports and performance data to selected recipients.
The IntelliSpray Proportioner automatically connects
to the internet when it is powered on and within cell
coverage. No user interaction is required to connect the
Proportioner to the internet.
Initial cellular fees (up to 12 months) are included in the
purchase price, with ongoing rates subject to purchase
and /or service agreements.
Cellular Modem Antenna
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EN EN 20 REMOTE ACCESS
Full Interface (VNC) access on the computer
The remote access capabilities of the IntelliSpray
Proportioner enables service providers to connect to any
system and provide assistance in the form of remote
diagnostics, application optimization, remote software
upgrades, and training on system use.
Users can call or text their authorized support contact to
initiate a remote support session. If escalation to second
and third level support staff is required, those individuals
can also connect to the Proportioner.
All parties can be connected to a Proportioner
simultaneously if required to resolve issues or answer
questions.
Note: A user does not have to be in the spray rig to
initiate a remote service event, but the IS40 must be
powered on and within cell-range to establish a remote
connection.
When a user calls or texts their authorized service
provider, that provider can remotely access the
IntelliSpray Proportioner and in some cases resolve
the issue without the user having to leave the spray
environment.
IntelliSpray Engineer
(Third Level Support)
Regional IntelliSpray Field Specialist
(Second Level Support)
Distributor Service Tech
(First Level Support)
IntelliSpray User
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EN EN20 REMOTE ACCESS
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EN EN 22 MANUAL REVISIONS
MANUAL REVISIONS
Date Description Version
02/12/2021 Initial release. A
06/08/2022 Additional screen functions, Automatic Viscosity Control (AVC), Added alarm
tables, changes to electronics for CE compliance (starting S/N 1094) B
07/15/2024 Formatting changes to the document. Added 400V model configuration. C
07/22/2025 Updated document formating to Binks 2025 standard. D
21 MANUAL REVISIONS
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EN EN22 MANUAL REVISIONS
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EN 22 WARRANTY
WARRANTY POLICY
This product is covered by Binks’ materials and workmanship limited warranty.
The use of parts or accessories from sources other than Binks will void all warranties. Failure to follow reasonable
maintenance guidance provided can invalidate the warranty.
For specific warranty information, please contact Binks.
For technical assistance or to locate an authorized distributor, contact one of our international sales
and customer support locations listed below.
www.binks.com 341162 D (03/2025)249 / 249
REGION BINKS CONTACT
Americas Tel: 1-800-992-4657
Europe, Africa, Middle East Tel: +4401202571111
India marketingroa@binks.com
China Tel: +862133730108
Korea Tel: +82313663303
Japan Tel: +81457856421
Australia Tel: +61085257555
WARRANTY PAGE
22 WARRANTY
EN
Binks is a global leader in innovative finishing technologies.
Binks reserves the right to modify equipment specifications without prior notice.
Binks®, DeVilbiss® and Ransburg® are registered trademarks of Binks US, LLC.
©2025 Binks US, LLC. All rights reserved.
03 eu declaration of conformity
04 SAFETY
04.1 SAFETY PRECAUTIONS
04.2 ADDITIONAL SAFETY INFORMATION
05 IMPORTANT ISOCYANATE INFORMATION
05.1 General HANDLING GUIDELINES
05.2 Material Self Ignition
05.3 KEEP COMPONENTS A & B SEPARATE
05.4 EXPOSURE TO MOISTURE
05.5 foam resins WITH 245 FA blowing agents
05.6 changing materials
05.7 electrical ground
06 SYSTEM OVERVIEW
07 IS40 SPECIFICATIONS
08 IS40 OVERVIEW
09 FLUID MODULE
09.1 MODULE ASSEMBLIES: OVERVIEW
09.2 MODULE FLUID PATHWAYS
09.3 FILTER MODULE
09.4 LOW PRESSURE MODULE
09.5 PUMP MODULE
09.6 HIGH PRESSURE MODULE
10 CONTROL MODULE
10.1 CONTROL MODULE: OVERVIEW
10.2 CONTROL MODULE: ENCLOSURE
10.3 MAIN PANEL: 200-240V
10.4 MAIN PANEL: 380-415V
10.5. CIRCUIT BREAKERS
11 QUICKHEAT™ HOSE
12 INSTALLATION
12.1 INSTALLATION PROCEDURE
13 QUICK-START GUIDE
14 OPERATION TIPS
15 DISPLAY SCREENS
15.1 DISPLAY SCREENS: OVERVIEW
15.2 DISPLAY SPECIFICATIONS
15.3 SPRAY SCREEN: OVERVIEW
15.3.1 SPRAY SCREEN: USER INFORMATION
15.3.2 SPRAY SCREEN: USER ACTIONS
15.3.3 SPRAY SCREEN: USE
15.3.4 SPRAY SCREEN: OTHER FUNCTIONS
15.3.4.1 DRUM TEMPERATURE
15.3.4.2 FLUID COUNTER
15.3.4.3 FLUID
15.3.4.4 FLOW RATE AND TRIGGER %
15.3.4.5 ALARMS
15.3.4.6 RESET
15.3.4.7 PREHEATER Temperature OFFSET
15.3.4.8 ALARM DETAILS
15.3.4.9 INLET COMPENSATION
15.4 AUTOMATIC VISCOSITY COMPENSATION (AVC™)
15.5 AUTOMATIC INLET COMPENSATION (AIC)
15.6 EXCHANGE SCREEN: OVERVIEW
15.6.1 EXCHANGE SCREEN: USE
15.6.2 EXAMPLE 1: INITIAL SYSTEM BLEED
15.6.3 EXAMPLE 2: A SIDE MANUAL PURGE
15.6.4 EXAMPLE 3: B SIDE PURGE AMOUNT
15.6.5 EXAMPLE 4: PREHEAT B DRUM MATERIAL
15.6.6 EXAMPLE 5: SIDE AIR PURGE
15.7 ALARM SCREEN: OVERVIEW
15.7.1 ERRORS
15.7.2 ALARM SCREEN: USE
15.8 SYSTEM STATUS SCREENS: OVERVIEW
15.8.1 SYSTEM STATUS SCREENS: IO PAGE 1
15.8.2 SYSTEM STATUS SCREENS: IO PAGE 2
15.8.3 SYSTEM STATUS SCREENS: SENSOR BYPASS
15.8.4 SYSTEM STATUS SCREENS: inlet HEALTH
15.8.5 SYSTEM STATUS SCREENS: TREND CHARTS
15.8.5.1 SELECT PLOT PARAMETERS
15.8.5.2 SELECT TIME SCALE (TREND TIME)
15.9 SETTINGS SCREENS: OVERVIEW
15.9.1 SETTINGS SCREENS: SYSTEM INFORMATION
15.9.2 SETTINGS SCREENS: FIRMWARE UPDATES
15.9.3 SETTINGS SCREENS: SYSTEM STATUS
15.9.4 SETTINGS SCREENS: CONFIGURATION SETTINGS
15.9.5 SETTINGS SCREENS: DISPLAY SETTINGS
15.9.6 SETTINGS SCREENS: SYSTEM SETTINGS
15.9.7 SETTINGS SCREENS: HOSE CONFIGURATION
15.9.8 SETTINGS SCREENS: DRIVE STATUS LOG
15.9.9 SETTINGS SCREENS: SUPPLY SETTINGS
15.9.10 SETTINGS SCREENS: YIELD CALCULATOR
15.9.11 SETTINGS SCREENS: MATERIAL DATA
15.10 SECURITY
15.11 RECIPE SCREENS: OVERVIEW
15.11.1 RECIPE SCREENS: RECIPE MANAGEMENT
15.11.2 RECIPE SCREENS: EDITING
15.12 REPORTS: OVERVIEW
15.12.1 REPORTS: AUDIT REPORT
15.12.2 REPORTS: JOB NOTES
15.13 JOB REPORTS: OVERVIEW
15.13.1 JOB REPORTS: LOG ENTRIES
15.13.2 JOB REPORTS: MATERIAL DATA
15.13.3 JOB REPORTS: REPORT CONTENT
15.13.4 JOB REPORTS: REPORT MANAGEMENT
15.14 LANGUAGES
15.15 VARIABLE RATIO OPERATION
15.15.1 ENABLE VARIABLE RATIO
15.15.2 ENABLE FIRST TIME
16 SERVICING
16.1 Fluid module depressurization
16.2 inlet filter servicing
16.3 CHECK PUMP TSL LEVEL
16.4 BURST DISK REPLACEMENT
16.4 FILTER MAINTENANCE
17 Troubleshooting
17.1 system errors
18 MAINTENANCE
18.1 REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS
18.2 FLUID MODULE
18.3 LOW-PRESSURE MODULE
18.4 PUMP MODULE
18.5 HIGH-PRESSURE MODULE
18.6 PUMP I/O MODULE
18.7 FLUID MODULE O-RINGS AND SEALS
18.8 IS40 CONTROL MODULE ENCLOSURE
18.9 IS40 CONTROL MODULE CONTROL PANEL 200V-240V
18.10 IS40 CONTROL MODULE CONTROL PANEL 380V-415V
18.11 IS40 CABLES
18.12 IS40 ACCESSORIES AND KITS
19 electrical schematics
19.1 electrical diagrams 200v-240v
19.2 ELECTRICAL DIAGRAMS 380V-400V
20 REMOTE ACCESS
21 MANUAL REVISIONS
22 warranty
