Carlisle QuickHeat Hose Owner's manual

Carlisle
Brand
Carlisle
Model
QuickHeat Hose
Type
Owner's manual
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PRODUCT MANUAL
QUICKHEAT HOSE
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COMPLIANCE
Item Descripon
2006/42/EC Machinery Direcve
2014/35/EU Low Voltage Direcves
2011/65/EU RoHS Direcve with Amendment 2015/863
COMPLIANCE
Compliance to the following standards is indicated by the corresponding mark on the product.
COMPLIANCE PENDING
EC Direcves
Item Descripon
ISO 12100 Machinery Safety
EN60204-1 Safety of Machinery – Electrical Equipment
IEC 63000 New Harmonized Standard to Demonstrate RoHS Compliance
Safety Standards
Item Descripon
TUV NNNN
FCC
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CONTENTS
SAFETY .................................................................................................................................................. 6
INTRODUCTION .................................................................................................................................... 15
PRODUCT FEATURES .......................................................................................................................................... 15
SYSTEM COMPONENTS ...................................................................................................................................... 16
INSTALLATION ...................................................................................................................................... 21
REQUIRED TOOLS AND HARDWARE .................................................................................................................. 21
PROPORTIONER-TO-HOSE CONNECTIONS......................................................................................................... 21
HOSE-TO-HOSE CONNECTIONS .......................................................................................................................... 23
HOSE-TO-GUN CONNECTIONS ........................................................................................................................... 25
HOSE USAGE ........................................................................................................................................ 26
KEY OPERATIONAL REQUIREMENTS .................................................................................................................. 26
FIBER OPTIC CABLE LED INDICATORS ................................................................................................................ 26
PRODUCT TROUBLESHOOTING ............................................................................................................ 27
PRODUCT MAINTENANCE .................................................................................................................... 29
REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS ............................................................... 29
SPARE PARTS & REPAIR KITS .............................................................................................................................. 30
HOSE SECTION REPLACEMENT .......................................................................................................................... 31
WARRANTY .......................................................................................................................................... 37
CONTENTS
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SAFETY
SAFETY
SAFETY PRECAUTIONS
Before operang, maintaining or servicing any Carlisle system, read
and understand all of the technical and safety literature for your
products. This manual contains informaon that is important for you
to know and understand. This informaon relates to USER SAFETY and
PREVENTING EQUIPMENT PROBLEMS.
To help you recognize this informaon, we use the following symbols.
Please pay parcular aenon to these secons.
WARNING
A WARNING! states informaon to alert you to a situaon that might
cause serious injury if instrucons are not followed.
WARNING
The user MUST read and be familiar with the Safety Secon in this
manual and the Ransburg safety literature therein idened.
This equipment is intended to be used by trained personnel ONLY.
This manual MUST be read and thoroughly understood by ALL
personnel who operate, clean or maintain this equipment! Special care
should be taken to ensure that the WARNINGS and safety
requirements for operang and servicing the equipment are followed.
The user should be aware of and adhere to ALL local building and re
codes and ordinances as well as any applicable country safety
standards, prior to installing, operang, and/or servicing this
equipment.
WARNING
The hazards shown on the following pages may occur during the
normal use of this equipment.
CAUTION
A CAUTION! states informaon that tells how to prevent damage to
equipment or how to avoid a situaon that might cause minor injury.
NOTE
A NOTE is informaon which is relevant to the procedure in progress.
While this manual lists standard specicaons and service procedures,
some minor deviaons may be found between this literature and your
equipment. Dierences in local codes and plant requirements, material
delivery requirements, etc., make such variaons inevitable. Compare
this manual with your system installaon drawings and appropriate
equipment manuals to reconcile such dierences.
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SAFETY
Connued in next page...
Read the following warnings before using this equipment
WARNING
READ THE MANUAL read and
all safety, and maintenance in
the
TIP/CRUSH HAZARD Do not p unit. In mobile or seismic installaons be
sure unit is secured to oor and wall per instrucons.
TRAINING All must be before
equipment. STATIC CHARGE Fluid may develop a stac charge that must be
dissipated through proper grounding of the equipment, objects to be
sprayed and all other electrically conducve objects in the dispensing
area. Improper grounding or sparks can cause a hazardous condion and
result in re, explosion or electric shock and other serious injury.
AUTOMATIC EQUIPMENT Automac equipment may start suddenly
without warning.
EQUIPMENT HAZARD can cause the
to or start and result in
injury.
LOCK OUT / TAG-OUT Failure to de-energize, disconnect, lock out and
tag-out all power sources before performing equipment maintenance
could cause serious injury or death.
PRESSURE RELIEF PROCEDURE Always follow the pressure relief
procedure in the equipment instrucon manual.
WEAR RESPIRATOR Toxic fumes can cause serious injury or death if
inhaled. Wear a respirator as recommended by the uid and solvent
TOXIC FLUID & FUMES Hazardous uid or toxic fumes can cause serious
injury or death if splashed in the eyes or on the skin, inhaled, injected or
swallowed. LEARN and KNOW the specic hazards or the uids you are
ELECTRICAL SHOCK HAZARD Disconnect all power sources before
accessing any electrical connecons in the Control Module, Fluid
Modules, or Hoses. Equipment must be serviced by trained personnel
INSPECT THE EQUIPMENT DAILY Inspect the equipment for worn or
broken parts on a daily basis. Do not operate the equipment if you are
uncertain about its condion.
KEEP EQUIPMENT GUARDS IN PLACE Do not operate the equipment if
the safety devices have been removed.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE OF
AN EMERGENCY
WEAR SAFETY GLASSES Failure to wear safety glasses with side shields
could result in serious eye injury or blindness.
FIRE AND EXPLOSION HAZARD Improper equipment grounding, poor
venlaon, open ame or sparks can cause a hazardous condion and
result in re or explosion and serious injury.
MEDICAL ALERT Any injury caused by high pressure liquid can be serious.
If you are injured or even suspect an injury:
• Go to an emergency room immediately.
• Tell the doctor you suspect an injecon injury.
• Show the doctor this medical informaon or the medical alert card
provided with your airless spray equipment.
• Tell the doctor what kind of uid you were spraying or dispensing.
• Refer to the Material Safety Data Sheet for specic informaon.
NEVER MODIFY THE EQUIPMENT Do not modify the equipment unless
the manufacturer provides wrien approval.
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NOISE HAZARD You may be injured by loud noise. Hearing protecon
may be required when using this equipment.
PROJECTILE HAZARD You may be injured by venng liquids or gases that
are released under pressure, or ying debris.
PROP 65 WARNING: This product contains chemicals known to the State
of California to cause cancer and birth defects or other reproducve
harm.
It is the of the to this to the of the
PINCH POINT HAZARD Moving parts can crush and cut. Pinch points are
basically any areas where there are moving parts.
Read the following warnings before using this equipment
WARNING
GET IMMEDIATE MEDICAL ATTENTION To prevent contact with the uid,
please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or ngers over the spray p.
• Never aempt to stop or deect uid leaks with your hand, body,
glove or rag.
• Always have the p guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before spraying.
• Always lock the gun trigger safety when you stop spraying.
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AREA
Tells where hazards may
occur
HAZARD
Tells what the hazard is
SAFEGUARDS
Tells how to avoid the hazard
Spray Area High
Voltage
Equipment
Electrical Discharge
There is a high voltage device that can induce
an electrical charge on ungrounded objects
which is capable of igning coang materials.
Inadequate grounding will cause a spark
hazard. A spark can ignite many coang
materials and cause a re or explosion.
Parts being sprayed and operators in the spray area must be properly
grounded.
Parts being sprayed must be supported on conveyors or hangers that
are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to NFPA-33.)
Operators must be grounded. Rubber soled insulang shoes should
not be worn. Grounding straps on wrists or legs may be used to
assure adequate ground contact.
Operators must not be wearing or carrying any ungrounded metal
objects.
When using an electrostac handgun, opera- tors must assure contact
with the handle of the applicator via conducve gloves or gloves with
the palm secon cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC COUNTRY SAFETY CODES
REGARDING PROPER OPERATOR GROUNDING.
All electrically conducve objects in the spray area, with the
excepon of those objects re- quired by the process to be at high
voltage, must be grounded. Grounded conducve ooring must be
provided in the spray area.
Always turn o the power supply prior to ushing, cleaning, or
working on spray system equipment.
Unless specically approved for use in hazardous locaons, all
electrical equipment must be located outside Class I or II, Division 1 or
2 hazardous areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system where the solvent
supply is ungrounded.
Do not touch the applicator electrode while it is energized.
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AREA
Tells where hazards may
occur
HAZARD
Tells what the hazard is
SAFEGUARDS
Tells how to avoid the hazard
Electrical
Equipment
Electrical Discharge
High voltage equipment is ulized in the
process. Arcing in the vicinity of ammable or
combusble materials may occur. Personnel
are exposed to high voltage during operaon
and maintenance.
Protecon against inadvertent arcing that may
cause a re or explosion is lost if safety circuits
are disabled during operaon.
Frequent power supply shutdown indicates a
problem in the system which requires
correcon.
An electrical arc can ignite coang materials
and cause a re or explosion.
Unless specically approved for use in hazardous locaons, the power
supply, control cabinet, and all other electrical equipment must be
located outside Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the equipment.
Test only in areas free of ammable or combusble material.
Tesng may require high voltage to be on, but only as instructed.
Producon should never be done with the safety circuits disabled.
Before turning the high voltage on, make sure no objects are within
the sparking distance.
Toxic
Substances
Chemical Hazard
Certain materials may be harmful if inhaled, or
if there is contact with the skin.
Follow the requirements of the Safety Data Sheet supplied by coang
material manufacturer.
Adequate exhaust must be provided to keep the air free of
accumulaons of toxic materials.
Use a mask or respirator whenever there is a chance of inhaling
sprayed materials. The mask must be compable with the material
being sprayed and its concentraon. Equipment must be as
prescribed by an industrial hygienist or safety expert, and be NIOSH
approved.
Spray Area Explosion Hazard —
Incompable Materials
Halogenated hydrocarbon solvents for
example: methylene chloride and 1,1,1, -
Trichloroethane are not chemically compable
with the aluminum that might be used in many
system components.
The chemical reacon caused by these solvents
reacng with aluminum can become violent
and lead to an equipment explosion.
Spray applicators require that aluminum inlet ngs be replaced with
stainless steel.
Aluminum is widely used in other spray applicaon equipment - such
as material pumps, regulators, triggering valves, etc. Halogenated
hydrocarbon solvents must never be used with aluminum equipment
during spraying, ushing, or cleaning. Read the label or data sheet for
the material you intend to spray. If in doubt as to whether or not a
coang or cleaning material is compable, contact your coang
supplier. Any other type of solvent may be used with aluminum
equipment.
SAFETY
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SAFETY
AREA
Tells where hazards may
occur
HAZARD
Tells what the hazard is
SAFEGUARDS
Tells how to avoid the hazard
Toxic
Substances
ISOCYANATE Condions Spraying or dispensing uids that contain isocyanates creates
potenally harmful mists, vapors, and atomized parculates. Workers
exposed to isocyanates can develop a range of short and long-term
health problems.
Read and understand the uid manufacturer’s warnings and Safety
Data Sheet (SDS) to know specic hazards and precauons related to
isocyanates.
Use of isocyanates involves potenally hazardous procedures. Do not
spray with this equipment unless you are trained, qualied, and have
read and understood the informaon in this manual and in the uid
manufacturer’s applicaon instrucons and SDS.
Use of incorrectly maintained or mis-adjusted equipment may result
in improperly cured material which could cause o-gassing and
oensive odors. Equipment must be carefully maintained and
operated according to instrucons in the manual.
To prevent inhalaon of isocyanate mists, vapors and atomized
parculates, everyone in the work area must wear appropriate
respiratory protecon. Always wear a properly ng respirator,
which may include a supplied-air respirator. Venlate the work area
according to instrucons in the uid manufacturer’s SDS.
Avoid all skin contact with isocyanates. Everyone in the work area
must wear chemically impermeable gloves, protecve clothing and
foot coverings as recommended by the uid manufacturer and local
regulatory authority. Follow all uid manufacturer recommendaons,
including those regarding handling of contaminated clothing. Aer
spraying, wash hands and face before eang or drinking.
Hazard from exposure to isocyanates connues aer spraying.
Anyone without appropriate personal protecve equipment must stay
out of the work area during applicaon and aer applicaon for the
me period specied by the uid manufacturer. Generally this me
period is at least 24 hours.
Warn others who may enter work area of hazard from exposure to
isocyanates. Follow the recommendaons of the uid manufacturer
and local regulatory authority. Posng a sign outside the work area is
recommended.
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AREA
Tells where hazards may
occur
HAZARD
Tells what the hazard is
SAFEGUARDS
Tells how to avoid the hazard
Personal
Protecve
Equipment
Always wear appropriate personal protecve
equipment and cover all skin when spraying,
servicing equipment, or when in the work area
Protecve equipment helps prevent serious injury, including long-
term exposure; inhalaon of toxic fumes, mists or vapors; allergic
reacon; burns; eye injury and hearing loss. This protecve
equipment includes but is not limited to:
• A properly ng respirator, which may include a supplied-air
respirator
• Chemically impermeable gloves
• Protecve clothing and foot coverings as recommended by the
uid manufacturer and local regulatory authority
• Protecve eyewear
• Hearing protecon.
Toxic
Substances
Toxic Fluid or Fumes Hazard Toxic uids or fumes can cause serious injury or death if splashed in
the eyes or on skin, inhaled or swallowed.
Read Safety Data Sheet (SDS) for handling instrucons and to know
the specic hazards of the uids you are using, including the eects of
long-term exposure.
When spraying, servicing equipment, or when in the work area,
always keep work area well venlated and always wear appropriate
personal protecve equipment. See Personal Protecve Equipment
warnings in this manual.
Store hazardous uid in approved containers and dispose of it
according to applicable guidelines.
SAFETY
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SAFETY
AREA
Tells where hazards may
occur
HAZARD
Tells what the hazard is
SAFEGUARDS
Tells how to avoid the hazard
Spray Area Skin Injecon Hazard High-pressure uid from gun, hose or ng leaks, or ruptured
components may pierce skin. This may look like just a cut, but it is a
serious injury that can result in amputaon. Get immediate medical
treatment.
Do not point the spray gun at anyone or at any part of the body.
Do not put your hand or ngers over the gun uid nozzle or any
ngs in the hose or proporoner.
Do not aempt to stop or deect leaks with your hand, body, glove,
or rag.
Do not “blow back” uid; this is not an air spray system.
Follow Pressure Relief Procedure, before cleaning, checking, or
servicing equipment.
Use lowest possible pressure when purging, recirculang, or
troubleshoong.
Check hoses, couplings, and ngs daily. Service or replace leaking,
worn, or damaged parts immediately. High pressure hose secons
cannot be recoupled; replace the hose secon.
Equipment Equipment Misuse Hazard Misuse can cause serious injury or death.
For professional use only.
Use equipment only for its intended purpose. Call your Carlisle
distributor for informaon.
Read manuals, warnings, tags, and labels before operang
equipment. Follow instrucons.
Check equipment daily. Repair or replace worn or damaged parts
immediately.
Do not alter or modify equipment. Use only Carlisle parts and
accessories.
Do not exceed the maximum working pressure or temperature rang
of the lowest rated system component. See Technical Data in all
equipment manuals.
Use uids and solvents that are compable with equipment weed
parts.
Route hoses and cables away from trac areas, sharp edges, moving
parts, and hot surfaces.
Do not use hoses to pull equipment.
Comply with all applicable safety regulaons.
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INTRODUCTION
INTRODUCTION
The Carlisle IntelliSpray Spray Polyurethane Foam (SPF) system consists of the IS40 Proporoner, QuickHeat Hose, and ST1 Spray Gun. The
IntelliSpray system has been designed for ease of use, increased producvity, “best in class” process control, easy service, and real-me rao
control.
The QuickHeat hose has roughly double the heang power compared to most other SPF hoses and directly heats the uid from inside the hose,
which results in fast and ecient uid heang, even in cold climate condions. QuickHeat hoses have embedded temperature and pressure
sensors, independent A & B hose heang, and up to six independent heang zones to improve temperature control. QuickHeat hoses provide
sensor power and signal communicaon without cables or connectors, providing reliability and reducing failure opons. 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.
The IS40 proporoner is specically designed to use Carlisle QuickHeat Hoses. These hoses contain high-power internal electric heang cables,
ensuring that all of the heang energy is transmied directly to the uid. QuickHeat hoses are provided in 100, 150 or 200 foot (30, 45, or 60m)
lengths. Heated whip hoses (Smart Ends) are available in 20 and 40 foot (6 or 12m) lengths. Insulated whips are available in 6 or 10 foot (2 or 3m)
lengths. Each length of a heated hose begins with a uid manifold or “modem” that contains pressure and/or temperature sensors, heater cable
connectors, and electronics used to send informaon over the hose to the system’s Control Module. With this approach, no sensor power or
communicaon cables are required, which are a common source of hose failures in other systems. It also provides the proprietary architecture for
two way communicaon between the hose, proporoner and remote devices .
PRODUCT FEATURES
Fast and reliable heat
Independent A & B embedded heater wire submerged in hose uid achieving > 100˚F (37˚C) DeltaT in under 15 minutes on average.
Real-me system control
Pressure and temperature data communicated and controlled within hose to spray gun to maximize control and accuracy.
Cut service costs
Reduced need for service with fully poed electronics/sensors and the ability to replace A & B side independently when needed.
Reduced electrical connecons
Resulng in less maintenance issues.
More heat control and less risk
Independent heat sensors allow system to adjust temperature.
Lighter and more exible hoses for less sprayer fague
SYSTEM COMPONENTS
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INTRODUCTION
The QuickHeat hose has the following components:
• Poed modem (1 per hose segment)
• Material Hoses (1 per material and per segment)
• Heater wires (1 per material and per segment)
• Heater power cables (1 per material and per segment)
• Master hose low voltage (24 VDC) power cable
• Master hose EtherCAT cable
• Fiber Opc status light cable
• Air hose (one per hose segment)
Hose Conguraons
Depending on the length needed for the enre hose system, you can set it up in 2 dierent conguraons. The hose length cannot exceed 350
for either the IS30 or IS40 systems.
Hose Pneumac, Hydraulic and Power connecons
The QuickHeat hose structure and connecons vary depending on the conguraon selected.
1. Proporoner Control Module
2. Material A Fluid Module
3. Material B Fluid Module
4. Zone 1, 2, 3 & 4 Heater Wire Power Cable
5. Zone 1 & 2 Heater Wire Power Cable
6. Zone 3, 4, 5 & 6 Heater Wire Power Cable
7. Hose Segment Modem
8. Power Cable Splier
9. Material A & B Circuit board Power Cable
NOTE
Communicaon from modem to modem (aer the Master) travels
through the communicaon layer in the hose (referenced in the
“Hose Layer” secon).
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INTRODUCTION
1
2
3
4
7
9
1
2
3
5
6
9
8
9
8
7
7
7 7
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Poed Modem Structure
Each hose segment has a poed modem at the start of the segment. The modems may dier depending on whether they are part of a master,
mid or smart-end segment. The dierences are included in the installaon secon of this manual. The B-side of the modem below is shown
1. Material A input
2. Material B input
3. Material temperature probes (A & B) (not shown
in diagram below)
4. Fluid heater cables
5. Fluid pressure sensors
6. Circuit boards
7. Material A output
8. Fiber opc status cable
1
2
3
5
6
7
8
9
INTRODUCTION
without a cover for reference.
Benets
• Fully ruggedized poed electronics
• Fully sealed set of uid ngs
• Built-in mul-colored LED and beropc feedback for system status
• High-resoluon process control and communicaon electronics
• Independently-replaceable A and B side design
• Minimized connecons
4
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• Independent pressure and temperature sensing control
Hose Layers
1. Santoprene
2. Proprietary communicaon layer
3. Thermoplasc Urethane (TPU)
4. Fiber braid
5. Nylon core
5 4 3 2 1
Item Details
Dimensions (Length)
Master hose: 100, 150, or 200 length (30, 45, or 60m)
Mid hose: 100 or 150 length (30 or 45m)
Smart-end: 20 or 40 length (6 or 12m)
Whip: 6 or 10 length (2 or 3m)
Dimensions (Diameter) The hose has an internal diameter of 3/8 in (Master, Mid, and Smart-end) and 1/4 in ID
on the insulated whip
Weight 150-250lb (68-113kg) (depending on added components and conguraon) without any
Temperature dierenal >100˚F (37˚C) DeltaT (over full length of hose system)
Maximum working pressure 2,250 PSI (155 BAR)
Maximum operang temperature 200˚F (93˚C)
Minimum bend radius 8 in (20cm) (enre hose bundle)
INTRODUCTION
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Carlisle QuickHeat Hose Owner's manual

Carlisle
Brand
Carlisle
Model
QuickHeat Hose
Type
Owner's manual
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