Foamit DS4-2P Series User manual

Twin-Line Concentrate Doorway
Foam Unit for 2-Part Products
User Manual
DS4-2P
READ ALL INSTRUCTIONS BEFORE USING, OR SERVICING, THIS EQUIPMENT. KEEP THIS MANUAL IN A
LOCATION THAT IS READILY AVAILABLE TO USERS AND SERVICE TECHNICIANS.
English (Original Instructions)

1 Safety .......................................................3
2 System Overview...........................................5
System Overview ........................................... 5
Component Overview ........................................7
3Installation..........................................8
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly.................................................. 8
4Operation .................................................. 11
Timer Setup................................................11
Operation..................................................11
5Maintenance................................................12
6Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Box Assembly.......................................14
Nozzle Assembly ...........................................15
Replacement Nozzle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Contents
V20190919 •Page 2 of 15
Model: DS4-2P

1Safety
PEOPLE OR OBJECTS CAN BE HURT OR DAMAGED IF THIS UNIT IS NOT USED CORRECTLY!
Failure to read all the instructions before operating the unit may result in personal injury or death from
the improper use or the chemical solution. Anyone handling, operating or using the unit must read,
and understand, the instructions in the manual. The buyer assumes all responsibility for safety and
proper use in accordance with the instructions.
Using, or servicing, the unit without proper protective clothing, gloves, and
eye wear may result in serious injury such as burns, rashes, eye, throat
or lung damage and death. Always wear protective clothing, gloves, and
eye wear when using, or servicing, the unit. Protect eyes, skin, and lungs
against drifting spray.
Chemical solutions may pose a health risk and death if they contact the skin or eyes, are inhaled
or swallowed. Always read, and follow, all chemical safety precautions and handling instructions
provided by the chemical manufacturer and the Safety Data Sheet (SDS) associated with the chemical
solution being used before using the unit.
Pressure within the equipment may cause an unexpected release of the chemical solution and
cause serious injury such as burns, rashes, eye damage, throat or lung damage and death. Always
depressurize and clean the unit after each use. Release any remaining air pressure by twisting the
pressure relief valve to the right ½ turn. Never leave the unit unattended while pressurized.
Using the unit with fluid temperatures above 100°F (37.77°C) may result in scalding, burns, serious
injury or death. DO NOT use a solution with a temperature above 100°F (37.77°C).
Operating the unit when damaged or leaking may result in exposure to chemical solutions, serious
injury or death. Never use the unit if it is damaged or leaking.
Using incoming air pressure exceeding 100 psi (7 bar) may result in pressure buildup, explosion,
serious injury or death. DO NOT exceed 100 psi (7 bar) incoming air pressure when operating the unit.
Use of hydrocarbons and flammable products may result in explosions, fire and serious injury or
death. Never use hydrocarbons or flammable products with the unit.
Performing any maintenance with the unit turned ON, plugged into an electrical power source or
connected to the air and water supply may serious injury or death. Always ensure that the unit has
been turned OFF, unplugged from the electrical power source, and disconnected from the air/water
supply before conducting any maintenance.
Mixing an alkaline with an acid may result in a chemical reaction. Overheating of the mixture may
cause it to splatter caustic compounds or release hazardous fumes, gas and vapors. Always flush
the unit with fresh water for five (5) minutes when switching from an alkaline to an acid or an acid to
an alkaline.
V20190919 •Page 3 of 15
Model: DS4-2P
WARNING
!

Servicing, or modification, of this unit with parts not listed in this manual may cause the unit to operate improperly.
Do not use unauthorized parts when servicing the unit.
Use of an air lubricator before the unit may result in diminished performance and damage to the unit. Do not use an
air lubricator before the unit.
Moisture in the air lines will damage the pump and diminish the pumps life. The air must be filtered, clean, dry and
free of moisture. If needed, install an air dryer before the unit.
PROTECT THE ENVIRONMENT
Please dispose of packaging materials, old machine components, and hazardous fluids in an
environmentally safe way according to local waste disposal regulations
V20190919 •Page 4 of 15
Model: DS4-2P
NOTICE

System Overview
The DS4-2P series of Twin-Line Concentrate Doorway Foam Units has multiple configurations. One control box can
support up to three nozzle assemblies. Note: The combined distance between the control box and the nozzle(s)
must equal 100 ft. (30.5 m) or less. The following tables provide information regarding model configuration, model
hardware, system requirements and specifications.
Item number builder
Default options shown in italics. Other options require addition of option codes, as shown.
Model configurations are denoted by the model (i.e.: DS4), pump seal material (i.e.: Viton) and the number of nozzles
(i.e.: 3). The option codes denote the pump seal material and number of nozzles. For example:
• Model DS4-2P: is a standard 2-part product unit with Santoprene pump seals and one nozzle.
• Model DS4-2P-2: is a 2-part product unit with Santoprene pump seals and two nozzles
• Model DS4V-2P-2: is a 2-part product unit with Viton pump seals and two nozzles
Model hardware
2System Overview
V20190919 •Page 5 of 15
Model: DS4-2P
Items included DS4-2P DS4-2P-2 DS4-2P-3
Number of nozzle
assemblies
Control box and one
nozzle assembly
Control box and two
nozzle assemblies
Control box and three
nozzle assemblies
Type of spray tip 80° fan pattern, 20 gpm
flow rate
80° fan pattern, 10 gpm
flow rate
80° fan pattern, 6 gpm
flow rate
Length of tubing 1/2 in.
OD tubing 50 ft. (15.2 m) 100 ft. (30.4 m) 150 ft. (45.7 m)
1/2 in. union tee fittings 0 2 4
Base
item no. Pump seal material
DS4
Santoprene
Viton (V)
Kalrez (K)
2-Part Products
2P
2P
2P
Number of
nozzles
One (Standard)
Two (2)
Three (3)

Power type Compressed air, electricity
Chemical pickup type Draws from concentrated product
Dilution ratio range
(water:chemical)*
7:1 to 125:1
Note: Dilution rate can be set independently for each product
Number of products unit can
draw from Two products, simultaneously
Suction line length/diameter Two 8 ft. (2.4 m) clear hose with 1/4 in. (6.4 mm) inside diameter
Flow rate* 2 gal/min (7.6 l/min)
Pump seals Santoprene, Viton, or Kalrez
Timer operation type Repeat cycle
Coverage area
• One nozzle: up to 9x5 ft. (2.7x1.5 m)
• Two nozzles: up to 8x4 ft. (2.4x1.2 m) at each nozzle
• Three nozzles: up to 6x3 ft. (1.8x0.9 m) at each nozzle
Fan tip
• One nozzle: ST80200SS
• Two nozzles: ST80100SS
• Three nozzles: ST8060-1/2SS
Nozzle type Twin-line stainless steel nozzle assembly (GK7T)
Number of nozzles One control box can support up to three nozzle assemblies
Distance from nozzles to
control box
The combined distance between the control box and the nozzle(s) must equal
100 ft. (30.5 m) or less
Tubing/fitting sizes Designed for use with 1/2 in. (12.7 mm) outside diameter tubing between control
box and nozzle(s)
* Dilution rates and flow rates given are based on chemical with viscosity of water and factory air pressure settings.
** Area covered and run time may vary based on humidity, air flow, and product used.
Compressed air requirements 40-80 psi (3-5 bar) with 5-10 cfm (141-283 l/min)
Water requirements
30-100 psi (2.1-6.9 bar)
Backflow prevention is required. Consult local plumbing ordinances for
more information.
Liquid temperature range 40-100˚F (4.4-37˚C)
Electrical requirements 120 VAC at 60 Hz, 2 amps (GFCI protected outlet)
Operating voltage 120 VAC
Chemical compatibility
Chemical products used with this equipment must be formulated for this type
of application and compatible with unit materials and pump seals. For more
information on chemical compatibility, consult the manufacturer or SDS for your
product or contact our customer service department.
System requirements
System specifications
V20190919 •Page 6 of 15
Model: DS4-2P

1. Control box
2.Timer
3. Needle valve
4. Power cord
5. Water inlet
6. Dual injector
7. Suction lines
8. Nozzle bracket
9. Stainless steel nozzle
assembly
10. Solution outlet fitting
11. Air outlet fitting
12. Power switch
13. Air inlet
14. Control box mounting feet
Component Overview
Before you begin get to know the DS4-2P components
that you will need to use, adjust or assemble.
1
V20190919 •Page 7 of 15
Model: DS4-2P
12
14
DS4-2P Side/Back View
2
3
4
6
1011
7
8
9
5
13

Preparation
1. Remove all DS4-2P components from
the packaging.
2. Select an area to mount the control box.
Note: The control box should be mounted to a
vertical wall. We recommend mounting the control
box at a height of 6 feet or less.
The chemical suction line must reach the bottom of
the chemical container. The bottom of the chemical
container should not be positioned higher than the
bottom of the control box.
3. Select the area where the stainless steel nozzle
assembly will be mounted.
Note: Consider the foam pattern when selecting the
number of nozzles and location. The foam pattern
dimensions provided in this manual were measured
with nozzle assemblies mounted 6 inches (15 cm)
above the floor. Area of coverage
Assembly
4. Attach the control box mounting feet to the back of
the control box, using the four screws provided in
the parts package.
5. Mount the control box to the wall using four of
the screws and plastic anchors provided in the parts
package.
Note: Use a 5/16 inch drill bit to drill holes for the
plastic anchors.
V20190919 •Page 8 of 15
Model: DS4-2P
3Installation
DS4-2P DS4-2P-2 DS4-2P-3
Area of
coverage
Up to 9 x 5
ft. (2.7 x 1.5
m)
Up to 8 x 4
ft. (2.4 x 1.2
m) at each
nozzle
Up to 6 x 3
ft. (1.8 x 0.9
m) at each
nozzle
6 feet
max
6 inches
3
2
Drills into wall
5
Control box
mounting feet
44
5
4
4
5
5
Drills into
box

6. Mount the stainless steel nozzle assembly in the
desired location.
Fasten the two stainless steel brackets using the
screws and plastic anchors provided in the parts
package. Repeat this step if multiple nozzles are
needed.
7. Connect the tubing from the solution outlet fitting
on the control box to the solution inlet fitting on the
nozzle assembly.
8. Connect the tubing from the air outlet fitting on
the control box to the air inlet fitting on the nozzle
assembly.
Note: For multiple nozzles, run the tubing from the
control box into a tee fitting, as shown in the Tee
Fitting diagram below. Then, run tubing from the tee
fitting to the nozzle assemblies. For systems with
three nozzles, use a second tee fitting to split the
line again.
1/2 in. Union tee fitting diagram
Important! The air and solution lines must be routed
to the appropriate fittings or the foam quality of the
unit will be negatively impacted. Make sure to insert
the tubing all the way into the fittings to ensure
proper connection.
9. Connect the air inlet hose barb provided in the parts
package to the air inlet valve located on the side of
the control box.
Then attach a 3/8 inch I.D. air line from your air
compressor to the air inlet hose barb, and secure it
with the smaller hose clamp provided in the parts
package.
10. Connect a water line to the unit. The control box has
a ½ inch FPT fitting.
Important! A back-flow preventer must be installed
in the water line. Check your local plumbing codes
to ensure proper installation.
V20190919 •Page 9 of 15
Model: DS4-2P
Drills into wall
6
8
7
Control box
Air inlet
fitting
Air tubing
Air outlet fitting
7
8
Solution
inlet fitting
Nozzle assembly
9
Air inlet
Water line
connector
10
Solution
tubing
Out
Connecting the inlet
to the stem of the tee
creates even discharge
from each side.
Out In
Correct Incorrect
Connecting the inlet
to the side of the
tee creates uneven
discharge.
Out
In Out

11. Insert the proper metering tips and connect the
chemical intake lines to the injector inlet barb.
Note: Use the metering tip color chart (below) to
determine the appropriate metering tip based on
the product and dilution rate. The model DS4-2P has
two metering tips and two chemical intake lines.
Metering tip color chart
12. Place the other end of the chemical intake line into a
chemical container.
Note: The chemical suction line must reach the
bottom of the chemical container. A strainer must be
used on the chemical intake line.
13. Set the Timer for the desired ON and OFF time
(see Operation - Timer Setup for instructions).
14. With the power switch in the OFF position, plug the
unit into a GFCI protected 120 VAC power outlet.
* Injection rates will vary based on chemical
viscosity, air pressure, and many other factors. We
recommend testing unit output to verify injection
rate prior to use.
V20190919 •Page 10 of 15
Model: DS4-2P
Metering tip color Oz. / Gal. Ratio*
Tan 1.03 125:1
Orange 1.2 108:1
Turquoise 1.4 90:1
Pink 1.8 70:1
Light Blue 2.3 54:1
Brown 2.5 50:1
Red 3.2 40:1
White 3.5 37:1
Green 3.8 34:1
Blue 4.6 28:1
Yellow 6.6 19:1
Black 8.3 15:1
Purple 14 9:1
Gray 16.5 8:1
None 18.9 7:1
12
14
13
11
Metering tips
Timer

4Operation
Timer Setup
The TR120DS-A is an adjustable repeat cycle timer
with the ON time operating first. ON and OFF times can
range from 1 second to 511 minutes.
To set the timer:
1. Starting with the OFF TIME, move the top dip switch
to the left for MIN (minutes) or to the right for SEC
(seconds) to select the desired time interval.
2. The next 9 dip switches will be used to control the
total active time. To the left is active and to the right
is inactive.
Combine the numbers of active dip switches to
achieve the desired time. The increments are 1, 2, 4,
8, 16, 32, 64, 128, 256.
3. Repeat the above steps for the ON TIME setting.
4. Timer indicator light will appear red when unit
output is o. The indicator turns green when
output is on.
Operation
1. Verify that the unit is connected to compressed air,
water, power, and chemical.
2. Open the compressed air inlet valve.
3. To activate the unit, turn the power switch ON.
The unit will begin cycling through the ON time and
OFF time intervals set on the Timer, beginning with
the ON time.
4. While the unit is running and discharging product,
adjust the needle valve, as needed to
regulate the wetness or dryness of the foam
following the steps below:
a. Close needle valve completely in clockwise
direction.
b. Open needle valve in counter-clockwise
direction two (2) complete turns.
c. Continue to open needle valve in ¼ turn
increments, allowing 30 seconds between
adjustments, until desired consistency of foam
is achieved.
5. To deactivate the unit, turn the power switch OFF.
V20190919 •Page 11 of 15
Model: DS4-2P
1
2
4
8
16
32
64
128
256
1
2
4
8
16
32
64
128
256
SEC (o) / MIN (on)
SEC (o) / MIN (on)
MIN/SEC
MIN/SEC
OFF TIME
VALUE
OFF TIME
ON TIME
ON TIME
VALUE
1
2
3
4
ON
35
4
2
Power switch
Air inlet
valve

5Maintenance
Performing any maintenance with the unit turned ON,
plugged into an electrical power source and connected
to the air and water supply may serious injury or
death. Always ensure that the unit has been turned
OFF, unplugged from the electrical power source,
and disconnected from the air/water supply before
conducting any maintenance.
WARNING
!
NOTICE
Servicing, or modification, of this unit with parts not listed
in this manual may cause the unit to operate improperly.
Do not use unauthorized parts when servicing the unit.
To keep your foam unit operating properly, periodically
perform the following maintenance procedures:
• Inspect the pump (P56/P56K/P56V) for wear and
leaks.
• Inspect all hoses for leaks or excessive wear. Make
sure all hose clamps and push-fittings are in good
condition and properly secured.
• Replace the filter (AFR25) located within the air
regulator (R25) as needed. Clean by unthreading
the air regulator bowl (ABR25) from the air regulator
(R25).
• Check the chemical metering tip, suction line and
strainer for debris and clean as needed.
• Drain your air compressor tank on a regular basis
to help extend pump life. An air source with a high
moisture content will accelerate pump wear. Note:
If your air source has a high moisture content, you
may wish to install a water separator (item number
WS-20CFM, sold separately) before the unit.
V20190919 •Page 12 of 15
Model: DS4-2P

6Troubleshooting
Issue Solution
Air Regulator Bowl or Air
Filter has debris such as
water, oil, or rust particles
• Clean by unthreading the air regulator bowl from the air regulator.
Pump is cycling improperly
due to lack of air pressure
• The needle valve is open too far. Close and readjust the needle valve by
opening the compressed air inlet valve.
• Ensure proper foaming chemical and concentration are being used.
The solution backs up into
the air regulator bowl. • The check valve needs to be replaced.
Foam comes out wet, no
matter where the needle
valve is positioned
• Check for proper air pressure on the air gauge. The air regulator is factory set
at 50 psi (3.4 bar). Operating range is 40 to 80 psi (3 to 5 bar) with 3.5 to 8 CFM
(99 to 226.5 l/min).
• The check valve may need to be replaced.
The unit operates at a
reduced pressure
• Check the chemical metering tip, suction line and strainer for debris or damage.
Clean or replace as needed. To prevent damage to the unit, the strainer must
always be used.
• Check the air compressor supplying the unit. If the pressure is less than 40 psi,
turn the unit o until the compressor can catch up.
• If the air supply is 50 psi (3.4 bar) or above, check the air gauge, which should
read near 50 psi (3.4 bar). If the air gauge reads more or less than 50 psi (3.4
bar), adjust the pressure by turning the knob on the top of the air regulator.
• Check for proper water pressure on the water pressure gauge. To check
the pressure:
1. Activate the unit and allow it to run through an on time cycle.
2. During the subsequent o time cycle, check the water pressure gauge.
The pressure should read 30 psi (2.1 bar) during the o time cycle or when
deadheaded.
3. If necessary, adjust the water regulator using the flathead screw on the
regulator body. The water pressure should be set at 30 psi (2.1 bar) when
deadheaded. Setting the pressure higher or lower may damage the unit or
cause it to malfunction.
V20190919 •Page 13 of 15
Model: DS4-2P

7Parts
PB16138-A
WR1A
P56-BRKT
P56, P56K or P56V
HBSSEL1438
PN1238
ACV1D38
CV38-AP
HBELF3838
TR120DS-A
ACV1
WR12SS
R25
SN1414
TS2
NV14Y
SSA12
SSE12
AG100
WRG14
QF1212
SCI-125X2
HBF3812
BVB14
V20190919 •Page 14 of 15
Model: DS4-2P
Control Box Assembly
Item number Description
ACV1 MAC valve 1/4 in. 110vac
ACV1D38 3/8 npt Solenoid valve - 110vac
AG100 1.5 in. Dry model 20 dual scale gauge
BVB14 Air inlet valve - 1/4 in. mpt x 1/4 in. mpt
CV38-AP White pvc check valve 3/8 barbs -
hastelloy spring - teflon ball
NV14Y Flow control valve (with black knob)
P56
Pump with santoprene seals (includes
hose barbs, air fitting, and exhaust
barb)
P56K Pump with kalrez seals (includes hose
barbs, air fitting, and exhaust barb)
P56V Pump with viton seals (includes hose
barbs, air fitting, and exhaust barb)
Item number Description
PB16138-A 16 X 13 x 8 polypropylene control
box assembly
QF1212 Quick fit - 1/2 mpt x 1/2 od tube
(polypropylene)
R25 Air regulator - 1/4 fpt two port 1/8 fpt
two port (includes filter and bowl)
SCI-125X2 Stainless chemical injector - .125 orifice
- dual barb - 3/8 mpt
TR120DS-A Repeat cycle timer - adjustable
digi-set - 120vac part
TS2 Toggle switch spst
WR12SS Water pressure regulator - stainless
steel - 1/2 inch fpt (includes gauge)
WR1A 18/3 Power cord with grounded plug -
9 ft. long (black)

Nozzle Assembly
Adjustable nozzle detail
Item number Description
ABTN12 1/2 mpt x 1/2 fpt adjustable ball socket
(polypropylene)
ABTNTB12 1/2 mpt threaded ball for ABTN12
(polypropylene)
CV12F7-AP
1/2 Check valve 7 lb. spring - hastelloy
spring - ep seals - acid proof - blk/wht
chk
H12CP 1/2 in. od polyethylene tubing (natural
color)
HHSB11412 Hex head stainless bushing 1-1/4 mpt x
1/2 fpt
QF1212 Quick fit-1/2 mpt x 1/2 od tube
(polypropylene)
QF12 Union tee 1/2 in. tube (polypropylene)
SN1212 Stainless hex nipple 1/2 mpt x 1/2 mpt
SSE12 Street elbow 1/2 in. (316 series s.s.)
SSFT Stainless foam tube 1-1/2 fpt - 9-1/2 in
long
SSFTB Stainless foam tube bracket
SSMESH Stainless steel mesh (1 pc)
SSST Screen disc .687 dia. 10 X 10 mesh @
.020 dia. (300 series s.s.)
SST12 Stainless tee 1/2 fpt
ST80100SS Spray tip - 80 degree - 10.0 gpm -
stainless - 1/2 mpt
ST80200SS Spray tip - 80 degree - 20.0 gpm-
stainless - 1/2 mpt
ST8060-1/2SS Spray tip - 80 degree - 6.0 gpm -
stainless - 1/2 mpt
V20190919 •Page 15 of 15
Model: DS4-2P
ST80200SS, ST80100SS or ST8060-1/2SS
Note: Spray tip size varies based on
number of nozzle assemblies used - see
specifications chart for more information.
ABTN12
ABTNTB12
This unit includes an adjustable ball-type
nozzle that may be installed to hold the
spray tip as shown.
QF1212
CV12F7-AP
SN1212
HHSB11412
SSE12
SSFT
QF1212
HHSB11412
SST12
SSE12
SN1212