USER MANUAL - FOAM-iT | Chemical Management & …foamit.com/storage/resources/DS4_UserManual.pdf · · 2017-04-18USER MANUAL MODEL NUMBER: DS4 DS4K DS4V AND RELATED UNITS Twin-Line

USER MANUALMODEL NUMBER:DS4DS4KDS4VAND RELATED UNITS

Twin-Line Concentrate Doorway Foam Unit

English (Original Instructions)

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User Manual: Twin-Line Concentrate Doorway Foam Unit | English

READ ALL INSTRUCTIONS BEFORE OPERATING EQUIPMENT

Model No.: DS4, DS4K, DS4V

Read this manual completely and understand the machine before operating or servicing it.• Readallinstructionsbeforeinstallingoroperatingunit.• Alwayswearappropriatepersonalprotectiveequipment

(PPE)whenoperatingorservicingunit.• Alwaysfollowallchemicalsafetyprecautionsand

handlinginstructionsprovidedbythechemicalmanufacturerandSafetyDataSheet(SDS).

• Ifthisunitismodifiedorservicedwithpartsnotlistedinthismanual,theunitmaynotoperatecorrectly.

• Donotexceedanincomingairpressureof100psi(7bar).

• Donotexceedafluidtemperatureof100˚F(37˚C).• Alwaysflushtheunitwithfreshwaterfor5minutes

whenswitchingfromanalkalinetoanacidoranacidtoanalkaline.

• Neveruseunitwithhydrocarbonsorflammableproducts.

• Onlyusecleananddryair.Airmustbefilteredandfreeofmoistureorpumplifewillbediminished.Ifneeded,installanairdryerbeforeunit.

• Donotuseanairlubricatorbeforetheunit.• Neveruseunitifitisdamagedorleaking.• Disconnectunitfromelectricalpowersourcebefore

servicing.

WARNING

PROTECT THE ENVIRONMENTPleasedisposeofpackagingmaterials,oldmachinecomponents,andhazardousfluidsinanenvironmentallysafewayaccordingtolocalwastedisposalregulations.

Alwaysremembertorecycle.

*Specificationsandpartsaresubjecttochangewithoutnotice.

OPTIONSPump Seal Material Number of Nozzles

DS4

Santoprene(standard)

-

One (standard)Viton (V) Two (2)

Kalrez(K) Three (3)Addboldoptioncodestoitemnumberasshown.Forstandardoptions,nooptioncodeisneeded.Examples:• DS4(standardunitwithSantoprenepumpsealsandone

nozzle)• DS4-2(unitwithSantoprenepumpsealsandtwo

nozzles)• DS4V-2(unitwithVitonpumpsealsandtwonozzles)

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COMPLETE SYSTEMSItem Number: DS4 DS4-2 DS4-3Includes: Controlboxandonenozzle

assemblyControlboxandtwonozzleassemblies

Controlboxandthreenozzleassemblies

Spraytip: ST80200 ST80100 ST8060-1/2Foampattern: Upto9x5ft.(2.7x1.5m) Upto8x4ft.(2.4x1.2m)ateach

nozzleUpto6x3ft.(1.8x0.9m)ateachnozzle

Tubing(H12CP)included:

50ft.(15.2m) 100ft.(30.4m) 150ft.(45.7m)

Teefittings(QFT12)included:

0 2 4

REPLACEMENT NOZZLE ASSEMBLIESItem Number: GK7T GK7T-2 GK7T-3Includes: OnenozzleassemblywithST80200

spraytipOnenozzleassemblywithST80100spraytip,plusoneextraST80100spraytip

OnenozzleassemblywithST8060-1/2spraytip

Intendeduse: Replacementnozzlefora1-nozzlesystem

Replacementnozzlefora2-nozzlesystem,orconversionkittoturnanexisting1-nozzlesystemintoa2-nozzlesystem

Replacementnozzlefora3-nozzlesystem

Spraytip: ST80200 ST80100(alsoincludesanextratiptoretrofitanexistingnozzle)

ST8060-1/2

Tubing(H12CP)included:

50ft.(15.2m) 50ft.(15.2m) 50ft.(15.2m)

Teefittings(QFT12)included:

0 2 4

System Overview:Onecontrolboxcansupportuptothreenozzleassemblies.Thecombineddistancebetweenthecontrolboxandthenozzle(s)mustequal100ft.(30.5m)orless.

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SPECIFICATIONSPowertype Compressedair,electricityChemicalpickuptype DrawsfromconcentratedproductDilutionratiorange(water:chemical)*

38:1to183:1

Numberofproductsunitcandrawfrom(andwhetheritdrawssimultaneouslyoroneatatime)

Oneproduct

Suctionlinelength/diameter 8ft.(2.4m)clearhosewith1/4in.(6.4mm)insidediameterFlowrate* 2gal/min(7.6l/min)Pumpseals Santoprene,Viton,orKalrezTimeroperationtype RepeatcycleCoveragearea Withonenozzle:upto9x5ft.(2.7x1.5m);

Withtwonozzles:upto8x4ft.(2.4x1.2m)ateachnozzle;Withthreenozzles:upto6x3ft.(1.8x0.9m)ateachnozzle

Fantip Withonenozzle:ST80200;Withtwonozzles:ST80100;Withthreenozzles:ST8060-1/2

Nozzletype Twin-linestainlesssteelnozzleassembly(GK7T)Numberofnozzles OnecontrolboxcansupportuptothreenozzleassembliesDistancefromnozzlestocontrolbox

Thecombineddistancebetweenthecontrolboxandthenozzle(s)mustequal100ft.(30.5m)orless.

Tubing/fittingsizes Designedforusewith1/2in.(12.7mm)outsidediametertubingbetweencontrolboxandnozzle(s)

*Dilutionratesandflowratesgivenarebasedonchemicalwithviscosityofwaterandfactoryairpressuresettings.

REQUIREMENTSCompressedairrequirements 40-80psi(3-5bar)with5-10cfm(141.6-283.3l/min)Waterrequirements 10-100psi(0.69-6.9bar)

Backflowpreventionisrequired–consultlocalplumbingordinancesformoreinformation.Liquidtemperaturerange 40-100˚F(4.4-37˚C)Electricalrequirements 120VACat60Hz,2amps(GFCIprotectedoutlet)Operatingvoltage 120VACChemicalcompatibility Chemicalproductsusedwiththisequipmentmustbeformulatedforthistypeofapplication

andcompatiblewithunitmaterialsandpumpseals.Formoreinformationonchemicalcompatibility,consultthemanufacturerorSDSforyourproductorcontactourcustomerservicedepartment.

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Installation Instructions:1. Removeallcomponentsfrompackaging.2. Selectanareatomountthecontrolbox.

Note:Thecontrolboxshouldbemountedtoaverticalwall.Werecommendmountingthecontrolboxataheightof6feetorless.Thechemicalsuctionlinemustreachthebottomofthechemicalcontainer.Thebottomofthechemicalcontainershouldnotbepositionedhigherthanthebottomofthecontrolbox.

3. Attachthecontrolboxmountingfeettothebackofthecontrolbox,usingthefourscrewsprovidedinthepartspackage.

4. Mountthecontrolboxtothewallusingfourofthescrewsandplasticanchorsprovidedinthepartspackage.Note:Todrillholesfortheplasticanchors,usea5/16inchdrillbit.

5. Mountthestainlesssteelnozzleassemblyinthedesiredlocation,usingtwostainlesssteelbrackets(SSFTB)andfourofthescrewsandplasticanchorsprovidedinthepartspackage.Repeatasneededformultiplenozzles.Note:Thefoampatterndimensionsprovidedinthismanualweremeasuredwithnozzleassembliesmounted6in.(15cm)abovethefloor.

6. Runtubingfromthesolutionoutletfittingonthecontrolboxtothesolutioninletfittingonthenozzleassembly.Formultiplenozzles,runthetubingfromthecontrolboxintoateefitting(QFT12),asshowninthediagram.Then,runtubingfromtheteefittingtothenozzleassemblies.Forsystemswiththreenozzles,useasecondteefittingtosplitthelineagain.

7. Runtubingfromtheairoutletfittingonthecontrolboxtotheairinletfittingonthenozzleassembly.Formultiplenozzles,splitthelineusingoneormoreteefittings(QFT12),asdescribedinstep6andshowninthediagram.Note:Theairandsolutionlinesmustberoutedtotheappropriatefittings(aslabeled),orthefoamqualityoftheunitwillbenegativelyimpacted.Makesuretoinsertthetubingallthewayintothefittingstoensureproperconnection.

TEE FITTING (QFT12) DIAGRAM

IN

OUT

OUT

IN

OUT OUT

Correct Incorrect

IN

OUT

OUT

IN

OUT OUT

Correct Incorrect

Connectingtheinlettothestemoftheteecreatesevendischarge

fromeachside

Connectingtheinlettoonesideoftheteecreatesuneven

discharge

8. Connecttheairinlethosebarb(HBSS1438)providedinthepartspackagetotheairinletvalve(BVB14)locatedonthesideofthecontrolbox.Thenattacha3/8inchI.D.airlinefromyouraircompressortotheairinlethosebarb,andsecureitwiththesmallerhoseclampprovidedinthepartspackage.

9. Connectawaterlinetotheunit.Thecontrolboxhasa1/2inchFPTwaterinletfitting(SSA12).Note:Aback-flowpreventermustbeinstalledinthewaterline–checklocalplumbingcodestoensureproperinstallation.

10.Openthecoverofthecontrolbox.Insertthepropermeteringtipandconnectthechemicalintakelinetotheinjectorinletbarb.Note:Usetheincludedmeteringtipcolorcharttodeterminetheappropriatemeteringtipbasedontheproductanddilutionrateyouwillbeusing.

11.

INJECTION RATESMETERING TIP COLOR OZ./GAL. RATIO*TAN 0.70 183-1ORANGE 0.90 142-1TURQUOISE 1.15 111-1PINK 1.55 83-1LIGHTBLUE 1.80 71-1

BROWN 1.85 69-1RED 2.65 48-1WHITE 3.40 38-1

**Injectionrateswillvarybasedonchemicalviscosity,airpressure,andmanyotherfactors.Werecommendtestingunitoutputtoverifyinjectionratepriortouse.

Placetheotherendofthechemicalintakelineintoachemicalcontainer.Note:Thechemicalsuctionlinemustreachthebottomofthechemicalcontainer.Astrainermustbeusedonthechemicalintakeline.

12.Setthetimerforthedesiredontimeandofftime,asdescribedinthetimeradjustmentinstructions.

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13.

TIMER ADJUSTMENT INSTRUCTIONS

120 VAC INPUT

OUT TOSOLENOIDS

FOA

M-IT

PN: TR

120DS-A

MIN

SEC

SEC

23

-+

1120 VA

C IN

LOA

D O

UT

1 2 4 8 16 32 64 128 256

GR

EE

N = O

UTP

UT O

N R

ED

= OU

TPU

T OFF

OFF TIM

E

ONMIN

CO

MB

INE

SW

ITCH

ES

FOR

TOTA

L TIME

ON

TIME

OFF

OFF

ON

1 2 4 8 16 32 64 128 256

TIMER ADJUSTMENT INSTRUCTIONS: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.

1: Starting with the ON time, move the top dip switch to the left for SEC (seconds) or to the right for MIN (minutes) to set the desired time interval.

2: The next 9 dip switches will be used to control the total active time. To the left is inactive and to the right is active. Combine the numbers next to the active dip switches to achive the desired time.

3: Repeat the above steps for the OFF time setting.

TheTR120DS-AisanadjustablerepeatcycletimerwiththeONtimeoperatingfirst.ONandOFFtimescanrangefrom1secondto511minutes.

To set the timer:1. StartingwiththeONtime,movethetopdipswitchtotheleft

forSEC(seconds)ortotherightforMIN(minutes)toselectthedesiredtimeinterval.

2. Thenext9dipswitcheswillbeusedtocontrolthetotalactivetime.Totheleftisinactiveandtotherightisactive.Combinethenumbersnexttotheactivedipswitchestoachivethedesiredtime.

3. RepeattheabovestepsfortheOFFtimesetting.

WiththepowerswitchintheOFFposition,plugtheunitintoaGFCIprotected120VACpoweroutlet.

Operation Instructions:1. Verifythattheunitisconnectedtocompressedair,water,

power,andchemical.2. Openthecompressedairinletvalve(BVB14).3. Toactivatetheunit,turnthepowerswitchON.The

unitwillbegincyclingthroughtheontimeandofftimeintervalssetonthetimer,beginningwiththeontime.

4. Whiletheunitisrunninganddischargingproduct,adjusttheneedlevalve(NV14Y),locatedinsidethecontrolbox,asneededtoregulatethewetnessordrynessofthefoamfollowingthestepsbelow:a. Closeneedlevalve(NV14Y)completelyinclockwise

direction.b. Openneedlevalve(NV14Y)incounter-clockwise

direction2completeturns.c. Continuetoopenneedlevalvein¼turnincrements,

allowing30secondsbetweenadjustments,untildesiredconsistencyoffoamisachieved.

5. Todeactivatetheunit,turnthepowerswitchOFF.

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Maintenance Instructions:Tokeepyourfoamunitoperatingproperly,periodicallyperformthefollowingmaintenanceprocedures:Note:Beforeperforminganymaintenance,ensurethattheunithasbeenturnedOFF,unpluggedfromtheelectricalpowersource,anddisconnectedfromtheair/watersupply.• Inspectthepump(P56/P56K/P56V)forwearandleaks.• Inspectallhosesforleaksorexcessivewear.Makesureall

hoseclampsandpush-fittingsareingoodconditionandproperlysecured.

• Replacethefilter(AFR25)locatedwithintheairregulator(R25)asneeded.Cleanbyunthreadingtheairregulatorbowl(ABR25)fromtheairregulator(R25).

• Checkthechemicalmeteringtip,suctionlineandstrainerfordebrisandcleanasneeded.

• Drainyouraircompressortankonaregularbasistohelpextendpumplife.Anairsourcewithahighmoisturecontentwillacceleratepumpwear.Note:Ifyourairsourcehasahighmoisturecontent,youmaywishtoinstallawaterseparator(itemnumberWS-20CFM,soldseparately)beforetheunit.

Troubleshooting Instructions:• Checktheairregulatorbowl(ABR25)andairfilter(AFR25)

fordebrissuchaswater,oil,orrustparticles.Cleanbyunthreadingtheairregulatorbowl(ABR25)fromtheairregulator(R25).

• Iftheneedlevalve(NV14Y)isopentoofar,thepump(P56/P56K/P56V)maycycleimproperlyduetolackofairpressure.Ifthisoccurs,closeandreadjusttheneedlevalve(NV14Y)asdescribedinOperationInstruction#2.

• Makesureproperfoamingchemicalandconcentrationarebeingused.

• Ifairpassesthroughthepump(P56/P56K/P56V)withoutcycling,thepumpneedstobereplaced.

• Ifsolutionbacksupintotheairregulatorbowl(ABR25),thecheckvalve(CV38)needstobereplaced.

• Iffoamcomesoutwet,nomatterwheretheneedlevalve(NV14Y)ispositioned,thecheckvalve(CV38)mayneedtobereplaced.

• Checkforproperairpressureontheairgauge(AG100).Theairregulator(R25)isfactorysetat50psi(3.4bar).Operatingrangeis40to80psi(3to5bar)with3.5to8CFM(99to226.5l/min).

• Iftheunitoperatesatareducedpressure: o Checktheaircompressorsupplyingtheunit.Ifthepressureislessthan40psi,turntheunitoffuntilthecompressorcancatchup.

o Iftheairsupplyis50psi(3.4bar)orabove,checktheairgauge(AG100),whichshouldreadnear50psi(3.4bar).Iftheairgaugereadsmoreorlessthan50psi(3.4bar),adjustthepressurebyturningtheknobonthetopoftheairregulator(R25).

• Checkthechemicalmeteringtip,suctionlineandstrainerfordebrisordamage.Cleanorreplaceasneeded.Topreventdamagetotheunit,thestrainermustalwaysbeused.

• Checkforproperwaterpressureonthewaterpressuregauge(WRG14).Tocheckthepressure:

o Activatetheunitandallowittorunthroughanontimecycle.

o Duringthesubsequentofftimecycle,checkthewaterpressuregauge(WRG14).Thepressureshouldread30psi(2.1bar)duringtheofftimecycleorwhendeadheaded.

o Ifnecessary,adjustthewaterregulatorusingtheflatheadscrewontheregulatorbody.Thewaterpressureshouldbesetat30psi(2.1bar)whendeadheaded.Settingthepressurehigherorlowermaydamagetheunitorcauseittomalfunction.

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PBFT-PP

CC8463

TS2PLATE

TS2TSBT12

SN1414

CC3224BVB14

WR1A

PB16138-LATCH

R25DT

TR120DS-A

TS2

SN1414

R25

ACV1

SN1414

AG100

QF1212

NV14Y

FWP78

SSE12

SSA12

WR12SS

WRG14

P56-BRKT-SCREW

CV38

HBSSEL1438

HBF3812

PN1238

P56-BRKT

P56, P56K or P56V

ACV1D38

P203CT

HBELF3838

CONTROL BOX ASSEMBLY

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NOZZLE ASSEMBLY

SSE12

SSE12

QF1212

CV12F7-AP

HHSB11412

SN1212

SSFT

ST80200, ST80100 or ST8060-1/2

SST12

QF1212

HHSB11412

SN1212

(Spraytipsizevariesbasedonnumberofnozzleassembliesused-seespecifcationschartformoreinformation.) ABTN12

ABTNTB12

NOZZLE ASSEMBLY DETAILThisunitincludesanadjustableball-typenozzlethatmaybeinstalledtoholdthespraytipasshown.

PARTS INFORMATION - LEGACY/DISCONTINUED COMPONENTS

LEGACYPARTSDIAGRAM

PEL34F

HHSB34GH12

SSA12

WR15G34

PN3834ITEM NUMBER DESCRIPTIONHHSB34GH12 STAINLESSHEXHEADBUSHING3/4inMGHBY1/2FPT

PEL34F 3/4inFEMALEPOLYPIPEELBOW90

PN3834 POLYREDUCERNIPPLE3/8inMPTX3/4inMPT

WR15G34 WATERPRESSUREREGULATOR-3/4inFGHBY3/4inMPTBodyABS,internalparts,SS,PPandSanto

LEGACYPARTSLISTLEGACY WATER REGULATOR ASSEMBLY

Conversion kit to upgrade to current water inlet: CK-WR12SS.

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ITEM NUMBER DESCRIPTION

ABTN12 ADJUSTABLEBALL-TYPENOZZLE1/2inNPT

ABTNTB12 1/2inTHREADEDBALLFORABTN12

ACV1 MACVALVE1/4in110VAC

ACV1D38 110VACSOLENOIDVALVE3/8in

AG100 1.5INCHDRYMODEL20DUALSCALEGAUGE

B10321 10-32X1PHILTRUSSMACHSCR18-8

B10321.25 10-32X11/4PHILTRUSSMACH18-8

BVB14 AIRINLETVALVE-VABRS025-4F4F-BT,NICKEL

CC3224 LTCBLACK1/2NPT

CC8463 1/2inNPTBLACKLOCKNUT

CV12F7-AP 1/2CHECKVALVE7LBSPRING-HASTELLOYSPRING-EPSEALS-ACIDPROOF-BLK/WHTCHK

CV38 PVCCHECKVALVE3/8BARBS-SSSPRING

EC14-2 OETIKERCLAMP13.8

FWLG14 .569IDX1.28ODX.08THICKFLATWASHERSS18-8

FWP12 7/8IDX1.5ODX0.05THKSSFW

FWP78 7/8inBY.137BY11/4inFLATWASHER18-8PLN

H12CP 1/2INODPOLYETHYLENETUBING-NATURAL-Availableperft.

H14B-H 1/4INCHBLUEHOSE-Availableperft.

H38B-H 3/8INCHBLUEHOSE-Availableperft.

HBELF3838 HOSEBARBELBOW3/8”BYFPT3/8”

HBF3812 HOSEBARB3/8XFEMALEPIPETHREAD1/2IN

HBSS1438 STAINLESSHOSEBARB1/4MPTX3/8BARB

HBSSEL1438 STAINLESSHOSEBARBELBOW1/4NPTX3/8HOSEBARB

HBSSEL1814 304STAINLESSELBOW1/8INCHNPTX1/4INCHHOSEBARB

HHSB11412 HEXHEADSTAINLESSBUSHING11/4INBY12IN

NV14Y FLOWCONTROLVALVE-INCLUDESBLACKKNOB

NV14Y-HNDL BLACKKNOBFORNEEDLEVALVE-2839-1/4

P203CT PLASTICINJECTORKITINCLUDESINJECTOR-INTAKEHOSE-FOOTSTRAINERANDWEIGHT-TIPKIT

P56 5700PUMPWITHSANTOPRENESEALS-INCLUDESHOSEBARBS,AIRFITTING,ANDAIRPORT

P56K 5700PUMPWITHKALREZSEALS-INCLUDESHOSEBARBS,AIRFITTING,ANDAIRPORT

P56V 5700PUMPWITHVITONSEALS-INCLUDESHOSEBARBS,AIRFITTING,ANDAIRPORT

20756103B PolyproG57AirPortxHBStraight,w/Vitono-ring

HB14P 1/4inBRASSHBAIRFITTING/G57/P56

HB5638 HOSEBARBFORP56PUMP

HB5638K HOSEBARBFORP56KPUMP

HB5638V HOSEBARBFORP56VPUMP

P56-BRKT PUMPBRACKET-STAINLESSSTEEL

P56-BRKT-SCREW

HILOSCREWFORRETAININGP56-BRKT

PB16138 POLYPROPYLENECONTROLBOX-WORKINGDIMS16x13x8-PUMPMOUNT

PB16138-GSKT NEOPRENEGASKET0.220INCHROUNDCORDSTOCK-61.125INCHES

PB16138-LATCH

LATCHFORPB16138

PB16138-PIN STAINLESSSTEELHINGEPINFORCONTROLBOXPB16138

PBFT-PP MOUNTINGFEETFORPOLYBOX-PB16138-POLYPROPYLENE

PL16138 POLYPROPYLENE-16x13x8-HINGEDLOCKABLELID

PN1238 1/2inMPTX3/8inMPTPOLYNIPPLE

QF1212 MALECON.1/2inTUBEX1/2inMPT-POLYPROPYLENE

QFT12 UNIONTEE1/2inTUBE-POLYPROPYLENE

R25 AIRREGULATOR-1/4fptTWOPORT1/8fptTWOPORT-INCLUDESFILTERANDBOWL

AFR25 AIRFILTERforR25

ABR25 METALAIRBOWLforR25

R25DT CLEARTUBINGFORR25DRAIN

S1034FHL 10X3/4PHILFLATHI-LOTHRDSCREW18-8

SN1212 1/2inHEXSTAINLESSSTEELNIPPLE

SN1414 STAINLESS1/4MPTX1/4MPTNIPPLE

SSA12 STAINLESSMALE/FEMALES.S.ADAPTOR1/2inX1/2in

SSC38 WORMGEARCLAMP,S/S(.25-.63)

SSE12 STREETELBOW1/2in-316S.S.

SSFT StainlessSteelFoamTube11/2in@8INCHCUT

SSFTB STAINLESSSTEELFOAMTUBEBRACKET

SSMESH STAINLESSSTEELMESH

SSST [email protected]

SST12 1/2inFPT304S.S.TEE

ST80100 VEEJETNOZZLE,80100

ST80200 VEEJETNOZZLE,80200

ST8060-1/2 1/2INCHVEEJETNOZZLE,BRASS8060

TR120DS-A REPEATCYCLETIMER-ADJUSTABLEDIGI-SET-120VAC

TS2 TOGGLESWITCHSPST

TS2PLATE ON/OFFSWITCHPLATE

TSBT12 TOGGLESWITCHBOOT

WCB14F 14-16-1/4FEMINSULATEDCONNECTOR

WCB14FY 10-12-1/4inFEMALEINSULATEDCONNECTOR

WMS14 14X11/4HEXW/HSMSSLOTT,S/S

WMS14A 5/16X11/2STRAIGHTPLASTICANCHOR

WR12SS WATERPRESSUREREGULATOR-STAINLESSSTEEL-1/2INCHFPT

WR1A 18/3SJOOW90BLACKN.A.W/5-15P&7inROJ

WRG14 WATERPRESSUREREGULATORGAUGEFORWR12SS

Documents

USER MANUAL - FOAM-iT | Chemical Management & …foamit.com/storage/resources/DS4_UserManual.pdf · · 2017-04-18USER MANUAL MODEL NUMBER: DS4 DS4K DS4V AND RELATED UNITS Twin-Line