DS4-2P Concentrate Doorway Foam Unit
“
Specifications
- Model: DS4-2P
- Supports up to three nozzle assemblies
- Maximum combined distance between control box and nozzle(s):
100 ft. (30.5 m)
Product Information
The DS4-2P series of Twin-Line Concentrate Doorway Foam Units is
designed for use with 2-part products. It is a versatile system
that offers multiple configurations to suit various needs. The unit
ensures efficient and controlled application of chemical
solutions.
Product Usage Instructions
Safety Precautions
Before operating the unit, ensure that all users and service
technicians have read and understood the user manual. Always wear
proper protective clothing, gloves, and eye protection to prevent
injuries from chemical exposure. Avoid using the unit if damaged or
leaking.
Chemical Handling
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.
Avoid mixing incompatible chemicals to prevent hazardous
reactions.
Operation Guidelines
1. Ensure the unit is turned OFF and disconnected from power and
air/water supply before conducting any maintenance.
2. Maintain incoming air pressure below 100 psi (6.9 bar) to
prevent pressure buildup and potential hazards.
3. Use only compatible non-flammable products with the unit to
avoid fire or explosion risks.
4. Flush the unit thoroughly with fresh water when switching
between alkaline and acid solutions to prevent chemical
reactions.
FAQ
Q: How many nozzle assemblies can be supported by the DS4-2P
unit?
A: The DS4-2P unit can support up to three nozzle
assemblies.
Q: What is the maximum combined distance allowed between the
control box and the nozzles?
A: The maximum combined distance between the control box and the
nozzle(s) should not exceed 100 ft. (30.5 m).
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Twin-Line Concentrate Doorway Foam Unit for 2-Part Products
User Manual DS4-2P
READ ALL INSTRUCTIONS BEFORE USING OR SERVICING THIS UNIT. KEEP THIS MANUAL IN A LOCATION THAT IS READILY AVAILABLE TO USERS AND SERVICE TECHNICIANS.
English (Original Instructions)
Scan this code for user manual
Safety
! WARNING
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 (37.8°C) may result in scalding, burns, serious injury or death. DO NOT use a solution with a temperature above 100°F (37.8°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 (6.9 bar) may result in pressure buildup, explosion, serious injury or death. DO NOT exceed 100 psi (6.9 bar) incoming air pressure when operating 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 thoroughly when switching from an alkaline to an acid or an acid to an alkaline.
Model: DS4-2P
V20250807 · Page 2 of 14
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. 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
Model: DS4-2P
V20250807 · Page 3 of 14
Product Overview
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.
Item no. Pump seal material 2-Part Products Number of nozzles
Santoprene
2P
DS4
Viton (V)
2P
Kalrez (K)
2P
One (Standard) Two (2) Three (3)
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
Items included
Number of nozzle assemblies
Type of spray tip
Length of tubing 1/2 in. OD tubing 1/2 in. union tee fittings
DS4-2P
Control box and one nozzle assembly 80° fan pattern, 20 GPM flow rate
50 ft. (15.2 m)
0
DS4-2P-2
Control box and two nozzle assemblies 80° fan pattern, 10 GPM flow rate
100 ft. (30.4 m)
2
DS4-2P-3
Control box and three nozzle assemblies 80° fan pattern, 6 GPM flow rate
150 ft. (45.7 m)
4
Model: DS4-2P
V20250807 · Page 4 of 14
Requirements
Compressed air requirements
Water requirements
Liquid temperature range Electrical requirements Operating voltage
Chemical compatibility
40-80 psi (2.8-5.5 bar) with 5-10 cfm (141.6-283.2 l/min)
30-100 psi (2.1-6.9 bar) Backflow prevention is required. Consult local plumbing ordinances for more information.
40-100°F (4.4-37.8°C)
120 VAC at 60 Hz, 2 amps (GFCI protected outlet)
120 VAC
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.
Specifications
Power type
Compressed air, electricity
Chemical pickup type
Dilution ratio range (water:chemical)*
Number of products unit can draw from
Suction line length/diameter
Draws from concentrated product 7:1 to 125:1 Note: Dilution rate can be set independently for each product
Two products, simultaneously
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
· One nozzle: up to 9×5 ft. (2.7×1.5 m)
Coverage area
· Two nozzles: up to 8×4 ft. (2.4×1.2 m) at each nozzle
· Three nozzles: up to 6×3 ft. (1.8×0.9 m) at each nozzle · One nozzle: ST80200SS
Fan tip
· Two nozzles: ST80100SS
Nozzle type
· Three nozzles: ST8060-12SS Twin-line stainless steel nozzle assembly
Number of nozzles
One control box can support up to three nozzle assemblies
Distance from nozzles to control box
Tubing/fitting sizes
The combined distance between the control box and the nozzle(s) must equal 100 ft. (30.5 m) or less
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.
Model: DS4-2P
V20250807 · Page 5 of 14
Component Overview
Before you begin get to know the DS4-2P components that you will need to use, adjust or assemble.
2
3 1
6
4
11
10
5
1. Control box
2. Timer
3. Needle valve
4. Power cord
5. Water inlet
6. Dual injector
7. Suction lines
8. Nozzle bracket
8
9. Stainless steel nozzle assembly
10. Solution outlet fitting
11. Air outlet fitting
12. Power switch
13. Air inlet
9
14. Control box mounting feet
Model: DS4-2P
7
12 13
14 DS4-2P Side/Back View
V20250807 · Page 6 of 14
Installation
Preparation
1. Remove all DS4-2P components from 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
2
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.
6 feet max
3
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.
Assembly
Area of coverage
DS4-2P
6 inches
DS4-2P-2 DS4-2P-3
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.
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
Control box
5 mounting feet
5 Drills into wall
4
4
Drills into box
Model: DS4-2P
4 4 5 5
V20250807 · Page 7 of 14
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
Correct
Out
Out
Incorrect
In
Out
6
Control box
Drills into wall
9
Air inlet
In
Out
Connecting the inlet to the stem of the tee creates even discharge
from each side.
Connecting the inlet to the side of the
tee creates uneven discharge.
Air outlet fitting
8
7
Air tubing
10 Water line
connector
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.
8
Air inlet fitting
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.
Nozzle assembly
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.
Model: DS4-2P
Solution tubing
7
Solution inlet fitting
V20250807 · Page 8 of 14
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
Metering tip color
Tan Orange Turquoise Pink Light Blue Brown Red White Green Blue Yellow Black Purple Gray None
Oz. / Gal. Ratio*
1.03
125:1
1.2
108:1
1.4
90:1
1.8
70:1
2.3
54:1
2.5
50:1
3.2
40:1
3.5
37:1
3.8
34:1
4.6
28:1
6.6
19:1
8.3
15:1
14
9:1
16.5
8:1
18.9
7:1
* 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.
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.
Timer
Metering tips
11
13 14
12
Model: DS4-2P
V20250807 · Page 9 of 14
Using your unit
Timer Setup
The timer 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 off. The indicator turns green when output is on.
MIN/SEC OFF TIME
VALUE MIN/SEC ON TIME
VALUE
ON
SEC (off) / MIN (on) 1
1
2 4
OFF TIME 2
8
16
32
64
128
256
SEC (off) / MIN (on)
1 2
ON TIME 3
4
8
4
16
32
64
128
256
Operating Instructions
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.
53
Power switch
2
Air inlet valve
4
Model: DS4-2P
V20250807 · Page 10 of 14
Service Guide
! WARNING
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. 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.
Maintaining Your Unit
To keep your foam unit operating properly, periodically perform the following maintenance procedures: · Inspect the pump for wear and leaks. · Inspect all hoses for leaks or excessive wear. Make sure all hose clamps are in good condition and properly secured. · Replace the filter located within the air regulator as needed. Clean by unthreading the air regulator bowl from the air regulator. · 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, install a water separator (sold separately) before the unit.
Model: DS4-2P
V20250807 · Page 11 of 14
Troubleshooting Your Unit
If your unit is not operating properly, try using these troubleshooting tips:
Issue
Solution
Air Regulator Bowl or Air Filter has debris such as water, oil, or rust particles Pump is cycling improperly due to lack of air pressure The solution backs up into the air regulator bowl. Foam comes out wet, no matter where the needle valve is positioned
The unit operates at a reduced pressure
· Clean by unthreading the air regulator bowl from the air regulator.
· 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 check valve needs to be replaced.
· 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 (2.8 to 5.5 bar) with 3.5 to 8 CFM (99.1 to 226.5 l/min).
· The check valve may need to be replaced. · 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, (2.8 bar) turn the unit off 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 off time cycle, check the water pressure gauge.
The pressure should read 30 psi (2.1 bar) during the off time cycle or when dead-headed. 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 dead-headed. Setting the pressure higher or lower may damage the unit or cause it to malfunction.
Model: DS4-2P
V20250807 · Page 12 of 14
Parts
Control Box Assembly
PBA-16138 BRKT-P56
P56, P56K or P56V
CV38-AP HBSSEL1438
PN1238 FCV38-120VAC
HBELF3838 SCI-125X2 HBF1238
QF1212
TMR-RPT-120VAC R25 TSW-BDY
AG100
BVB14
ACV14120VAC SN1414
NV14
WR1838-WPLG
SSE12
WRG14
WR12SS-WRG-RH
SSA12
Item number
Description
ACV14-120VAC
Air control valve – MAC – 1/4 in. FPT in – 2x 1/4 in. FPT out aluminum body – 120 VAC solenoid – normally closed 18 in. 18 AWG flying leads
AG100
Air gauge – 1/8 in. NPT – 0-100 PSI markings – dry model
BVB14
Ball valve – brass – nickel plated – air inlet valve 1/4 in. FPT x 1/4 in. FPT
CV38-AP
Check valve – 3/8 in. barbs – PVC body – Hastelloy spring – Teflon ball – white
FCV38-120VAC
Fluid control valve – DEMA – 3/8 in. FPT – 7 GPM polypropylene body – Viton diaphragm – 120 VAC solenoid – normally closed – 18 in. 18 AWG flying leads
NV14
Needle valve – ¼ in. NPT – includes black knob
P56
Pump with Santoprene seals – includes hose barbs, air fitting, exhaust barb
P56K
Pump with Kalrez seals – includes hose barbs, air fitting, exhaust barb
P56V
Pump with Viton seals – includes hose barbs, air fitting, exhaust barb
Item number
Description
PBA-16138
Poly box assembly – 16 in. x 13 in. x 8 in. gray polypropylene – includes brand label and mounting hardware
QF1212
Quick fit – 1/2 MPT x 1/2 od tube – polypropylene
R25
Regulator – air – 2x 1/4 in. FPT and 2x 1/8 in. FPT ports with bowl and filter – no gauge
SCI-125X2
Stainless chemical injector – 2 product – 2x 3/8 in. MPT – 1/4 in. hose barbs – DEMA rocket series – 2x 0.125 in. orifice – dark green – 3.7 GPM @ 100 PSI accepts MT832 metering tips
TMR-RPT-120VAC
Timer – repeat cycle – seconds and minutes adjustable digi-set – 120 VAC – screw terminal block includes instructions
TSW-BDY
Toggle switch – body – single pole single throw nickel-plated brass – 1/4 in. spade terminals – 1/2 in. mounting hole – 15/32-32 keyed Threaded bushing
WR12SS-WRG-RH
Water pressure regulator – stainless steel – FKM seals – 1/2 in. FPT – assembled with gauge facing left for use on right side of box
WR183-8-WPLG
Wire cord with us standard unpolarized grounded plug – 18awg 3 conductor – 8ft long – black rubber jacket – epdm insulation – type SJOOW – 10A rating
Model: DS4-2P
V20250807 · Page 13 of 14
Nozzle Assembly
QF1212 SST12 SN1212 HHSB11412
W114F912
QF1212 CV12F7 SN1212 SSE12
HHSB11412 SSE12
Adjustable nozzle detail
This unit includes an adjustable ball-type nozzle that may be installed to hold the spray tip as shown.
NZMNT12-BDY NZMNT12-BL
Item number
Description
BRKT-W114
Bracket – stainless steel – for mounting 1 1/4 in. discharge wand
CV12F7
1/2 Check valve 7 lb. spring – Hastelloy spring – EP seals – acid proof – blk/wht chk
HHSB11412
Hex head stainless bushing 1-1/4 MPT x 1/2 FPT
NZMNT12-BDY
Nozzle mount body – 1/2 in. MPT black and gray polypropylene accepts nozzle mount ball
NZMNT12-BL
Nozzle mount ball – 1/2 in. FPT – black polypropylene – for nozzle mount body
PRCH-MXSS-MSH
Mixing media – stainless – ball as purchased
QF1212
Quick fit – 1/2 MPT x 1/2 od tube polypropylene
SN1212
Stainless hex nipple 1/2 MPT x 1/2 MPT
SSE12
Stainless street elbow – 304 stainless steel – 1/2 in. FPT x 1/2 in. MPT
STRD114
Strainer – 316 stainless disc – 1 1/4 in. dia #20 mesh
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
ST8060-12SS
Spray tip – 80 degree – 6.0 GPM stainless – 1/2 MPT
TB12N-PE
1/2 in. od natural tube – polyethylene available per ft.
W114F912
1 1/4 in. FNPT and 1 1/4 in. FNPT foam tube polished stainless – 9 1/2 in. long
ST80200SS, ST80100SS or ST8060-12SS Note: Spray tip size varies based on number of nozzle assemblies used – see specifications chart for more information.
Model: DS4-2P
V20250807 · Page 14 of 14
Documents / Resources
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Twin-Line DS4-2P Concentrate Doorway Foam Unit [pdf] User Manual DS4-2P Concentrate Doorway Foam Unit, DS4-2P, Concentrate Doorway Foam Unit, Doorway Foam Unit, Foam Unit, Unit |