FOAMit DS3K Single Line Concentrate Doorway Foam Unit User Manual

FOAMit DS3K Single Line Concentrate Doorway Foam Unit

Product Information

Specifications

• Model Number: DS3, DS3K, DS3V
• Power Type : Compressed air, electricity
• Chemical Pickup Type: Draws from concentrated product
• Dilution Ratio Range (water:chemical): 38:1 to 183:1
• Number of Products Unit Can Draw From: One product
• Suction Line Length/Diameter: 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:
  • With one nozzle: up to 9×4 ft. (2.7×1.5 m)
  • With two nozzles: up to 5×3 ft. (2.4×1.2 m) at each nozzle
• Fan Tip: ST8070SS
• Nozzle Type: Single-line nozzle assembly (GK6T)
• Number of Nozzles: One control box can support up to two nozzle assemblies
• Distance from Nozzles to Control Box: The combined distance between the control box and the nozzle(s) must equal 25 ft. (7.62 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)

Installation Instructions

1. Remove all 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 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.

FAQ

• What are the compressed air requirements?
  The compressed air requirements are 40-80 psi (3-5 bar) with 5-10 cfm (141.6-283.3 l/min).

• What are the water requirements?
  There are no specific water requirements mentioned in the user manual.

• What is the electrical requirement?
  The electrical requirement is 120 VAC at 60 Hz, 2 amps (GFCI protected outlet).

• What is the 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.

WARNING
Read this manual completely and understand the machine before operating or servicing it.

• Read all instructions before installing or operating unit.
• Always wear appropriate personal protective equipment (PPE) when operating or servicing unit.
• Always follow all chemical safety precautions and handling instructions provided by the chemical manufacturer and Safety Data Sheet (SDS).
• If this unit is modified or serviced with parts not listed in this manual, the unit may not operate correctly.
• Do not exceed an incoming air pressure of 100 psi (7 bar).
• Do not exceed a fluid temperature of 100˚F (37˚C).
• Always flush the unit with fresh water thoroughly when switching from an alkaline to an acid or an acid to an alkaline.
• Never use unit with hydrocarbons or flammable products.
• Only use clean and dry air. Air must be filtered and free of moisture or pump life will be diminished. If needed, install an air dryer before unit.
• Do not use an air lubricator before the unit.
• Never use unit if it is damaged or leaking.
• Disconnect unit from electrical power source before servicing.

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.
• Always remember to recycle.
• *Specifications and parts are subject to change without notice.

OPTIONS
Add bold option codes to item number as shown. For standard options, no option code is needed.
Examples:

• DS3 (standard unit with Santoprene pump seals and one nozzle)
• DS3K (unit with Kalrez pump seals and one nozzle)
• DS3V (unit with Viton pump seals and one nozzle)

REQUIREMENTS

• Compressed air requirements 40-80 psi (3-5 bar) with 5-10 cfm (141.6-283.3 l/min)

• Water requirements 10-100 psi (0.69-6.9 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.

SPECIFICATIONS

• Model Number: DS3, DS3K, DS3V
• Power Type : Compressed air, electricity
• Chemical Pickup Type: Draws from concentrated product
• Dilution Ratio Range (water:chemical): 38:1 to 183:1
• Number of Products Unit Can Draw From: One product
• Suction Line Length/Diameter: 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:
  • With one nozzle: up to 9×4 ft. (2.7×1.5 m)
  • With two nozzles: up to 5×3 ft. (2.4×1.2 m) at each nozzle
• Fan Tip: ST8070SS
• Nozzle Type: Single-line nozzle assembly (GK6T)
• Number of Nozzles: One control box can support up to two nozzle assemblies
• Distance from Nozzles to Control Box: The combined distance between the control box and the nozzle(s) must equal 25 ft. (7.62 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)

Installation Instructions

1. Remove all 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 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. Attach the control box mounting feet to the back of the control box, using the four screws provided in the parts package.

4. Mount the control box to the wall using four of the screws and plastic anchors provided in the parts package. Note: To drill holes for the plastic anchors, use a 5/16 inch drill bit.

5. Mount the nozzle assembly in the desired location, using the stainless steel bracket, four of the screws, and plastic anchors provided in the parts package. Repeat as needed for multiple nozzles.
   Note: The foam pattern dimensions provided in this manual were measured with nozzle assemblies mounted 6 in. (15 cm) above the floor.

6. Run tubing from the solution outlet fitting on the control box to the solution inlet fitting on the nozzle assembly. For multiple nozzles, run the tubing from the control box into a tee fitting (QFT12), as shown in the diagram. Then, run tubing from the tee fitting to the nozzle assemblies.

7. 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.

8. Connect a water line to the unit. The control box has a 1/2 inch FPT water inlet fitting.
   Note: A back-flow preventer must be installed in the water line – check local plumbing codes to ensure proper installation.

9. Open the cover of the control box. Insert the proper metering tip and connect the chemical intake line to the injector inlet barb.
   Note: Use the included metering tip color chart to determine the appropriate metering tip based on the product and dilution rate you will be using.

10. 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.

11. Set the timer for the desired on time and off time, as described in the Timer Adjustment Instructions on the next page.

12. With the power switch in the OFF position, plug the unit into a GFCI protected 120 VAC power outlet.

Operation 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, located inside the control box, as needed to regulate the wetness or dryness of the foam following the steps below:
   • Close needle valve completely in clockwise direction.
   • Open needle valve in counter-clockwise direction 2 complete turns.
   • 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.

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.
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.

Maintenance Instructions

To keep the unit operating properly, periodically perform the following maintenance procedures:
Note: Before performing any maintenance, ensure that the unit has been turned OFF, unplugged from the electrical power source, and disconnected from the air/water supply.

• Inspect the pump 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 located within the air regulator as needed. Clean by unthreading the air regulator bowl from the air regulator.
• Inspect mixing material in foam nozzle for chemical build up or material breakdown. Remove mixing material by untreading the solution inlet fitting on the nozzle. Replace with new mixing material if necessary.
• 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 (sold separately) before the unit.

Troubleshooting Instructions

• Check the air regulator bowl and air filter for debris such as water, oil, or rust particles. Clean by unthreading the air regulator bowl from the air regulator.
• If the needle valve is open too far, the pump may cycle improperly due to lack of air pressure. If this occurs, close and readjust the needle valve as described in Operation Instruction #2.
• Make sure proper foaming chemical and concentration are being used.
• If air passes through the pump without cycling, the pump needs to be replaced.
• If solution backs up into the air regulator bowl, the check valve needs to be replaced.
• If foam comes out wet, no matter where the needle valve is positioned, the check valve may need 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 (3 to 5 bar) with 3.5 to 8 CFM (99 to 226.5 l/min).
• If the unit operates at a reduced pressure:
  • Check the air compressor supplying the unit. If the pressure is less than 40 psi, 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 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 for proper water pressure on the water pressure gauge. To check the pressure:
  • Activate the unit and allow it to run through an on time cycle.
  • 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 deadheaded.
  • 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.

CONTROL BOX ASSEMBLY

NOZZLE ASSEMBLY

PARTS INFORMATION – LEGACY/DISCONTINUED COMPONENTS

LEGACY WATER REGULATOR ASSEMBLY

LEGACY PARTS DIAGRAM

LEGACY PARTS LIST

• HHSB34GH12 STAINLESS HEX HEAD BUSHING 3/4in MGH BY 1/2 FPT
• PEL34F 3/4in FEMALE POLY PIPE ELBOW 90
• PN3834 POLY REDUCER NIPPLE 3/8in MPT X 3/4in MPT
• WR15G34 WATER PRESSURE REGULATOR – 3/4in FGH BY 3/4in MPT Body ABS, internal parts, SS, PP and Santo
• ACV1 MAC VALVE 1/4in 110VAC
• ACV1D38 3/8 NPT SOLENOID VALVE – 110VAC
• AG100 AIR GAUGE-1/8IN NPT-100 PSI DRY MODEL
• B10321.25 10-32 X 1 1/4 PHIL TRUSS MACH 18-8
• BRKT-P56 PUMP BRACKET- STAINLESS STEEL
• BVB14 AIR INLET VALVE-1/4IN FPT X 1/4IN FPT
• CB-5 5 AMP CIRCUIT BREAKER-UL1077
• CB-B CLEAR BOOT FOR CIRCUIT BREAKER
• CC3224 1/2 NPT STRAIN RELIEF GRIP FITTING – BLACK
• CC8463 1/2 NPT LOCKNUT – BLACK
• CV38-AP CHECK VALVE-3/8IN BARBS-PVC BODY-HASTELLOY SPRINGTEFLON BALL-WHITE
• EC14 OETIKER EAR CLAMP FOR 1/4IN HOSE
• FWLG14 FLAT WASHER-0.569 ID X 1.28 OD X .078 THK-18-8 SS
• FWP12 7/8 ID X 1.5 OD X 0.05 THK SSFW
• FWP78 FLAT WASHER-7/8 F/W-.937 ID X 1.75 OD X .134 THK-18-8 SS
• H12C 1/2in CLEAR POLYVINYL TUBING
• H12CP 1/2IN OD POLYETHYLENE TUBING – NATURAL COLOR
• H14BL-F 1/4IN BLUE HOSE-HYBRID TPE-AVAILABLE PER FT
• H38BL-F 3/8IN BLUE HOSE-HYBRID TPE-AVAILABLE PER FT
• HB1238 1/2in MPT X 3/8in HOSE BARB
• HBELF3838 HOSE BARB ELBOW 3/8″ BY FPT 3/8″
• HBSS1438 STAINLESS HOSE BARB 1/4 MPT X 3/8 BARB
• HBSSEL1438 STAINLESS HOSE BARB 1/4 MPT X 3/8 BARB ELBOW
• HBSSEL1814 STAINLESS HOSE BARB 1/8 MPT X 1/4 BARB ELBOW
• NV14 NEEDLE VALVE-1/4IN NPT-INCLUDES BLACK KNOB
• NV14-HNDL BLACK KNOB FOR NEEDLE VALVE
• P203CT PLASTIC INJECTOR KIT INCLUDES INJECTOR – INTAKE HOSE –
• FOOT STRAINER AND WEIGHT – TIP KIT
• 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
• 20756103B Polypro G57 Air Port x HB Straight, w/ Viton o-ring
• HB14P 1/4in BRASS HB AIR FITTING /G57/P56
• HB5638 HOSE BARB FOR P56 PUMP
• HB5638K HOSE BARB FOR P56K PUMP
• HB5638V HOSE BARB FOR P56V PUMP
• PB16138 POLYPROPYLENE CONTROL BOX – WORKING DIMS 16x13x8 – PUMP MOUNT
• PBFT-PP MOUNTING FEET FOR POLYBOX – PB16138 – POLYPROPYLENE
• PB-LTCH POLY BOX LATCH FOR PB16138 AND PB12117
• PB-PIN STAINLESS STEEL HINGE PIN FOR PB16138 AND PB12117
• PL16138 CONTROL BOX LID 16X13X8-POLYPROPYLENE-HINGED LOCKABLE LID-INCLUDES GASKET-WITH LABEL
• PN1238 1/2in MPT X 3/8 in MPT POLY NIPPLE
• PW1210 1/2IN FPT X 1/2IN FPT-10IN LONG-BLACK POLYPRO
• QF1212 QUICK FIT-1/2 MPT X 1/2 OD TUBE-POLYPROPYLENE
• R25 AIR REGULATOR-TWO 1/4IN FPT PORTS-TWO 1/8IN FPT
• PORTS-INCLUDES FILTER AND BOWL
• AFR25 AIR FILTER for R25
• ABR25 METAL AIR BOWL for R25
• R25DT 3/16 X 5/16 CLEAR PVC TUBING – Available per ft.
• S1012-HL 10-16 X 1/2 IN SCREW-STAINLESS-HI LO
• S1034FHL 10 X 3/4 PHIL FLAT HI-LO THRD SCREW 18-8
• SEL14F S.S. ELBOW 1/4in FPT X 1/4in FPT
• SN1412 1/4IN X 1/2IN MPT STAINLESS NIPPLE
• SN1414 STAINLESS HEX NIPPLE 1/4 MPT X 1/4 MPT
• SSA12 STAINLESS ADAPTOR 1/2 MPT X 1/2 FPT
• SSC38 STAINLESS SCREW BAND CLAMP FOR 3/8 IN HOSE
• SSE12 STREET ELBOW 1/2in – 316 S.S.
• SSLB 14 14GA SS BRACKETS W/SLOTS
• ST8070SS SPRAY TIP-80 DEGREE-7.0 GPM-STAINLESS-1/4 MPT
• T5 1/2 POLY TEE
• TR120DS-A-P REPEAT CYCLE TIMER – ADJUSTABLE DIGI-SET – 120 VAC PART
• TS2 TOGGLE SWITCH SPST
• TS2PLATE ON/OFF SWITCH PLATE
• TSBT12 TOGGLE SWITCH BOOT
• TW916 1/2 INT TOOTH L/W 410SS
• WAAD-1X3 1IN X 3IN WADDING FOR FOAM UNITS-BROWN
• WCB14F 14-16 – 1/4 FEM INSULATED CONNECTOR
• WCB14FY 10-12 – 1/4in FEMALE INSULATED CONNECTOR
• WMS14 14 X 1 1/4 HEX W/H SMS SLOTT, S/S
• WMS14A 5/16 X 1 1/2 STRAIGHT PLASTIC ANCHOR
• WR12SS WATER PRESSURE REGULATOR – STAINLESS STEEL – 1/2 INCH FPT
• WR1A 18/3 POWER CORD WITH GROUNDED PLUG-9FT LONGBLACK
• WRG14 WATER PRESSURE REGULATOR GAUGE FOR WR12SS

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