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Zep

Zep C4 Entryway Foam System

uctionInstruction Manual

Installation Instructions

W59901 Stand Alone Unit

W60301 Pump Fed Unit

Water (40-80 PSI, Minimal 5 GPM)Premix Solution (40-80 PSI, Minimal 5 GPM)

Compressed Air (30-100 PSI, 7 SCFM), Clean and DryCompressed Air (30-100 PSI, 7 SCFM), Clean and Dry

Electricity

(15 A, 120 VAC)

Electricity

(15 A, 120 VAC)

W59901 Stand Alone UnitW60301 Pump Fed Unit(1) C 4 Foamer Unit1) C 4 Foamer Unit(1) 5 Feet ¾ Blue Discharge hose(1) 5 Feet ¾ Blue Discharge hose(1) 6 Feet ¼” Clear Pick-Up Hose w/Strainer ---(1) Metering Tip Kit---(2) Foam Nozzles Assemblies(2) Foam Nozzles Assemblies

You will need ¾”Sch. 80 pipe, ¾ hose clamps, mounting hardware, and fittings to connect the water/solution

and compressed air supplies to complete the installation (not included).

Page.2

Open the shipping box and check the contents. If you are missing any parts, please contact your ZEP representative.

2. Determine how many nozzles you will need to cover the doorway. Doors up to 5 feet wide require one nozzle; doors from 5 feet up to 10 feet wide require two nozzles.

Construct a foam header around the door using ¾”PVC fittings and PVC pipe are not (included) for two nozzle system,

build the header symmetrically to produce balanced flow and pressure between the nozzles.

4. Mount the C 4 unit on the wall near the door. Connect the discharge of the C 4 unit to the header with a short piece of the ¾” discharge hose barb adapters (

included) and the hose clamps (not included).

5. Connect the water supply (stand alone unit) or premixed solution supply (pump fed unit) and compressed air supply water to right side ½”NPT air lift side ¼”

NPT.

Water supply

Air supply

Minimal 7 CFM

120 VAC

Concentrate solution

C 4 Single Doorway Set Up

City pressure minimal 40 PSI Ideal. 60-70 PSI

Water supply

Air supply

Minimal 7 CFM

120 VAC

Concentrate solution

C 4 Double Doorway Set Up

City pressure minimal 40 PSI. Ideal 60-70 PSI

Page 3

Safety & Operational Precautions

When connecting to a potable water supply follow all local codes for backflow prevention.

For proper performance do NOT modify, substitute nozzle, hose diameter or length.

Manufacturer assumes no liability for the use or misuse of this unit.

Wear protective clothing, gloves and safety goggles when working with chemicals.

Always direct the discharge away from people and electrical devices.

Never

leave inlet ball valves on when unit is not in use

.

.

Follow

the chemical manufacturer's safe handling instructions.

NEVER mix chemicals without

first

consulting chemical manufacturer.

Ball Valve

Ball Valve

Lt Brown

0.25 512.0

Orange 0.50 256.0

Lt Green 0.75 170.7

Purple 1.00

128.0

Lt Blue

1.50

85.3 Peach

2.00 64.0 Red 3.00 42.7 Blue 4.00 32.0 Gray 5.00 25.6 Brown 7.00 18.3 Black 10.00 12.8 Dk Green 13.00

9.8

Pink 18.00 7.1

Yellow

22.00 5.8 White 25.00

5.1

Metering Tip Chart for the C 4 Entryway foam Sanitizer Gray Injector Body

Zep Product #

W29301

Page.4

3 GPM

OZ/GAL

RATIO

NOTE;

it is always best to determine the actual flow rate though flow the injector and base your Calculation on that result. It is also recommended that you confirm your metering tip

choice

with a pull test.

1. Thread the

metering tip

into the metering tip adapter on the sanitizer unit. Connect the ¼” pick up hose to the metering tip adapter and place the strainer into the product container.

2. Open the sanitizer unit and close the

needle valve by turning the knob to the right until it stops.3. With the OFF-CYCLE switch in the OFF position, press and hold the PRIME button until the ¼‘’ pick-up hose is full and the solution is flowing consistently though the foam nozzle(s).4. Release the PRIME button.5. Check the water pressure Gauge. The water pressure must be at least 40 PSI for the sanitizer unit to operate properly (50-60 PSI is ideal).6. Using the air Pressure regulator and gauge, set the air pressure 10-15 PSI lower than the water pressure. For example, if the water pressure is 60 PSI, set the air pressure at 45 PSI.7. Press and the PRIME button again until the solution is flowing consistently though the foam nozzle(s).8. While pressing the PRIME button, adjust the foam quality by slowly increasing the air volume with the needle valve (DO NOT adjust the air pressure regulator).9. Release the PRIME button and open the panel door to access the cycle timer.10. Turn the outside knob (green) to the desired (off ) time. (The off) time scale is 10 minutes.11. Turn the inside knob (red) to the desired (on) time. The (on)

time scale is 10 seconds.

Page. 5EXAMPLE: The (off) time is set for 10

minutes; the (on) time is set for 7-8 seconds.12.

Close the panel door and turn the OFF-CYCLE switch to the CYCLE position. The C 4 Entry Foam Sanitizer will now operate automatically. NOTE; The timer will always start with the off cycle when power is supplied.

Problems

12

3456

78910

11121314

Will not draw chemical

x

x

xx

xxxxxPoor foam qualityxxxxxxxxxFoam surges and/or sputtersxxxxxxx

xx

xxx

Foam output too wetx

xxxxx

xxx

x

x

Foam output too dry

x

Water flowing into container

x

Unequal solution flow (2)

nozzles

x

Troubleshooting Guide

Page. 6

Chemical pick-up hose is not immersed in the chemical supply or chemical supply is depleted- Immerse the hose in the chemical or replenish the chemical supply.

Air Pressure/volume is too high for available water pressure – Adjust the air regulator and/or needle valve.

Water pressure is too low – At least 40 PSI is required, increase the water pressure if possible or decrease the air pressure/volume.

Chemical-to-water ratio is too low – Correct the chemical-to-water ratio with a larger metering tip.

Foam hose or pipe is the wrong size or too long – The hose or pipe must be ¾” I.D and no more than 50’ long. Replace it with the correct I.D and/or shorten to overall length.

Inadequate air supply – Open the air inlet valve fully and check the needle valve.

Wrong chemical is being used – Ensure that the chemical is recommended for the application.

Use of a lubricator on the air supply may decrease foam quality – Use only clean, dry air.

Pin hole/cut in the chemical pick-up hose – Replace the hose.

Chemical Strainer or metering tip is blocked – Clean or replace the strainer and/or metering tip.

Chemical check valve is not working – Clean or replace the check valve.

Needle valve or air pressure regulator has failed – Clean or replace the needle valve and/or regulator

Water scale or chemical build-up may have formed in the injector – Remove injector and soak in descaling acid.

14. Foam nozzle branches are not equal in length – Reinstall the hose or pipe so that each nozzle branch is approximately the same length.

Water Gauge ¼ NPT

Part# W61201

Water Solenoid ½ NPT

120 Volt Part # W61401

Injector Body Part # T43001

¼ NPT St Elbow Part # CE00560

¼ NPT Check Valve Part # W51301

Metering Tip Holder Part # CE00532

¼ ID Pick up Hose Part #

S82401 by ft.

Cycle Timer Part # W60901

Page.7

Replaceable Parts Breakdown

¼ NPT Air regulator

Part #W61601

1/8 NPT Air Gauge Part # W61301

6

1/4 NPT Air Solenoid Valve Part # W61101

NPT air

¼ NPT Check Valve Part #

W51301

¼ NPT needle Valve adjustment for foam Quality Part # FM00332

8-Pin Relay Base Part #CE00356

W60101

10 Ft. Power CordW60901

Repeat Cycle TimerW61801 Green Prime Switch

W61901 Green Indicator Light

W62001 Off-Cycle SwitchW62101

8-Pin Relay Base

FM00332

Needle Valve

W62201

Foam NozzlesS82401 ¼ Vinyl Tube (Per Ft.)W62501 Swivel Nozzle HolderCE00536 ½” NPT Wye StrainerW29301 Metering Tip KitW61401 Water Solenoid ½” NPT 120 VACW61101 Air Solenoid ¼” NPT 120 VAC C 4 Parts and Accessories Description

Zep #

Page. 8All parts may be ordered by calling your local ZEP Rep or 877-I-BUY-ZEP (877-428-9937).