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Foam Brush freeze up. Only one though. Thoughts?

It could be possible that you have a leaking solenoid that is filling the purged line after it purges. It sometimes can take hours or over night.
 
OK,
So, the normally Open Dema solenoid is likely not closing fully (like I've never seen THAT happen) when the system switches to winter foam.
This would allow "contamination" of the winter foam diluting the freeze protection. Meaning you're likely getting a weaker than desired protection package.

Combine that with the 8' of unheated trough and...

The reason I asked about the pump cycling when the car wash is idle? The liquid solenoid for that bay may have a very tiny leak. This, will cause the FloJet to send an occasional pulse of juice into the foam brush supply line for that bay. And with a diluted winter mixture, the unheated trough, and subfreezing temps, the next morning that one brush is frozen...all the way up to the heated portion of the trough.
 
Couple of ways to test my theory:

#1. Swap the liquid lines from the culprit bay with the adjacent bay. Close those 2 bays overnight. Next morning check to see if the problem moved. Bad thing is, you're gonna have to thaw the bay...again!

#2. Raise the set point of the controller to 70 degrees. If equipped, close the manual outlet valve on the summer formula blend tank.
No valve? Pinch the hose closed with a pair of ViseGrips. Now, the system will ALWAYS deliver from the winter formula tank with no chance of dilution. Next morning check to see if the problem is solved. If YES, replace the Normally Open Dema Solenoid.
 
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