DEMA DILUTION-AT-HAND EXTREME
800 Series Chemical Dispensers
Overview
The DILUTION-AT-HAND EXTREME chemical dispenser series combines the proven technology
of the DEMA DILUTION-AT-HAND with a new look and modular chemical enclosures.
The dispenser series accurately dilutes chemical concentrates with water and dispenses the diluted
mixture at either a high flow rate to fill buckets and scrubbers or a low flow rate to fill bottles and
small containers.
Each dispenser can be set up to meet specific application needs with the ability to offer:
High and low flow dispensing
2 Liter or 1 Gallon (5 Liter) chemical cabinets
Selector valve option to dispense more than
one chemical per dispensing unit
Bottle filling or bucket filling
Option of a remote gun for bucket or scrubber
filling
Dilution ratios up to 3:1 for low flow
dispensing and up to 7:1 for high flow
dispensing
Supplied metering tips allow for leaner ratios
of dilution
Warnings
All installations must conform to local plumbing codes and use approved backflow
prevention devices. A pressure indicating tee is to be installed with existing faucets
according to local plumbing codes in the state of Wisconsin and any other state that
requires the use of a pressure indicting tee.
ALWAYS WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN
WORKING WITH CHEMICAL PRODUCTS.
I-951 Page 1 of 8
Rev. C-37524 1/16/12
Packing List
Part
Number
L1107
100-15K
61-107-2
98-42-2 TUBE 1 1 1 1 2 1 1 1 1 2 1
100-16E-1
100-16E-3
66-21K KEY SET 1 1 1 1 1
89-10-1 DRIP TRAY 1 1 1 2 1
Description
CHEMICAL
LABELS
METERING
TIP KIT
SMALL
CERAMIC
WEIGHT
TUBING &
FOOT VALVE
1/4" X 8'
TUBING &
FOOT VALVE
1/4" X 32"
801GAP
1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 4 4 1 4 2 5 2 5 5 2 2
1 4 1 4 2 5 2 5
1 4 5 2 2
803GAP
801GAP-S2L
803GAP-Q2L
802GAPRF
820GAP
804GAPRF
830GAP
822GAPRF
830GAPRF
830GAP-Q2L
820GAP-D2L
822GAP-S2L
89-30-GAP
89-30-AG
98-46-3
66-53-4
66-52
OUTLET
TUBING
HANGER
HOSE ASSY
OUTLET
TUBE 1/2" X
6'
MOUNTING
SCREW
WALL
ANCHOR
1 1 1
1 1 1
2 2 2 8 2 2 4 4 4 4 8 4 2
2 2 2 8 2 2 4 4 4 4 8 4 2
Operational Requirements
Minimum Maximum
Water Pressure 20 psi (1.38 bar) 125 psi (8.62 bar)
Water Temperature - 150ºF (65.5ºC)
Water Supply Requirements
I-951 Page 2 of 8
Rev. C-37524 1/16/12
Overall Size
Installation
Mounting
Dispenser Only
1. Remove selector knobs (if installed) by pulling on the knobs.
2. Remove the dispenser cover by depressing the tab on the top of the cover.
3. Position the dispenser on the wall and mark the screw locations.
4. Chemical containers can be no greater than 6’ (1.83 meters) below the dispenser.
5. Install the supplied anchors in the wall.
6. Mount the dispenser to the wall with the supplied screws.
7. Replace the cover and any selector knob.
I-951 Page 3 of 8
Rev. C-37524 1/16/12
Dispenser with Chemical Cabinets
1. Open the door(s) of the chemical cabinet(s) using the supplied key.
2. Position the dispenser on the wall and mark the screw locations.
3. Install the supplied anchors in the wall. Use two anchors and two screws for each
chemical cabinet.
4. Mount the dispenser to the wall with the supplied screws.
Metering Tips & Chemical Supply Tubes
1. Each dispenser is supplied with at least one metering tip
kit. Chose the appropriate color metering tip based on the
supplied chemical induction chart.
2. Remove any selector knobs (if installed) by pulling on the
knobs.
3. Remove the dispenser head by depressing the tab on the top
of the cover.
4. Screw the metering tip into the chemical barb on the
dispenser head.
5. Cut to length the chemical supply tube to remove excess
tubing.
6. Install a supplied ceramic weight onto the tube.
7. Push the tubing onto the proportioner barb.
8. Replace the cover and any selector knobs
9. Place the ceramic weight, tubing, and foot valve into the
chemical.
Water Supply
1. Water supply must have a pressure between 20 psi (1.38 bar) and 125 psi (8.62 bar).
2. Attach a garden hose to the water inlet of the unit.
Table 1: “Action Gap”/Proportioner Induction Flow Rates w/Standard 1/4" Barb and Tubing
Metering
Tip
Color
Tan
Orange
Turquoise
Pink
Light Blue*
Brown
Red
White
Green
Blue
Yellow
Black
Purple
Gray
No Tip
(1 GPM Flow Rate Action Gap Proportioner)
Injection Rates For Viscosities Shown
1 cps 75 cps 200 cps 1 cps 75 cps 200 cps
Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio
1.03 125-1 0.76 168-1 0.38 333-1 0.33 387-1 0.26 500-1 0.12 1090-1
1.24 103-1 0.98 130-1 0.53 241-1 0.42 307-1 0.32 430-1 0.17 735-1
1.43 89-1 1.07 119-1 0.61 211-1 0.51 251-1 0.34 382-1 0.19 676-1
2.47 52-1 1.58 81-1 0.92 139-1 0.78 165-1 0.56 230-1 0.3 422-1
3.05 42-1 2.1 61-1 1.06 121-1 0.87 147-1 0.67 192-1 0.33 391-1
3.48 37-1 2.31 55-1 1.15 111-1 0.99 129-1 0.74 174-1 0.37 345-1
4.38 29-1 2.83 45-1 1.23 104-1 1.37 93-1 0.91 141-1 0.44 289-1
5.33 24-1 3.1 42-1 1.37 93-1 1.52 84-1 1.04 123-1 0.48 264-1
6.38 20-1 3.63 35-1 1.4 91-1 1.72 74-1 1.22 105-1 0.52 244-1
6.77 19-1 3.78 34-1 1.45 88-1 2.13 60-1 1.27 101-1 0.54 239-1
9.90 13-1 5.1 25-1 1.48 86-1 3.05 42-1 1.71 75-1 0.56 229-1
15.00 9-1 6.54 20-1 1.53 84-1 4.50 28-1 1.96 65-1 0.57 224-1
24.94 5-1 7.28 18-1 1.57 82-1 7.75 17-1 2.4 53-1 0.59 217-1
35.94 4-1 8.5 15-1 1.64 78-1 9.86 13-1 2.54 50-1 0.63 204-1
73.21 2-1 9.35 14-1 1.87 69-1 19.63 7-1 3.16 40-1 0.67 190-1
(4 GPM Flow Rate Action Gap Proportioner)
Injection Rates For Viscosities Shown
I-951 Page 4 of 8
Rev. C-37524 1/16/12
Table 2: “Air Gap” Proportioner Induction Flow Rates w/Standard 1/4" Barb and Tubing
164 BAG (1 GPM Flow Rate Air Gap Proportioner)
Metering
Tip
Color
Tan
Orange
Turquoise
Pink
Light Blue*
Brown
Red
White
Green
Blue
Yellow
Black
Purple
Gray
No Tip
Note: All induction flow rates are based on a water pressure of 40 psi.
Leaner dilutions can be achieved by ordering DEMA ultra lean metering tip kit 100-15KU.
*Metering tip color was formerly clear.
Service Note: Standard size ¼” hose barbs and metering tips that come with this model are used for water thin (1cps) products.
Ratios as low as parts-per-million, can be achieved with the use of a capillary metering tip. More viscous products (75cps – 200cps)
may require larger 3/8” hose barbs and metering tips. If you are having difficulty achieving the ratio you require, call DEMA and ask
for the technical department.
Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio Oz/Gal Ratio
1.25 102-1 0.90 142-1 0.60 213-1 0.30 427-1 0.20 640-1 0.15 853-1
1.70 75-1 1.20 107-1 0.80 160-1 0.40 320-1 0.30 427-1 0.25 512-1
2.15 60-1 1.55 83-1 1.10 116-1 0.60 213-1 0.40 320-1 0.30 427-1
3.00 43-1 2.00 64-1 1.50 85-1 0.80 160-1 0.50 256-1 0.40 320-1
3.90 33-1 2.75 47-1 1.80 71-1 1.00 128-1 0.70 183-1 0.45 284-1
4.55 28-1 3.00 43-1 2.00 64-1 1.20 107-1 0.80 160-1 0.50 256-1
5.80 22-1 3.60 36-1 2.30 56-1 1.50 85-1 0.90 142-1 0.60 213-1
7.00 18-1 4.45 29-1 2.70 47-1 1.85 69-1 1.10 116-1 0.70 183-1
7.90 16-1 5.00 26-1 3.00 43-1 2.00 64-1 1.25 102-1 0.80 160-1
9.80 13-1 5.75 22-1 3.30 39-1 2.50 51-1 1.50 85-1 0.82 156-1
14.80 9-1 7.35 17-1 3.55 36-1 4.00 32-1 1.85 69-1 0.90 142-1
20.15 6-1 8.50 15-1 3.70 35-1 5.50 23-1 2.00 64-1 0.94 136-1
27.80 5-1 9.80 13-1 3.80 34-1 8.80 15-1 2.40 53-1 0.96 133-1
31.60 4-1 10.50 12-1 3.90 33-1 11.65 11-1 2.50 51-1 1.00 128-1
35.70 3.6-1 11.80 11-1 4.50 28-1 16.20 8-1 3.00 43-1 1.20 107-1
Injection Rates For Viscosities Shown
1 cps 75 cps 200 cps 1 cps 75 cps 200 cps
163 BAG (4 GPM Flow Rate Air Gap Proportioner)
Injection Rates For Viscosities Shown
Operation
Dispensing of diluted chemical can be performed in a number of ways
depending on the dispenser.
Lever / Button Activation – The unit can be operated by
pushing up on the lever. This lever can be locked in an “On”
position by depressing the lever inward. To unlock the “On”
position, either depress the lever or push up on the bottle fill
lever.
Bottle Fill Activation – Slide a bottle up to the bottom of the
unit and push up on the shown lever.
Remote Fill Activation - Depress the trigger on the handle of
the remote gun. The remote gun can be locked “On” by sliding
the red lever to one side. To disengage this lever, depress the
trigger.
I-951 Page 5 of 8
Rev. C-37524 1/16/12
Troubleshooting
(Some models may not include all items listed below)
Symptom Probable Cause Remedy
Proportioner fails to draw
chemical properly.
“Air Gap” Proportioner is
dripping or spraying a mist
(fan pattern) of water.
Water valve is not shutting
off completely.
Water valve is leaking. 1. Enclosing tube nut is too loose.
Threaded connections are
leaking water.
Proportioner continues to
draw chemical after water
valve is closed.
1. Insufficient water supply pressure.
2. Foot valve has dirt/chemical build-up.
3. Proportioner metering tip clogged with
dried chemical.
4. Mineral deposits are located on Air
Gap nozzle.
5. Bucket fill (4 GPM) side appears to
have slow flowing water stream.
1. Mineral deposits are located on Air
Gap nozzle.
1. “Sliding lever” return spring may be
missing.
2. “Sliding lever” is not returning all the
way down due to interference between
the sliding lever and either the
chemical supply and/or outlet tubing.
3. Bucket fill outlet hose is catching the
bottom edge of the sliding lever during
normal usage.
2. One or more of the valve o-ring
connections are out-of-position.
Identify each leak before disassembly.
1. The connection between the blend
center and water supply line is too
loose or rubber washer is missing.
2. Backflow prevention devices and/or
proportioners are too loose.
1. Concentrated chemical is positioned
higher than the proportioner.
1. 20 PSI is the minimum allowable pressure. Seek
Plumber if necessary to increase water pressure.
2. Soak in hot water to clean.
3. Soak in hot water to clean interior passages.
4. Soak nozzle and inlet screen in hot water or
product such as CLR to clean mineral deposits.
5. Flow disc assembly must be removed from lower
section of water valve assembly if installed.
1. Soak nozzle and inlet screen in hot water or off
the shelf product such as CLR to clean and remove
mineral deposits.
1. Remove cover and visually check for sliding lever
return spring. Replace if missing.
2. Remove cover and visually check for any tubes
rubbing the sliding lever. Routing of chemical
supply and outlet tubing must not restrict the
movement of the sliding lever. Reroute tubing.
3. Don’t pull the bucket fill outlet hose too tight from
either side otherwise sliding lever may not return
properly.
1. Shut water supply off first. Hand-tighten the
enclosing Hose nut. Do not overtighten w/tool.
2. “O-ring” seals may be pushed out of place or
missing when sub-assembling valve together.
1. Shut water supply off first. Carefully tighten the
female hose coupling on the blend center to the
inlet water supply line. Do not overtighten.
2. Tighten loose connection(s) with tools if
necessary. Do not overtighten if using tools.
1. Move the concentrated chemical so it is lower than
the proportioner.
Parts List (See pages 6-8)
BOTTLE/HOSE FILL APPLICATIONS
NO. PART NO. DESCRIPTION
1 63-35 Magnet
2 98-7-2 Enclosing Tube Nut
3 41-7-25 Enclosing Tube
4 98-41-1 Spring
5 98-24-1 Plunger
6 41-15-10 Diaphragm With Center Hole EPDM
7 98-25-1 Bottle/Hose Repair Kit
8 89-20-1 Flow Disc Assembly (1 GPM only)
I-951 Page 6 of 8
Rev. C-37524 1/16/12
REMOTE FILL APPLICATION
NO. PART NO. DESCRIPTION
1 98-5-2 Nut, Diaphragm
2 98-26-1 Diaphragm Without Center Hole EPDM
3 26-35 O-ring (EPDM)
4 98-15-1 Elbow
5 58-60 #6 Hi Lo Screw ½” Lg. (2 Required)
REMOTE FILL APPLICATION
NO. PART NO. DESCRIPTION
1 98-30-1 Remote Gun Fill Half (R.H.)
2 98-51 Trigger Lock Return Spring
3 98-37-1 Hose Clamp (2 Required)
4 98-38 Valve Assembly
5 98-31-1 Remote Gun Fill Half (L.H.)
6 58-60 #6 Hi Lo Screw ½” Lg.
7 58-102 #6 Hi Lo Screw ¾” Lg. (3 Required)
8 98-50 Remote Fill Assembly
BACK FLOW & PROPORTIONING DEVICES
NO. PART NO. DESCRIPTION
1 61-32BAG-2 Proportioner Assembly (1 GPM)
61-22-3BAG-EL2
2
3 16-30 Action Gap Assembly
4 61-99-2 Proportioner Assembly (1 GPM)
5 61-22-3 Proportioner Assembly (4 GPM)
6 63-96-2V-CK Selector and Knob Assembly (Vit o n)
7 63-82 Tube, 3/16” I.D. Outlet
8 98-43-1 Tube, 9/16” I.D. Outlet
9 98-30-AG Outlet 9/16" I.D. Hose W/Hange r (6' LG)
10 98-42-2 Tube, 1/2” I.D. Outlet
11 89-30-GAP Outlet 1/2" I.D. Hose W/Hanger (6' LG)
12 100-15K Metering Tip Kit (14 Sizes)
13 100-12 /100-12E Hose, 7/32” I.D. x 8’ Lg./7/32” I.D. x 50’ Lg.
14 61-107-2 Ceramic Weight, 3/8” I.D.
15 100-16E Foot Valve Assembly (EPDM)
Proportioner Assembly (4 GPM)
I-951 Page 7 of 8
Rev. C-37524 1/16/12
LABELS, LIFT BUTTON AND COVERS
NO. PART NO. DESCRIPTION NO. PART NO. DESCRIPTION
1 L1107 Chemical Label
2 89-5-1 Lift Button
3 63-36 Lift Button Return Spring
4 L1074 DEMA Label, Small
5 L1075 Selector label, Blank
6 L1108 Selector label, 4-Dilution
7 L1073 DEMA Label, Large
8 89-2-1 Cover, Single (Plain) 17 89-4-6 Cover, Dual (Both Lift Buttons & Both Selectors)
9 89-2-2
Cover, Single (Selector)
10
89-2-3 Cover, Single (Lift Button)
11
89-2-4 Cover, Single (Lift Button & Selector)
12
89-4-1 Cover, Dual (RH Lift Button)
13
89-4-2 Cover, Dual (LH & RH Lift Buttons)
14
89-4-3 Cover, Dual (RH Lift Button & RH Selector)
15
89-4-4 Cover, Dual (Both Lift Buttons & RH Selectors)
16
89-4-5 Cover, Dual (RH Lift Buttons & Both Selectors)
2 LITER AND 1 GALLON (5 LITER) STORAGE BOX ASSEMBLIES
2 LITER
NO.
PART NO.
1 89-11-1 89-11-1 Mounting Support (1for Single & 2 for Dual Unit)
2 44-116-5 44-116-5 #8 Hi-Lo Screws (4 Per Dispenser Unit)
3 44-116-1 44-116-5 #8 Hi-Lo Screws (2 per Mounting Support)
4 81-69 81-69 Cabinet Lock with Key / Key Only (66-21K)
5 89-8-1 89-9-1 Storage Box Door
6 89-10-1 89-10-1 Drip Tray
7 89-6-1 89-7-1 Storage Box Base
8 89-19-1 89-19-1 Door Retaining Clip (2 per Box Assy.)
9 98-40-1 98-40-1 #10 Screw & Anchor Set (Qty. 2 /Set)
10 89-12-1 89-12-1 Box Retaining Clip (2 for 2 Boxes +2 per Box)
11 89-16-1 89-17-1 Single Box Assy. Kit (1 Drip Tray & Mtg. Hardware)
12 89-16-2 89-17-2 Dual Box Assy. Kit (1 Drip Tray & Mtg. Hardware)
13 89-16-3 89-17-3 Triple Box Assy. Kit (1 Drip Tray & Mtg. Hardware)
14 89-16-4 89-17-4 Quad Box Assy. Kit (1 Drip Tray & Mtg. Hardware)
1GALLON
PART NO.
DESCRIPTION
Warranty
Merchandise Returns
No Merchandise will be Returned for Credit Without DEMA’S Written Permission. Returned Merchandise
Authorization Number is Required in Advance of Return.
Product Warranty
DEMA products are warranted against defective material and workmanship under normal use and service for
one year from the date of manufacture. This limited warranty does not apply to any products that have a
normal life shorter than one year or failure and damage caused by chemicals, corrosion, physical abuse, or
misapplication. Rubber and synthetic rubber parts such as “O”-rings, diaphragms, PVC tubing, and gaskets are
considered expendable and are not covered under warr anty. This warranty is extended only to the original
buyer of DEMA products. If products are alte red or repai red without prior approval of DEMA, this war rant y is
void.
Defective units or parts should be returned to the factory with transportation prep aid. If inspection sh ows them
to be defective, they will be repaired or replaced without charge, F.O.B. factory. DEMA assumes no liability
for damages. Return merchandise authorization number must be granted in advance of returned units for repair
or replacement (See “Merchandise Returns” above).
I-951 Page 8 of 8
Rev. C-37524 1/16/12
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