SuperKlean DURAMIX 8000 Manual

DURAMIX 8000
Mixing Unit
INSTALLATION AND
MAINTENANCE MANUAL
◆ PLEASE DO NOT THROW AWAY AFTER INSTALLATION ◆
◆ SAVE AND DISPLAY PROMINENTLY WHERE THIS
EQUIPMENT IS USED ◆
Contents
SafetyInformation..................................................................1
Pre-Installation........................................................................2
Installation...................................................................3-4
Operative Instructions.......................................................5
Maintanance Procedures...............................................6-7
Repair Instructions...............................................................8-11
Duramix 8000 Front View Drawing.................................12
Duramix 8000 Side View Drawing.....................................13
Duramix 8000 Automatic Shut O󰀨 Feature........................14
Duramix 8000 Labeled Parts Diagram.....................................15
Duramix 8000 Replacement Parts List..................................16
FAQ....................................................................................17
Troubleshooting..............................................................18-19

Safety Information
• Never allow children or unauthorized personnel to handle
equipment.
• Never put your hand or ngers in front of nozzle.
• Never point nozzle at your body — or anyone else.
• Never leave wash down station unattended without
• releasing pressure.
• Never use foreign means to hold trigger in open position.
• Never over tighten connections/threads. Use
appropriatesize wrench for tightening connections/
threads. Never use wrench extensions of any type.
• Never reuse gaskets that have been compressed, reuse
may cause unit to leak.
• Never pulse nozzle while operating mixing station.
Before/during nozzle spraying
• Hold nozzle rmly before pulling trigger.
• Adopt a proper body stance to anticipate high recoil force
by spray nozzle.
• Exercise care and caution when spraying.
• When spraying hot liquids avoid hand or body contact
with non-insulated parts of the nozzle.
• Wear protective clothing including heavy- duty insulated
gloves, boots, aprons and safety glasses.
• Stop spraying before becoming fatigued.
Before removing nozzle OR attempting services
• Shut o󰀨 water supplies.
• Discharge contents of hose and nozzle to eliminate
pressure.
Attention: Do not operate the equipment if there are any
leaks from spray nozzle, ttings, or hoses. High pressure
leaks can penetrate the skin causing serious injury.
CAUTION
HIGH
PRESSURE AND
HOT LIQUID
Pre-Installation
1. Unit requires minimum steam pressure of 30 PSI and
a maximum steam pressure of 150 PSI. Pressure
gauge installation (upstream, prior to steam inlet) is
recommended to determine proper and constant steam
pressure during all operation of mixing unit.
2. Unit requires minimum water pressure of 30 PSI and
a maximum water pressure of 150 PSI. Pressure
gauge installation (upstream, prior to water inlet) is
recommended to determine proper and constant water
pressure during all operation of mixing unit.
3. Steam trap is highly recommended (upstream, prior
to steam inlet) to relieve unit of any condensate. If the
steam chamber is lled with condensate, it will not
operate, and requires maintenance.
4. Steam and water supply lines should be thoroughly
ushed prior to installation to rid lines of foreign debris
which can a󰀨ect the performance of the mixing unit.
Strainers are highly recommended, particularly in
facilities with older piping.
5. Remove steam check valve from mixing body by
loosening check valve nut.
6. Make sure that there is no water in steam chamber by
turning mixing unit upside down and letting it drain.
7. Reinstall steam check valve and tighten check valve nut.
8. Check to make sure that both globe valves are fully
closed by turning hand-wheels clockwise until stop.
9. Check to make sure that the temperature control hand
wheel is fully opened by turning it counter-clockwise.
10.Mixing unit is ready to install.
12

Installation
1. Place the mounting plate on the wall and mark the 4
holes to be used to mount the plate to the wall.
2. Drill 12mm or equivalent holes on wall and install anchor
bolts (supplied). Make sure that holes are deep enough
to accomodate anchor bolts so that only the threaded
parts protrude, allowing the mounting plate to be installed
to the wall.
3. Mount plate to wall and secure using anchor bolt nuts
(supplied).
4. Mount mixing unit to plate and loosely secure with two
shorter top bolts (supplied).
5. Mount hose rack to mixing unit and secure with 2 longer
bottom bolts (supplied).
6. Secure unit to mounting plate by tightening all 4
supporting bolts.
7. If temperature gauge was supplied, remove front plug
and install temperature gauge. (Pipe thread sealant
or alternative such as Teon tape is recommended on
temperature gauge thread)
8. The mixing unit is now ready for piping.
9. Install water and steam supply lines to mixing unit inlets.
(Pipe thread sealant or alternative such as Teon tape is
recommended on piping thread)
10.If secondary upper hot water outlet is to be used, install
line to mixing unit top secondary output outlet. (Pipe
thread sealant or alternative such as Teon tape is
recommended on piping thread)
11. Attach hose with 3/4” NPT to outlet of mixing unit. (Pipe
thread sealant or alternative such as Teon tape is
recommended on tting thread).
12.Attach spray nozzle to outlet of hose with 1/2” NPT.
(Pipe thread sealant or alternative such as Teon tape is
recommended on tting thread).
Installation Continued
13.Gradually open cold water globe valve to pressurize
mixing station and check for leaks. If there are visible
leaks, immediately turn globe valve o󰀨, depressurize
mixing unit by spraying nozzle. Disassemble and reseal
leakage points. Once complete, reassemble and restart
procedure to check for leaks. If no more leaks, continue.
If leaks, repeat procedure.
14.Gradually open steam globe valve to pressurize mixing
station and check for leaks. If there are visible leaks,
immediately turn globe valve o󰀨, depressurize mixing unit
by spraying nozzle, allow mixing unit to cool down prior to
disassembly, and reseal leakage points. Once complete,
reassemble and restart procedure to check for leaks. If
no more leaks, continue. If leaks, repeat procedure.
15.With both globe valves fully open, unit is ready for
operation.
3 4
continued

Operative Instructions
Attention: If water pressure is higher than steam pressure,
please refer to section 6 below. If steam to water ratio is
more than 2:1, please refer to section 7 below.
1. Open cold water globe valve to its full open position by
turning hand wheel counter-clockwise.
2. Open steam globe valve to its full open position by
turning hand wheel counter-clockwise.
3. When shutting down unit, steam globe valve should be
shut down rst by turning clockwise and then cold water
globe valve can be shut down by turning clockwise.
DO NOT TURN OFF COLD WATER GLOBE VALVE BEFORE
TURNING OFF STEAM GLOBE VALVE.
4. Begin spray of water by pressing on lever of nozzle.
Make sure to maintain spray during the course of ouput
temperature adjustment of unit.
5. For temperature rise, begin to slowly close temperature
control hand wheel by turning it clockwise. Once you
reach your desired water temperature output, you may
leave the temperature control hand wheel at its current
position and use globe style valves above mixing unit to
shut down operation. To resume operation, simply open
globe style valves to their full open position.
6. If temperature output is too cold after full adjustment of
temperature control hand wheel, begin to choke down
water ow by slowly closing the cold water globe valve.
7. If temperature output is too hot after full adjustment of
temperature control hand wheel, begin to choke down
steam ow by slowly closing the steam globe valve. Once
desired temperature is achieved, loosen bottom nut by
turning clockwise. Begin to tighten top lock nut cap by
turning clockwise, until hand tight. Turn lower lock nut
clockwise until hand tight to secure lock nut cap.
8. If you close the cold water globe valve signicantly and
water temperature output is still sporadic, please check
to see if you meet and maintain the required water and
steam pressure of at least 30 PSI. If problem persists,
call SuperKlean for assistance.
Maintenance Procedures
CAUTION: Check to make sure that steam & cold water
supply globe valves are turned o󰀨 prior to disassembly.
Depressurize mixing unit by spraying nozzle and allow
mixing unit to cool down prior to disassembly. Unit is now
ready for maintenance.
Recommended Maintenance:
Hard Water: Every 3 months
Soft Water: Every 6 months
Water Chamber Cleaning
1. Remove hand wheel nut, lock washer, and name plate
from temperature control hand wheel located on the right
side of the unit.
2. Gently tap hand wheel outward and then wiggle o󰀨 by
hand.
3. Remove water chamber cover plate with 2” socket or box
end wrench.
4. Once water chamber plate is removed, stainless steel
piston should slip out. Thoroughly clean piston from any
debris prior to reassembly.
5. While stainless steel piston is out of mixing unit body,
thoroughly clean internal piston contact wall from any
debris so that piston will be able to slide smoothly back
inside.
6. Remove water chamber cover plate Teon gasket
(Dura8-18).
7. Replace water chamber cover plate Teon gasket
(Dura8-18).
8. Reverse instructions to reassemble.
NOTE: Never reuse gaskets. Always use a new gasket when
reassembling the unit to prevent leaks.
5 6

Steam Poppet & Steam Poppet Seat Cleaning
Attention: Recommended only if experiencing signicant
steam leakage through mixing valve possibly caused by
calcium deposits over an extended period of good service.
1. Remove steam chamber cover plate with 2” socket or
open wrench.
2. With the steam chamber cover plate removed, the steam
poppet will simply slide o󰀨. Once steam poppet is out use
a ne brass wire brush to clean contact area on steam
poppet. After thoroughly cleaning the steam poppet,
make sure to also clean steam poppet seat inside steam
chamber using brass wire brush. Once both areas have
been thoroughly cleaned, re-insert steam poppet into its
original position.
3. Using a small at tip screwdriver, remove steam chamber
cover plate Teon gasket (Dura8-18).
4. Replace steam chamber cover plate Teon gasket
(Dura8-18).
5. Reverse instructions to reassemble. New steam chamber
cover plate gasket should be used.
6. Once reassembled, test unit for leakage. If signicant
leakage is still visible, steam poppet and seat will have to
be ground slightly between steam poppet and seat using
valve grinding compound commonly found at auto parts
stores.
7. Repeat removal instructions above until you have access
to steam poppet.
8. Apply grinding compound onto steam poppet contact
surface and reinsert into steam poppet seat and begin to
slightly rotate contact surfaces with grinding compound
in a circular manner while applying gentle pressure to
steam poppet for approximately 1-2 minutes. As you
grind, make sure to often “pick up”, rotate a quarter
turn, then place steam poppet back onto steam poppet
seat and continue to grind as per above. Repeating this
procedure will assure an even contact surface. continued
NOTE: Never reuse gaskets. Always use a new gasket when
reassembling the unit to prevent leaks.
9. Clean contact surfaces completely of grinding compound
and reassemble as per above instructions, or replace
steam poppet/seat set (Dura8-14S/13).
Repair Instructions
CAUTION: Check to make sure that steam & cold water
supply globe valves are turned o󰀨 prior to disassembly.
Depressurize mixing unit by spraying nozzle and allow
mixing unit to cool down prior to disassembly. Unit is now
ready for maintenance.
Check Valve Replacement:
1. Remove check valve connection nut.
2. Remove check valve from globe valve.
3. Reverse instructions to install new check valve (Dura8-1B
(bronze) / Dura8-1S (SS)).
Water Chamber Cover Plate Gaskets:
1. Remove hand wheel nut, lock washer, and name plate
from temperature control hand wheel located on the right
side of the unit.
2. Gently tap hand wheel outward and then wiggle o󰀨 by
hand.
3. Remove water chamber cover plate with 2” socket or box
end wrench.
4. Remove water chamber cover plate Teon gasket
(Dura8-18).
5. Replace water chamber cover plate Teon gasket
(Dura8-18).
6. Reverse instructions to reassemble.
7 8

Temperature Control Hand Wheel Stem Guide Filling
1. Remove hand wheel nut, lock washer, and name plate
from temperature control hand wheel located on the right
side of the unit.
2. Gently tap hand wheel outward and then wiggle o󰀨 by
hand.
3. Remove water chamber cover plate with 2” socket or box
end wrench.
4. Remove push down nut from stem guide and Teon stem
guide lling will be visible. This nut is on the exterior of
the cover plate.
5. Turn temperature control hand wheel stem guide
clockwise until you reach stopper.
6. Remove inside locking plug located on the inside of the
cover plate using a crescent wrench.
7. Temperature control hand wheel stem can now be
extracted through the inside by turning it clockwise.
8. Using a pick or equivalent, remove as much packing
material as possible from the inside of the water chamber
cover plate.
9. Reinsert the temperature control hand wheel stem by
turning it counter-clockwise. Make sure to reinsert stem
back through locking plug as when removed.
10.Begin to tighten locking plug inside water chamber cover
plate. Please only hand tight.
11. Insert new Teon lling into stem.
12.Insert push down nut into stem and begin to tighten.
Please only hand tighten at this moment.
13.Reverse instructions to reassemble. New water chamber
cover plate gasket should be used.
14.Once reassembled and reinstalled onto unit, operate
unit as usual, if there is minimal leakage through stem
packing, tighten push down nut slowly (quarter turn at a
time) until leakage disappears.
NOTE: Never reuse gaskets. Always use a new gasket when
reassembling the unit to prevent leaks.
Globe Valve Stem Guide Filling & Poppet
1. Remove globe valve stem nut using crescent wrench or
box end wrench by turning it counter-clockwise. Once
completely loosened, entire stem will simply fall o󰀨 along
with globe valve poppet and stem nut gasket. Please
note that globe valve poppet is “free oating” and thus will
simply fall o󰀨 its guide.
2. Remove hand wheel nut, lock washer, and name plate
from globe valve hand wheel.
3. Gently tap hand wheel outward, then wiggle o󰀨 by hand.
4. Remove hold down nut for stem using crescent wrench
or box end wrench. If working on a steam globe valve,
locking nut, cap and locking pin will have to be removed
rst.
5. On steam globe valve, remove push down nut from stem
guide and Teon stem guide lling will be visible.
6. On cold water globe valve, remove push down cap and
push down sleeve from stem guide and Teon stem guide
lling will be visible.
7. Turn hand wheel stem guide clockwise until it can be
extracted through the inside.
8. Using a pick or equivalent, remove as much packing
material as possible from the inside of the globe valve.
9. Reinsert the hand wheel stem by turning it counter-
clockwise.
10.Insert new Teon lling into stem.
11. Insert push down nut into stem and begin to tighten.
Please only hand tighten at this moment.
12.Insert new globe valve poppet and gasket on globe valve
stem.
13.Reverse instructions to reassemble.
14.Once reassembled and reinstalled onto unit, operate
unit as usual, if there is minimal leakage through stem
packing, tighten push down nut slowly until leakage
disappears.
NOTE: Never reuse gaskets. Always use a new gasket when
reassembling the unit to prevent leaks.
9 10

Steam Chamber Cover Plate Gaskets
Attention: Do not open steam side chambers unless
signicant steam leakage is noticed
1. Remove steam chamber cover plate with 2” socket or
open wrench.
2. Using a small at tip screwdriver, remove steam chamber
cover plate Teon gasket.
3. Replace steam chamber cover plate Teon gasket.
4. Reverse instructions to reassemble.
Steam Poppet & Steam Poppet Seat Replacement
1. To replace steam poppet, the steam chamber plate must
be removed. Please follow instructions above for this.
2. With the steam chamber cover plate removed, the steam
poppet will simply slide o󰀨. Once steam poppet is out,
unscrew poppet seat using a 1 1/16” socket. Reinstall
new poppet seat along with new copper o-ring. Reinstall
new steam poppet. (NOTE: Steam poppet is only sold with
matching seat. Do not mix as seat is made to t designated steam
poppet.) Minor pre-grinding may be necessary between
steam poppet and seat using valve grinding compound
commonly found at auto parts stores. Apply grinding
compound onto steam poppet contact surface and
reinsert into steam poppet seat and begin to slightly
rotate contact surfaces with grinding compound in a
circular manner while applying gentle pressure to steam
poppet for approximately 1-2 minutes. As you grind,
make sure to often “pick up”, rotate a quarter turn, then
place steam poppet back onto steam poppet seat and
continue to grind as per above. Repeating this procedure
will assure an even contact surface.
3. Clean contact surfaces completely of grinding compound.
4. Reverse instructions to reassemble. New steam chamber
cover plate gasket should be used.
5. Apply air pressure to steam inlet and insert mixing unit
outlet into bucket of water to check and see if continuous
air bubbles can be observed. If continuous air bubbles
are visible, repeat procedure.
Duramix 8000
Front View Drawing
11 12

Duramix 8000
Side View Drawing
Automatic Shut O󰀨 Feature:
1. Water enters and passes through check valve. (Note:
Water is not able to go back into water supply line
because spring loaded check valve will only allow ow
into unit)
2. With nozzle open, water pressure and ow allows the
free oating piston to activate and opens steam poppet
by pushing it towards the left side, thus allowing steam to
mix with incoming water.
3. If there is an interruption of water pressure or water ow
(such as shutting nozzle down), steam poppet spring
pushes steam poppet back into its closed position within
5 seconds. Similarly, in the case of a sudden loss of
water supply.
Duramix 8000 Automatic Shut O󰀨 Feature
13 14

Part # Description
DURA8-1B Check valve assembly. Includes check
valve poppet, spring, and Teon coated
copper connection gasket. Bronze.
DURA8-1S Check valve assembly. Includes check
valve poppet, spring, and Teon coated
copper connection gasket. Stainless
steel.
DURA8-2-T Globe valve connection gasket. Teon.
Cold water side.
DURA8-2-C Globe valve connection gasket. Copper.
Steam side.
DURA8-3 Check valve connection gasket. Teon
coated copper.
DURA8-4 Temperature control stem guide Teon
lling.
DURA8-6 Globe valve stem guide nut gasket.
Teon.
DURA8-7 Globe valve stem guide Teon lling.
DURA8-10B Globe valve poppet. Brass.
DURA8-10S Globe valve poppet. Stainless steel.
DURA8-12B Steam chamber cover plate assembly.
Bronze.
DURA8-12S Steam chamber cover plate assembly.
Stainless steel.
DURA8-13 Steam poppet. Stainless steel.
DURA8-14S Steam poppet seat. Stainless steel.
(Must be purchased with DURA8-13)
DURA8-15 Steam poppet seat copper gasket.
DURA8-18 Temperature control chamber plate
gasket. Teon.
Duramix 8000 Parts List Labeled Diagram Duramix 8000 Replacement Parts List
15 16

Frequently Asked Questions Troubleshooting
17 18
SuperKlean does recommend the use of strainers at the
inlets simply because they reduce the ow into the unit and
thus a󰀨ects the operation of the unit. This is particularly
recommended in facilities with older pipings, as debris may
be more prevalent. It is recommended that all inlet supply
lines are thoroughly ushed prior to installation to rid them of
debris.
SuperKlean highly recommend the use of a steam trap to rid
unit of condensation build up which causes steam poppet
lock-up if unit sits at idle for a long period of time. Steam
poppet lock up will make unit inoperable.
Because of the variety of scenarios, SuperKlean
recommends that the customer try both outlets at the same
time to see if they are satised with the output ow rates.
Please note that higher inlet pressures are preferred for the
use of both outlets at the same time. If insu󰀩cient ow rates
are noticed, one outlet at a time will have to be used.
Output pressure is very similar to input water pressure.
SuperKlean highly recommends the use of an inline pressure
pump in order to boost incoming water pressure. We do not
recommend and will not warranty the mixing station if parts
are removed and/or modied to allow the unit to operate
under our specic inlet pressure requirements.
Depending on the facility, is a strainer required at the inlets
on the mixing unit to prevent debris from entering the unit?
Do you need to install a steam trap?
Can you use both outlets at the same time?
What is the output pressure of the mixing unit?
What can I do if my inlet water pressure is below 30 PSI?
Nozzle delivers cold water only or temperature output is
not high enough after regulating unit
Make sure that you have a minimum water pressure of
30 PSI. Gradually open steam supply globe valve until
completely open or desired temperature is achieved. If
this does not correct problem, check for steady steam
pressure. If steam pressure is steady and steam globe
valve is fully opened, try adjusting temperature output by
closing temperature control hand wheel on the side of the
unit. If temperature control hand wheel is completely closed,
gradually begin to close cold water supply globe valve until
desired temperature is achieved. If there is still no hot water
exiting nozzle, contact us.
Note: Steam pressure should normally be higher than water
pressure to achieve reasonable water temperature output.
The use of pressure gauges at inlets is highly recommended.
Steam escapes from hose nozzle sporadically
Immediately shut down and decommission washdown
station and contact us.
Hot water outlet temperature is too high
Gradually adjust temperature control hand wheel on the side
of the unit by opening it. If completely opened, gradually
close steam supply globe valve until completely closed
or desired temperature is achieved while pulling nozzle
trigger. If this does not correct problem, check to make sure
water supply is fully open and steady water pressure is
available. Check for steady steam supply pressure. If water
temperature is still too high, decommission the unit and
contact us.
Note: Steam pressure should normally be higher than water
pressure to achieve reasonable water temperature output.
If steam to water pressure is more than 2:1 ratio, higher
temperature output is expected. The use of pressure gauges
at inlets is highly recommended.

WORLDWIDE HEADQUARTERS
CORPORATE ADDRESS
SuperKlean Washdown Products
1 Edwards Court, Suite 101
Burlingame, CA 94010
EMAIL
[email protected]
DIRECT
[phone]
[phone]
TECHNICAL SUPPORT
[phone]
SHIPPING/LOGISTIC SUPPORT
[phone]
SUPERKLEAN BUSINESS HOURS
8am-5pm Monday-Friday PST
19
Outlet pressure is too low or non-existant
Ensure all steam and water valves leading to and including
the washdown unit are fully opened and that a minimum
pressure of 30 PSI on both inlets is available. Re-adjust
globe valves to desired temperature and check pressure
again.
Leaking pipe threads
Ensure that pipe thread sealant was used when mating
threads. Standard pipe threads
require pipe thread sealant to make a proper seal (e.g. ANSI/
ASME B1.20.1 Pipe Thread
Standard)
Water pressure/temperature is sporadic at outlet
Verify you meet and can maintain the required water and
steam pressures. The use of pressure gauges at inlets is
highly recommended. If pressures on both inlets are not
constant, the use of a pressure regulator is recommended.