Douglas BDW-HD-BH-EL User manual

BDW-HD-BH-EL
OPERATION GUIDE
WASHING AND SANITIZING SYSTEMS

Second Edition (April 2021)
This book is a publication of Douglas Machines Corp. Service Department.
Future editions will reect changes in procedures or technical details.
Use and duplication of this document is encouraged.
For technical assistance, please call
1-800-331-6870.
© Copyright Douglas Machines Corp 2021.

SAFETY
Qualified installation personnel, individuals, firms,
corporations, and companies are responsible for:
Wear appropriate P.P.E. ie… hearing protection, thermal resistant gloves,
and eyewear.
Know where the exits are located.
Always turn off and drain the machine before entering. Allow a cool
down period. Follow facility’s L.O.T.O. procedure.
Never enter a machine where flooring has been removed. –Fall Hazard.
Use non-permit required confined space guidelines for entering.
When loading a rack into the washer keep hands away from the door
edges. Keep hands on the horizontal bars inside of the rack. Do not hold
racks on the vertical support bars or outside edges. Push the rack with
both hands. Never strain yourself to move racks if racks are too heavy
unload some product.
Always use Caution. –Use mats to help reduce slip hazards.
Ensure that float switches and level probes are well maintained and cleaned
daily. Failure to do so can result in unintended heater startup and
potential fire.
Never leave your machine idle (not in use) for more than 4 hours. This can
result in water evaporating out of the rinse tank causing damaging. Do not
touch Rinse tank without a cool-down period.

DougMac.com
BDW-1-HD-BH-EL
4
PRE-INSTALLATION .......................................................................................................................................................................... 5
DELIVERY .............................................................................................................................................................................................. 6
SAFETY PRECAUTIONS................................................................................................................................................................... 7
DO’S AND DO NOT’S........................................................................................................................................................................ 8
SET UP.................................................................................................................................................................................................... 9
LOWER WASHER CIRCUIT SET-UP............................................................................................................................................ 9
START UP ...........................................................................................................................................................................................10
OPERATION.......................................................................................................................................................................................12
MAINTENANCE.................................................................................................................................................................................13
DAILY MAINTENANCE....................................................................................................................................................................13
PERIODIC MAINTENANCE............................................................................................................................................................13
PROGRAMMING ...............................................................................................................................................................................14
1827 PC BOARD...............................................................................................................................................................................14
TECHNICAL INFORMATION .........................................................................................................................................................14
FACTORY SETTINGS .......................................................................................................................................................................14
PROGRAMMING THE AUTO FILL ...............................................................................................................................................15
TROUBLE SHOOTING.....................................................................................................................................................................16
TROUBLESHOOTING ......................................................................................................................................................................18
ERROR CODES..................................................................................................................................................................................18
ERROR CODE VALUE TABLE .......................................................................................................................................................18
TROUBLESHOOTING TABLE FOR THE 1827 PC BOARD.................................................................................................20
TROUBLESHOOTING TABLE FOR THE 1827 PC BOARD, CONT’D...............................................................................21
TROUBLESHOOTING TABLE FOR THE 1827 PC BOARD, CONT’D...............................................................................22
CONTENTS

BDW-1-HD-BH-EL
DougMac.com
5
IMPORTANT
PRE-INSTALLATION
Qualied installation personnel, individuals, rms, corporations, and companies are responsible for:
6The installation or replacement of the gas piping and connection, installation, repair, or servicing of
the equipment. Qualied installation personnel must be experienced in such work, familiar with all
precautions required, and have complied with all requirements of state or local authorities having
jurisdiction. Reference National Fuel Gas Code, NFPA 54 or latest edition or ANSI Z223.1 or latest
edition, Section 1.4.
6The installation of electrical wiring from the electric meter, main control box, or service outlet to
the appliance. Qualied installation personnel must be experienced in such work, familiar with all
precautions required, and have complied with all requirements of state or local authorities having
jurisdiction. Reference National Electrical Code, ANSI/NFPA 70 or latest edition. In Canada, Canadian
Electrical Code Pan I (Std. 22.1 or latest).
6The installation of gas heated units in Canada. Qualied installation personnel should comply with the
Installation Codes for Gas Burning Appliances and Equipment, (CAN-I-B 149.1 and B-149.2) and any
local codes or approvals.
6The installation of washers equipped with casters. These washers shall be made with a connector that
complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z2 1.69 or latest, and a
quick-connect device that complies with the Standard for Quick-Disconnect Devices for use with gas
fuel, ANSI Z2 1.41 or latest.
6Water and waste piping and connections shall comply with the International Plumbing Code,
International Code Council (ICC) or the Uniform Plumbing Code, International Association of Plumbing
and Mechanical Ofcials (IAPMO). NSF/ANSI 3-2009
6Douglas Machines Corp. highly discourages the use of tankless or demand water heating units as
a hot water supply for our machines. They typically are not properly sized nor can they meet the
demand required by our machines.
Note: A xed restraint must be provided if casters are used in conjunction with a exible connector for movable
appliances. This restraint must secure the washer to a non-movable surface to eliminate stress on the connec-
tor. If the washer is moved, the restraint must be reconnected after the washer is returned to its normal posi-
tion.

DougMac.com
BDW-1-HD-BH-EL
6
DELIVERY
Upon delivery of your Douglas washer:
6 Inspect the machine for any external damage. Any evidence of damage should be noted on
the delivery receipt and signed by you and the driver.
6Remove packaging from the washer and check for any concealed damage. Carrier must be
notied of damage immediately. Please retain packaging for inspection if claim is led.
6Douglas Machines Corp. cannot accept responsibility for lost or damaged merchandise
suffered in transit. The carrier assumes full responsibility for delivery in good order; however,
we are prepared to assist you in any action needed regarding shipping damage.
Electrical Connections: Upon receiving your machine, all wire connections in the electric panel, pump motor and
electric heaters should be checked, including the wire nuts and lugs. Check connections monthly for the rst six
months and every 90 days after the rst six months of operation.

BDW-1-HD-BH-EL
DougMac.com
7
SAFETY PRECAUTIONS
Important: All safety precautions must be adhered to as to avoid personal injury.
Please Be Cautious!
BEFORE ATTEMPTING TO PERFORM ANY SERVICE TO THE UNIT ENSURE THAT THE ELEC- TRICAL
DISCONNECT HAS BEEN TURNED TO THE OFF POSITION AND LOCKED OUT WITH A PHYISCAL LOCKING
MECHANISM.
“THIS MACHINE MUST BE OPERATED WITH AN AUTOMATIC DETERGENT FEEDER AND, IF APPLI- CABLE AN
AUTOMATIC CHEMICAL SANITIZER FEEDER, INCLUDING A VISUAL MEANS TO VERIFY THAT DETERGENTS
AND SANITIZERS ARE DELIVERED OR A VISUAL OR AUDIBLE ALARM TO SIGNAL IF DETERGENTS AND
SANITIZERS ARE NOT AVAILABLE FOR DELIVERY TO THE RESPECTIVE WASHING AND SANITIZING SYSTEM.”
This manual will help with troubleshooting and the replacement of parts.
For parts or technical assistance please call Douglas Machines Corporation at 800-331-6870 and ask for the
Service Department. Please have your Serial Number available to assist with the call. If the call is an emergency
and after nor- mal working hours (Monday – Friday 8 AM - 4:30 PM) you can call your warranty
provider direct and follow it up with a call during normal hours of operations. Douglas Machines Corporation
will provide you with your local warranty provider contact information during the Factory Start up and
Demonstration.

DougMac.com
BDW-1-HD-BH-EL
8
DO’S AND DO NOT’S
DO’S
6 Before attempting any maintenance or repairs, ensure that electrical supply to the
6unit has been turned off and locked out. Wear safety glasses.
6 Check inside the unit before starting the cycle to ensure nothing is inside.
6 Keep hands and clothing clear of moving parts.
6 Ensure safety rules are followed at all times.
6 Ensure all electrical panel enclosures are closed before using the machine.
DO NOT’S
6Attempt to perform any maintenance, repairs or adjustments unless the
6supply power has been shut off and locked out rst.
6Open door during machine cycle. There may be a delay between cycle steps so ensure cycle is complete
by visually checking that the Run light in not illuminated.
6Hose down any electrical components.
6Remove any access panels or pit grids while unit is in use. Touch outside of cabinet without wearing
gloves.
6Attempt to do any service or make any adjustments to this unit unless you
6are qualied service person.

BDW-1-HD-BH-EL
DougMac.com
9
SET UP
Lower washer circuit set-up
Determine type of lower wash conguration desired and set wash valves as follows: See Illustration below
Protruding Wash Nozzle Conguration
6 Close Rotating Spray Arm Wash Valve
6 Close Spray Arm Rinse Valve
6 Open Protruding Nozzle Wash Valve
6 Open Protruding Nozzle Rinse Valve
Rotating Spray Arm Conguration
6Open Rotating Spray Arm Wash Valve
6Open Spray Arm Rinse Valve
6Close Protruding Nozzle Wash Valve
6Close Protruding Nozzle Rinse Valve

DougMac.com
BDW-1-HD-BH-EL
10
START UP
IMPORTANT: LOCATE AND REMEMBER WHERE YOU’RE ELECTRICAL DISCONNECTS ARE.
Some of the following steps will be performed in the electrical panel enclosure. We recommend disconnection
of all incoming power before doing any service in the electrical enclosure. Please Be Cautious!
6With incoming electrical power disconnected or turned off, remove electrical panel enclosure cover.
Turn all thermostats to the lowest or off position (turning knobs in the counter clockwise direction).
6 Locate and make sure the drain and pump petcock is in the closed position. The pump petcock will
remain in the closed position from now on unless service is needed on the pump. Shut off all breakers
going to the heaters if electrically heated (breakers will be marked WASH HEATER, RINSE HEATER).
6From inside the machine’s wash tank below the lter baskets, locate the oat switch and remove
the zip tie that was used for shipping. The oat will have a tag attached to it with (REMOVE ZIP TIE
BEFORE START UP).
6With electrical enclosure panel cover still off, turn incoming power back on. Make sure the circuit
breaker marked PUMP and breaker marked 120 is in the on position. APPLIES TO U.S. MODELS ONLY
(BE VERY CAUTIOUS THIS IS NOW A HOT PANEL).
6Turn the On/Off/Fill Switch to the Fill position and release it. At this point the machine will start to
ll. If it doesn’t ll to the overow, reprogramming of the auto ll may be necessary. You must also
make sure the incoming water pressure is in-between 20psi to 30psi ow pressure as stated in the
Recommend Installation Guide. Note: incoming water pressure over 30psi will void warranty to related
items.
6Select the Short Wash Cycle and push the Start Button, the wash pump should start running at this
point. If pump doesn’t start running, check that all fuses are in (if applicable) and all breakers marked
PUMP and 120 are in the on position. With pump running, check pump rotation, looking at the rear
of the pump motor, the fan should be rotating in a clockwise direction. If pump is not rotating in the
correct direction reversal of electrical phases will be necessary (contact your electrician or Douglas
Machines for details).
6Now its time to ll the rinse tank. Depress the Start button, the machine will now run through a
complete cycle. A complete cycle entails, wash (pump running), rinse (pump not running, rinse solenoid
valve open), and a one- (1) minute dwell & steam extraction (during dwell the machine can not be
restarted). Please note while the machine is in the rinse and dwell period you will not see any readings
on the jet pressure gauge. To ensure the rinse tank is lled, you need to physically hear water spraying
inside the wash cabinet after the wash pump has stopped running. You may need to run more than
one –(1) cycle to accomplish this. CAUTION: Before proceeding to the next step, make sure you can
hear water spraying in the cabinet after the wash pump stops running. If not heater damage may
occur, warranty will be void to related items.
6Now it’s time to set the thermostats. Were looking for a reading on the temperature gauges to be 150
degrees wash temperature and 190 degrees rinse temperature. Turning the thermostat knobs in a
clockwise motion, and using top dead center as our indicator, increase the thermostat marked WASH
to 150 degrees, now increase the thermostat marked RINSE to 190 degrees. Allow 30 to 60 minutes
for heat up time. Note: There can be as much as 12 to 15 degrees various between the thermostat and
the temperature gauge. Always set the thermostats to accommodate the desired temperature gauge
reading.

BDW-1-HD-BH-EL
DougMac.com
11
6At this point your heat source should be engaged. If electrically heated the wash and rinse heater
contactors will be engaged. If gas heated the burner or burners will re. If steam heated the steam
solenoids will open. If you are not sure or if the specic heat source is not on and the unit is not heating
up, contact Douglas Machines for assistance.
6Now that every thing is working ne. It’s time to put the electrical enclosure panel back on the
electrical enclosure and start washing.

DougMac.com
BDW-1-HD-BH-EL
12
OPERATION
With the machine turned on, lled to the overow, and heated up to the correct operating temperatures,
we’ll need to add detergent now. Note: You must use a non-foaming, non-caustic, low chlorine type of soap
(unless the machine has been specically manufactured for caustic use). If the machine is tted with an
automatic soap dispenser, ensure the dispenser is turned on and lled up. If machine is not equipped with an
automatic soap dispenser, follow your detergent manufacturer recommended specications for application
and concentration.
Loading your machine. When loading you must have the open end of the item being washed situated to drain
all the water back into the wash tank of the machine. This means that you’ll have the open end facing down.
Now that we’ve lled the machine, let it heat up, put detergent in it, and loaded it. It’s time to start washing!
All you have to do is choose you’re desired wash cycle time. To do this, select short (four- (4) minute cycle),
medium (six- (6) minute cycle), or long (eight- (8) minute cycle) cycle time. Let the machine run through its
entire cycle (wash, rinse, and dwell). If you open the door or hit the stop button any time during the cycle, the
machine will shut off. When you restart the machine it will not start from where it stopped, it will start from
the beginning of the cycle again. When full cycle has completed you will be able to unload and reload the
machine.

BDW-1-HD-BH-EL
DougMac.com
13
MAINTENANCE
Daily Maintenance
If your machine has an electric heater or heaters in the wash tank, it’s time to clean those now. The heater
coils will be located directly under the low water probe. Using a wire brush or scouring pad clean the exposed
heating coils on the heater or heaters, directing all debris into the drain.
Now that the wash cabinet, lters, wash tank reservoir, low water probe, and electric heater or heaters (if
applicable) have been cleaned. You can now put the lters back in place.
Inspect all the spray jets, look for any that are missing, obstructed, or worn out. If you nd any jets missing or
worn out, contact Douglas Machines Corp. for a replacement. If you nd any jets obstructed. Try to remove
the obstruction by pulling it out or by forcing it back into the jet pipe. If you need to force it back into the jet
pipe you’ll need to remove the jet pipe end cap (reference your parts manual for jet pipe end cap location) in
order to remove the obstruction from the pipe.
Clean the outside of the machine. Using a stainless steel cleaner or soft cloth with a mild detergent wipe
down the outside of the machine.
Close the drain valve, check that the lters are back in place, and turn the main power back on. Wait to rell
the machine till you’re ready to wash again (it’s easier and less expensive to heat warm water then cold). The
machine is now ready for the next shift or next day of washing.
Periodic Maintenance
Wash pump motor lubrication. You’ll nd two- (2) grease tting on the top of the wash pump motor, one- (1)
at each end. You’ll need to grease these under normal conditions every 90 days. Use an electric motor bearing
grease similar to Shell Dollum or Chevron SRI.
The removal of lime and or scale may be necessary at certain times. This will vary due to the condition of your
water. If you’re nding lime and scale building up on the interior walls of the machine, chances are they’re
also building up in the piping. This could impair washing ability. You’ll need to use some sort of lime and scale
removal chemical. Whatever you decide to use please make sure it’s safe to use on stainless steel, bronze,
and brass. If you have any questions on what to use or how to use it, do not hesitate to contact Douglas
Machines Corp.
Electrical Connections – The rst 6 months that you have your unit, you should go over all wire connections in
the electric panels as well as check the wire nuts on all motor leads. After the rst 6 months, you should only
need to do this every 90 days.

DougMac.com
BDW-1-HD-BH-EL
14
PROGRAMMING
1827 PC Board
Technical Information
The controller is an open board construction intended to be installed inside of an electrical panel. The board
operates on nominal 120 VAC line.
The basic function of the board is to control the operation of the unit, going through a cycle of Wash, Rinse,
and then Fan (Dwell).
The six relays on the board control six outputs. One relay controls two of the outputs, and the sixth relay is a
master control relay.
The outputs include a ready light, a fan, a heater contactor, a wash pump motor contactor, a rinse solenoid
valve, and a ll valve.
Three potentiometers control Wash time: Short, Medium, and Long. Two switch inputs control which pot is
selected. The Long switch selects the long pot, the Medium switch selects the medium pot, and the Short
switch selects the short pot.
Routine Operation/Connections
Be aware that the board also controls a Fill cycle.
Note that the Fill cycle turns on the Fill valve and waits until the water level in the machine reaches the level
probe.
At this point, the Fill valve is left on for the pre-programmed time to ll above the probe and then turned off.
Setting the Times
To set times on the 1827 PC board, several steps are required:
Open the control box.
Locate the PC board, a device approximately 8” x 5” with 6 relays and a transformer.
The timer settings are located to the right of the transformer and are ½” blue squares with a white dial. They
are labeled Long, Medium, Short, and Rinse
To decrease the time, turn the timer counter-clockwise.
To increase the time, turn the timer clockwise.
Factory Settings
CyCle Duration
Rinse 30 Seconds
Long 8 Minutes
Short 4 Minutes
Note that the Rinse pot is xed @ 30 sec. for NSF, and that non-NSF Rinse time is adjustable.

BDW-1-HD-BH-EL
DougMac.com
15
Programming the Auto Fill
Before starting, make sure there is no water in the machine and that the drain valve is closed.
Turn the Off/On/Fill switch to the On position, but make sure not to turn all the way to Fill.
Locate the Program button on the PC board.
This black button is located on the right hand side just below the Program LED and labeled with the letters
PGM.
Push in the PGM button but do not hold the button down, as it will then execute a test Mode.
When the Program light located above the button begins to ash, turn the Off/On/Fill switch to the Fill
position.
The solenoid valve then opens and the machine begins to ll.
When the water reaches the overow level, turn the Off/On/Fill switch again to the Fill position.
Observe that the Fill Time is set.

DougMac.com
BDW-1-HD-BH-EL
16
TROUBLE SHOOTING
Note: Some of the following remedies may need to be performed in the electrical panel. Before you perform
any task in the electrical panel, please make sure all incoming power is disconnected or turned off.
Problem Things to Check
Machine will not turn on 6Incoming power turned on
6Machine circuit breakers and/or fuses in
place and turned on
Machine will not heat up (gas heated) 6Machine is lled to correct level
6Low water probe is clean
6Gas supply is on
6Thermostats set to desired temperature
Machine will not heat up (electric heated) 6Machine is lled to correct level
6Low water probe is clean
6Circuit breakers and or fuses marked
heaters
6Thermostats set to desired temperature
Wash pump will not start 6Machine is lled to correct level
6Low water probe is clean
6Door is in the closed position
6Circuit breakers and or fuses marked
wash pump motor
Wash pressure is low 6Machine is lled to correct level
6Filters are clear and in place
6All wash jets and end caps are in place
6Excessive amount of foam is present
6Pump is rotating in correct direction
6Pressure gauge
Not rinsing 6Incoming water pressure
6Door is closed
6Rinse solenoid valve

BDW-1-HD-BH-EL
DougMac.com
17
Problem Things to Check
Rinse temperature not hot enough 6Incoming water temperature (120° -
140°max.)
6Incoming water pressure (no less than
20psi. and no more than 30psi. of ow)
6Thermostat set to correct temperature
(180° - 210°max.)
6Heat source engaged
Not cleaning 6Detergent level
6Wash pressure (see door sticker for
minimum pressure)
6Wash temperature
6Wash jets (clogged)
6Water Level
6Filters clear
6If rotary table, check if table turning
freely
If you are experiencing any other problems or have any questions or concerns, please do not hesitate to con-
tact the Service Department at 1-800-331-6870.

DougMac.com
BDW-1-HD-BH-EL
18
TROUBLESHOOTING
ERROR CODES
To aid in troubleshooting, the PGM LED also serves as an error code indicator. In case of error, the LED ashes
on and off at ½ second on and ½ second off and then pauses for 3 seconds.
The ashing pattern continues as long as the controller is in Idle Mode. The number of times the LED ashes
between 3 second pauses indicates the number of the error.
Error Code Value Table
PGM Error Interpretation
1Watchdog timeout on lling to
level probe
6When the controller is in either a Fill cycle or a
Teach Fill cycle, there is a 15 minute time limit until
the water level reaches the level probe.
6If the ll valve is on for 15 minutes, the valve shuts
off and the Fill cycle aborts. The controller reverts
to Idle Mode.
2Watchdog timeout on lling above
the level probe
6When in a Fill cycle or a Teach Fill cycle, there is
a 5 minute limit for which the ll valve may be on
after the water reaches the level probe.
6This error could occur in a Fill cycle only if an
incorrect time were stored in the EEPROM or read
from the EEPROM.
6In Teach Mode, this could occur if the operator
walked away from the machine while it was in
Teach Mode. If this timeout occurs, the ll valve
turns off and the machine returns to Idle Mode.
3Loss of master control relay during
machine cycle
6This error could occur if the door was opened or
if the motor overloads opened during a Wash or
Rinse cycle.
4Loss of water level during a ma-
chine cycle
6This could occur in two situations:
6a) If the water in the machine drops during a
cycle because a large container being washed is
collecting wash water, or
6b) The water level in the machine is very low
and the wash water circulating in the pump and
plumbing is enough to lower the water level below
the probe.
6The water level must be low for 5 seconds for
the cycle to be aborted. The heater output will,
however, be turned off immediately when the
water level is below the probe.

BDW-1-HD-BH-EL
DougMac.com
19
PGM Error Interpretation
5EEPROM read error 6Data stored in the EEPROM is redundant, and the
two redundant numbers are compared. If they
don’t match, a read error is generated.
6This error could occur if a Fill cycle is started, but a
Teach cycle has not been done to program the Fill
time. It should not occur, as Douglas will program
a Fill time as part of the test procedure.
6The error could also occur if installing a new board.
6Attempt to start a Fill cycle or
Teach Fill cycle when the water
level is already at the level probe
6Clear the code by starting a new cycle.
7Attempt to start machine cycle
without water to the level probe
6If unit has water and a clean, low water probe, see
Low Water Section.
6Note that when one of these errors occurs, the controller reverts to Idle Mode.
6Note that the error code ashes on the LED as long as it is in Idle Mode.
6 Note that as soon as a successful machine cycle, Fill cycle, or Teach Fill cycle
executes, the error LED goes out.
6There is no need to reset anything by turning the machine off.
6 For example, if the operator were to try to ll the machine a second time and the
water were already at the level probe, nothing would happen. The error would ash
on the PGM LED, but if the cover were on the electrical box, no one would see it. If the
start button were then pressed, the error LED would go out and a normal machine
cycle would be executed.

DougMac.com
BDW-1-HD-BH-EL
20
Troubleshooting Table for the 1827 PC Board
Problem Likely Source Corrective Procedures
Wash pump will not start Door 6Make certain that the door is closed.
6Make certain that the door is contacting the
door switch, or is within 1/8” of Prox switch.
6Check to see if the door switch is bad.
6If using a door switch, perform a continuity
check.
6If using a Prox switch, jump out connections at
PC board.
6Check to see if the OK LED on the PC board is
illuminated.
6To see if the spring-loaded Stop button is stuck
in, press it in
Pump Motor 6Check to see if the pump motor overload has
tripped.
6Press the Reset button on the overload (blue
button located in the electrical panel).
6See Overloads in the Reference Section.
Circuit Breaker 6Check to see if the circuit breaker for the pump
motor has tripped.
6Try resetting the breaker.
Pump Motor
Fuses
6Check to see if any of the fuses for the pump
motor are blown.
6Check all fuses.