Douglas BELT WASHER User manual

BELT WASHER
OPERATION GUIDE

Congratulations, and thank you for choosing the CYCLONE Belt Washer. When properly operated and maintained,
your belt washer will provide years of efcient, trouble free belt washing. We ask that you familiarize yourself with
the operation and maintenance information in this manual to maximize the effectiveness of your belt washer.
OVERVIEW
The patented CYCLONE Washing Head consists of specially angled high pressure jet nozzles that provide
thorough cleaning over the entire surface of the belt. When properly positioned with the correct speed of the jet
nozzles, the belt can be thoroughly cleaned in one (1) to two (2) passes using only 3 to 4 G.P.M. Your rst cleaning
may take longer.
The Rotary version of the Cyclone Belt Washer is designed to clean open type belting where as the Linear
version is designed to clean at top type belts.
SPECIFICATIONS
Washer Cart 60” x 30”
Washer Head Weight Under 30 lbs.
Power 230VAC @ 25 amps or 460VAC @ 15 amps
Water Usage 3-4 gallons per minute
Air Requirement 5-10 CFM (cubic feet per minute) @ 90 psi
Electric Panel NEMA 4X - UL/CUL with ground fault protection
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.

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Contents
PRE-INSTALLATION .......................................................................................................................................................................... 5
DELIVERY .............................................................................................................................................................................................. 6
SAFETY PRECAUTIONS................................................................................................................................................................... 7
DO’S AND DO NOT’S ........................................................................................................................................................................ 8
SET-UP AND OPERATION (ROTARY HEAD) ............................................................................................................................ 9
SET-UP & OPERATION (LINEAR HEAD) .................................................................................................................................11
SETTING TRAVEL LENGTH AND TIMING (LINEAR HEAD) ...............................................................................................14
MAINTENANCE (COMMON).........................................................................................................................................................16
90 DAYS (COMMON).......................................................................................................................................................................17
180 DAYS (COMMON) ....................................................................................................................................................................18
30 DAYS (ROTARY HEAD ONLY) ................................................................................................................................................19
MAINTENANCE SCHEDULE (Rotary Head)............................................................................................................................20
TROUBLESHOOTING (Common) ................................................................................................................................................21
TROUBLESHOOTING (Rotary Head).........................................................................................................................................22
TROUBLESHOOTING (Linear Head)..........................................................................................................................................23
PARTS LIST.........................................................................................................................................................................................24

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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 connector. If the washer is moved, the restraint must be
reconnected after the washer is returned to its normal position.

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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.

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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 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.

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DO’S AND DO NOT’S
DO’S
6Before attempting any maintenance or repairs, ensure that electrical supply to the unit has
been turned off and locked out. Wear safety glasses.
6Check inside the unit before starting the cycle to ensure nothing is inside.
6 Keep hands and clothing clear of moving parts.
6Ensure safety rules are followed at all times.
6Ensure all electrical panel enclosures are closed before using the match
DO NOT’S
6Attempt to perform any maintenance, repairs or adjustments unless the supply 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 are qualied service
person.

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SET-UP AND OPERATION
(Rotary Head)
Note: Head should be removed during production to prevent cross contamination.
6 Perform an initial check of the belt washer to verify that it is in good working order. See
maintenance section for more details.
6Check the drive chain transmission from the air motor to the rotating washing arm. Check for
sprocket and chain wear and that the chain is properly tensioned.
6Check that all hardware is present and secure.
6Check that all air hoses and water lines are secure and in good condition. Replace all worn
hoses
6Verify that the water pump has the proper oil level. Oil level at dot in sight glass
6Verify that the air line Oilier is properly lled with food grade air tool lubricant. Oiler lled with
food grade air tool lube.
6Best cleaning results are obtained when the bottom of the belt washer’s aluminum head
housing is positioned 3 inches above the surface of the belt that is to be cleaned.
6Connect the air and water lines between the washer head and the washer cart.
6Check the water inlet lter screen in the inlet water hose union connection tting for clogs.
Clean if required.
6Connect a water supply hose capable of supplying 5 gallons per minute to the inlet union
connection tting. For best cleaning results, the use of hot water less than 160 degrees F.
is recommended. DO NOT USE WATER HOTTER THAN 160 DEGREES F OR DAMAGE CAN
OCCUR TO THE WATER PRESSURE PUMP.
6 Connect the air pressure line to the washer cart air inlet tting. For proper operation, the air
supply must be capable of maintaining 90 PSI while the cleaning head is operating. Adjust
operating air pressure to 80 PSI by pulling up pressure regulator knob and turning to obtain
desired pressure.
6Plug in the main electrical power cord.
6Set timer on cart panel box to desired cleaning time. Note decimal point on timer display.
A setting of 30 minutes will be displayed as 30.00 (not .30). Moderately dirty belts can be
cleaned with 2 belt passes under the cleaning head. Very dirty belts will require 3 passes.
6Press the green start button to start the cleaning cycle.
6With the pump running, adjust the exit pressure from the water pump to be between 1000 to
1200 psi. This is achieved by rotating the top knob on the exit line water pump regulator.
6Adjust the washer arm rotation speed by turning the speed control knob.

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6To set the proper rotational speed, rst slow down the washer head to the point where
sections of the belt are exiting the washer head having not been washed by the rotating
cleaning nozzles. Slowly increase the rotational speed until the entire belt surface is washed.
The spray path of the rotating nozzles should just barely overlap the path of the previous
rotation. The speed is now properly set. If you set the speed too slow, sections of the belt will
not be washed by the rotating head. If you set the speed too fast, the washer nozzles will not
clean the belt as effectively as they would when properly set.
6Adjust the oil drip of the air line oiler using the green adjusting screw to 2-3 drips per minute.
Belt Washer Cyclone Controls