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

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SET-UP & OPERATION
(Linear Head)
Note: Head should be removed during production to prevent cross contamination.
Select a suitable location to mount Linear Head.
(Cyclone Linear Head Shown with Adjustable Brackets)
The positioning is very critical and needs to comply with set-up DWG. Refer to the Linear Cyclone Head Set-
Up document.
Perform an initial check of the belt washer to verify that it is in good working order. See maintenance section
for more details.
6Check that all hardware is present and secure.
6Check that all air hoses, water lines and electrical leads are secure and in good condition.
6Replace all worn hoses.
6Verify that the water pump has the proper oil level.
6The oil level should be at the dot in the sight glass.
6Verify that the air line Oilier is properly lled with food grade air tool lubricant.

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Connect the air, water and 6 Pin connector lines between the washer head and the washer cart.
(Oiler Filled With Food Grade Air Tool Lube)
Check the water inlet lter screen in the inlet water hose union connection tting for clogs. Clean if required.
Connect 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.
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.
Plug in the main electrical power cord.
Set 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.
Press the green start button to start the cleaning cycle.
With 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.
Adjust the oil drip of the air line oilier using the green adjusting screw to 2-3 drips per minute.
Select a suitable location for the portable cart. (Reference Cyclone manual Set-Up and Operation Rotary
Head.)

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6Allowing hoses and cables to be connected to the head with slack.
6Air hose from cart to quick tting in control box on head.
6Set air pressure regulator @ 80 PSI.
6Set speed control to full out position for Linear Head application.
6Also used to control speed of Rotary & Linear Heads.
6Test the set up to ensure complete cleaning.
6Determine the time needed for one pass of your belting system.
6Set the timer for one or more passes based on soil conditions.
6Run system

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SETTING TRAVEL LENGTH AND TIMING (LINEAR HEAD)
Your Cyclone Linear Head is factory set to run at safe maximum speed.
6This set-up allows maximum speed at full stroke without the internal piston hitting /
slamming into the end blocks.
6This is accomplished by setting the prox. Switches inwards away from the end blocks to
switch the air control valve in advance of the hard stop allowing the load to decelerate
utilizing the trapped air in the cylinder. When properly adjusted the load travels past
the switch, the air valve closes, and starts compressing the trapped air until it stops and
changes direction. The stopping point should be just before the hard stop thus allowing a
dampened stop and not a hard slam.

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It is recommended that you run the linear head at factory setting and simply adjust the conveyor speed from
5 to 10 FPM.
If you slow the speed of the load; the reversing point will start moving in towards the center. To
maintain proper travel length you would have to adjust the switches outward to compensate for
the slower speed.
Correct travel length is when the inside jet just passes the outside edge of the conveyor prior to
changing direction.
To adjust the prox switches:
6Use a at head jeweler’s screw driver to loosen the set screw.
6Relocate prox switch to desired location. Prox switch slides in channel.
6Tighten set screw and test system to ensure proper set-up.

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MAINTENANCE (Common)
Proper maintenance of the belt washer will result in years of trouble free operation. The following
maintenance schedule is based on the belt washer being used two days per week. If the washer is used more
than the two times per week, decrease the maintenance schedule time periods proportionally.
DAILY (COMMON)
6Check that all hardware is present and secure.
6Check that all air hoses and water lines are secure and in good condition.
6Replace all worn hoses
6Verify that the water pump has the proper oil level.
6Oil level at dot in sight glass
6Verify that the air line oiler is properly lled with food grade air tool lubricant.
6 Oiler lled with food grade air tool lube
6If the air motor oiler needs to be lled with oil, remove the screw as shown below
30 DAYS (COMMON)
Remove and check the water pump inlet strainer. Clean Strainer if Required

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90 DAYS (COMMON)
Drain oil in the water pressure pump by removing the lower drain plug in gear box. Replace the oil with 30W
non-detergent oil. CHANGE THE OIL AFTER 40 HOUR BREAK-IN PERIOD. THEREAFTER CHANGE THE OIL
EVERY 3 MONTHS OR 500 HOUR INTERVAL.
6After draining oil, remove dipstick to add oil.
6Fill with 30W non-detergent oil.
6Fill to dot in sight glass. DO NOT OVERFILL.
6Check spray nozzles for clogs and/or wear.
6Always make sure that the spray tip is parallel to the shaft.

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180 DAYS (COMMON)
Remove the bolts securing the motor to the pump’s bell housing. Check the motor coupling for worn, broken
or missing bushings. Repair/replace as required
Motor coupling inside bell housing
DAILY (ROTARY HEAD ONLY)
Check the drive chain transmission from the air motor to the rotating washing arm. Check for sprocket
and chain wear and proper chain tension. The drive chain needs 0.5” of slack. The tension is adjusted by
loosening the air motor on the washer head housing and repositioning the motor to obtain the correct
tension. Recheck tension after motor is rmly re-tightened to washer head housing.

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30 DAYS (ROTARY HEAD ONLY)
Grease the water union on the washer spray head. Use food grade grease only.
6Fill the Air Motor to proper oil level using 10W high detergent oil. Remove the upper level set
screw to add oil. Fill the air motor gear box until oil ows out of upper ll hole. Replace set
screw.
6Open the water union lter and check for debris build-up. Clean and repair as required
6After re-assembly, rotate nozzle-cleaning arm by hand and check for excessive wear in the arm
bushing.
6Check the Air Motor for clogging. Clean using solvent if required

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MAINTENANCE SCHEDULE (Rotary Head)
Procedure Daily Monthly 90 Days 180 Days
Days
Check the washer head drive chain tension X
Check the hardware condition X
Check all air and water hoses X
Check the water union inlet screen lter X
Grease the water union on washer spray head X
Check the spray nozzles for clogs and wear X
Change the oil in air motor X
Clean the water union lter X
Check the Air Motor Mufer X
MAINTENANCE SCHEDULE (Linear Head)
Procedure Daily Monthly 90 Days 180
Days
Check the hardware condition X
Check all air and water hoses X
Check the spray nozzles for clogs, wear and loose
mounting hardware.
X
MAINTENANCE SCHEDULE (Pump & Cart)
Procedure Daily Monthly 90 Days 180
Days
Check the hardware condition X
Check all air and water hoses X
Check the water pump oil level X
Check the air line Oilier oil level X
Check the water pump lter screen X
Change oil in water pump-30W non-detergent X
Check the water pump motor coupling X