Douglas GCW-1 User manual
GCW-1
OPERATION GUIDE
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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IMPORTANT ......................................................................................................................................................................................... 5
PRE-INSTALLATION .......................................................................................................................................................................... 5
DELIVERY .............................................................................................................................................................................................. 6
SAFETY PRECAUTIONS................................................................................................................................................................... 7
DO’S AND DO NOT’S........................................................................................................................................................................ 8
START UP ............................................................................................................................................................................................. 9
LOCATE THEM BOTH........................................................................................................................................................................ 9
OPERATION.......................................................................................................................................................................................11
MAINTENANCE.................................................................................................................................................................................12
PROGRAMMING ...............................................................................................................................................................................14
1827 PC BOARD...............................................................................................................................................................................14
PROGRAMMING THE TOUCH PAD PC BOARD....................................................................................................................16
CONTENTS
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IMPORTANT
PRE-INSTALLATION
Qualied 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. Qualied 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. Qualied 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. Qualied 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 Ofcials (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
notied 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 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.
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DO’S AND DO NOT’S
DO’S
6 Before attempting any maintenance or repairs, ensure that electrical supply to the unit 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 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 qualied service person.
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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).
6Locate 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.
6Shut off all breakers going to the heaters if electrically heated (breakers will be marked
WASH HEATER, RINSE HEATER).
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 overow, reprogramming of the auto ll may be necessary
(refer to Programming the 1827 Board). 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 30 psi 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. We’re 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
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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.
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 specic 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.
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OPERATION
With the machine turned on, lled to the overow, 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 specically 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 specications 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.
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MAINTENANCE
Daily Maintenance
Note: As a precaution please disconnect, or turn off all incoming power to machine before proceeding with
any maintenance.
Regular maintenance is essential in keeping your machine in good working order and operating at maximum
efciency. The following maintenance items listed are a minimum requirement; frequency of maintenance is
dependent on the number of hours the machine is in use and amount and type of soil being removed.
These daily maintenance items need to be done at the end of a regular shift, or if you feel the machine is not
cleaning as well as it was previously.
6With the Power Coming To The Machine Turned Off, start draining the machine. Unless
machine is equipped with electric drain. If machine does have electric drain, leave power on
until drained. After the machine has drained. Clean the inside of the wash cabinet. Direct all
debris toward and into the lter baskets. Remove and clean the lter baskets, leaving them
out for the following steps.
6With the lter baskets removed. Finish cleaning the wash tank reservoir. Direct all remaining
debris into the open drain located in the bottom of the reservoir tank.
6Now will need to clean the low water probe. This probe will be a white plastic item mounted
into the side of the wash reservoir tank under the lter basket location, its 3/8” in diameter
2½” long with a 3/16” x 1/4” metal tip. The purpose of this probe is not to allow the heat
source or pump motor to turn on unless the wash tank is full of water. Clean the metal tip of
this probe with some sort of scouring pad. Remove all scale and residue. Failure to do this
will void warranty to related items.
6If 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.
6Now 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.
6Inspect 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.
6Clean the outside of the machine. Using a stainless steel cleaner or soft cloth with a mild
detergent wipe down the outside of the machine.
6Close the drain valve, check that the lters are back in place, and turn the main power back
on. Wait to rell 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.
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Periodic Maintenance
6Wash pump motor lubrication. You’ll nd two- (2) grease tting on the top of the wash
pump motor, one- 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.
6The 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.
6Electrical 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.
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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.
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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 overow level, turn the Off/On/Fill switch again to the Fill position.
Observe that the Fill Time is set.
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PROGRAMMING THE TOUCH PAD PC BOARD
Before starting the programming, make sure the 120 volt service is turned on and there is no water in the
wash tank. With the control voltage turned on, the colon on the touch pad display will be illuminated and
ashing.
To initiate programming, depress the stop button, then depress the power button by holding both buttons
at the same time until you hear a beep and see four 0’s (0.00:0) on the display. At this point the machine will
automatically ll with water until the level reaches the probe. After this, you may begin the programming.
The programming for the ll of the wash tank will be rst, and could be the only function you need to pro-
gram. All other functions have been factory preset.
Initiate Auto Fill by depressing the long cycle button. The ll process will start and the display timing will
begin. After the water level has reached overow, depress the medium cycle button. This will stop the ow
of water and display timer. Next, depress the short button to enter the programmed time into the PC Board.
After programming the wash tank ll, depress the short button to scroll through the remaining functions
either to exit the program mode or make any changes to the following functions. In order to exit the program
mode, you may scroll through the remaining functions or depress the stop button for two seconds.
61. Auto Fill Time
62. Heater Delay (preset at 15 seconds)
63. Short Wash Cycle Time (preset at 4 minutes)
64. Medium Wash Cycle Time (preset at 6 minutes)
65. Long Wash Cycle Time (preset at 8 minutes)
66. Rinse Time (preset at 30 seconds)
67. Dwell and Fan Time (preset at 1 minute)
The settings on these functions can be changed while viewing the preset times. Depressing the medium
cycle button will decrease the time. Depressing the long cycle button will increase the time. After any change
has been made, you must depress the short button to enter the change.
If an error code is present on the display, you must identify the error, resolve the problem and clear the error
code from the PC Board. To clear error codes from the touch pad display depress the stop button. Error
codes are as follows:
6Er01: The machine has exceeded the allowable ll time, indicating low incoming
water pressure
6Er02: The stop button has been pressed during the wash cycle
6Er03: Excessive water loss during operation
6Er04: Control board error, may need reprogramming
6Er05: Operation of the machine has been attempted without adequate water in the
wash tank
6Er06: Door has not closed properly
6Er07: Pump overload device has been tripped
WASHING AND SANITIZING SYSTEMS
IMPORTANT NUMBERS
FOR WARRANTY WORK YOU MUST CALL DOUGLAS MACHINES CORP.
AT 800-331-6870 AND WE WILL ISSUE A PURCHASE ORDER
TO THE LOCAL SERVICE AGENT.
FOR PART OR TECHINCAL SUPPORT, PLEASE CALL
DOUGLAS MACHINES CORP. AT 800-331-6870
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