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17501-MANUAL PROCECO.pdf
1. TYPHOON
®
-RCP
Reciprocating Nozzle Frame Washer
PROCECO Serial Nº: 17-501
Model: RCP 4×4×10-G-10000-R-BO-SC
Customer:
Operation, Maintenance & Parts Manual
ABOUT THIS PDF VERSION OF YOUR MANUAL
• This PDF is designed for 2-sided printing and contains some drawings on 11"x17" size paper. If your printer
does not have this size of paper, be sure to set your PDF print settings to "Fit".
• The documents listed in the SUPPLIER DOCUMENTS section of the Table of Contents are not included in
this PDF but are available in the "Supplier documents" sub-folder of the CD accompanying this manual
when shipped with the Proceco equipment or from Proceco Customer Service Department if this manual
is provided by E-mail.
11. WUA
WARRANTY
WARRANTY POLICY
PROCECO warrants each machine manufactured to be free from defects in materials, parts and workmanship under normal
use and service. Such obligation under this warranty being limited to making good at PROCECO's factory, any part or parts
thereof which shall, within one (1) year after shipping date to the original purchaser, be returned to PROCECO with transpor-
tation charges by customer, and which PROCECO's examination shall disclose to its satisfaction to have been defective.
PROCECO does not accept any responsibility for consequential damages or losses caused by malfunction of the equipment.
During the warranty period, any modifications or service must be made with the agreement of PROCECO. The customer is
responsible for scheduled maintenance, and only replacement parts specified by PROCECO can be used during the warranty
period.
The use of any chemistry other than that identified for use in the equipment during the equipment approval stage is not PRO-
CECO’S responsibility. To seek approval of the safe use of alternate chemistry, please submit a written request for approval
to PROCECO Service (service@proceco.com) along with MSDS and product data sheets.
14. 17501-IA1 INSTALLATION BULLETIN
PAGE 2 OF 5 INSTALLATION INSTRUCTIONS FOR PROCECO RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
MOVING YOUR EQUIPMENT
WARNING
Every precaution should be taken when moving
heavy loads. Only qualified personnel with ade-
quate equipment should move or lift such loads.
Whenever possible, we recommend moving your washer
with a crane fitted with cables or belts
LIFTING POINTS
Your washer has four lifting holes located inside the cabinet
as illustrated above. The cabinet doors must be fully open
when lifting the equipment.
Use proper lifting cables or chains with a crane. These
should be long enough to keep the machine balanced when
lifting.
IMPORTANT
Keep in mind that the center of gravity will not be
at the exact venter of the machine but somewhat
closer to the sludge conveyor end of the washer.
UNPACKING AND PLACING
The first step in getting your new Proceco washer up and
running is to unpack the entire system, place the equipment
at its intended location, and tighten any fittings that may
have become loose during transport.
Unpack Equipment
1. Remove all blocking, strapping and protective covering
provided for the transportation to the site.
2. Remove any tie-wraps that may have been used to im-
mobilize float switches
3. Close all tank drain valves (the machines are normally
shipped with the drain valves open).
Level the Washer
It is important to properly level your equipment to ensure
the correct operation of pumps and other moving parts.
1. Identify the location for the unit’s corner footpads and
clean the area.
2. Place the washer at its intended location.
3. Using straight levels on the edge of the unit (item 1 in
the illustration above), level the equipment in one di-
rection (2) by adding shims of various thicknesses
where needed under all feet.
4. Level in the other direction (3) by adding shims only un-
der the feet on the side that is lowest.
5. Be sure to ensure that the equipment is level before at-
tempting to fill its solution tanks.
Anchor the Washer
Once the washer is level, anchor the entire assembly to
your shop floor through the holes in the footpads.
Tighten All Fittings
Vibrations occurring during transportation can cause fit-
tings to loosen. Please verify the tightness of all fittings dur-
ing installation.
Check Nozzles
Nozzles are normally installed and adjusted for optimal per-
formance at our factory. Check to ensure that none were
damaged or removed during shipment. For more infor-
mation, see any relevant nozzle bulletins in the MAINTE-
NANCE section of this manual.
Install Components Removed for Transport
Exhaust Blower
Install exhaust blower and motor if it was removed for
shipment.
1. Prepare all surfaces to be joined by applying a silicone
bead to ensure a good seal.
2. Bolt blower in position with gasket. Make connections
to the motor. All wires are identified for ease of recon-
nection.
NOTE
For exhaust ducting, contact a qualified ventila-
tion specialist.
Triple Bag Filter Assembly
Install the triple bag filter assembly as indicated on the
drawing in the DESCRIPTION section of this manual. Be sure
to use the supplied gaskets and apply silicone sealant to all
joints to ensure a good seal.
2
HOOKS
2
HOOKS
1
2
3
15. 17501-IA1
INSTALLATION INSTRUCTIONS FOR PROCECO RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501 PAGE 3 OF 5
Gas Heating System
The gas heating system installation is explained in “Gas
Heating” on page 4.
INSTALLING SERVICE CONNECTIONS
WARNING
Only qualified and properly trained personnel
should install and assemble the different com-
ponents of this machine.
All services must be sized accordingly and con-
form to local codes, standards and regulations.
Customer is responsible for the sizing, supply
and connection of all services.
Gas burner ducting should installed by a quali-
fied specialist according to your local codes and
regulations.
Solution Tank Drain Connection
Connect all tank drain outlets to the plant sewer or water
treatment system as required by local codes.
Solution Tank Overflow Connection
Connect the tank overflow outlet to the plant sewer or wa-
ter treatment system as required by local codes. The over-
flow outlet is identified with an engraved nameplate and is
shipped with a cap attached.
CAUTION
Do not attempt to operate your washer with the
overflow pipe capped and not connected. Fail-
ure to connect your washer’s solution tank
overflow outlets to the proper drain facilities
may result in damage to your equipment or
plant.
Container for Oil Skimmer Outlet
Place a container under the oil skimmer outlet pipe.
Containers for Sludge Conveyor Outlet
Place containers under the sludge conveyor outlet chute.
Water Inlet Connection
Connect the plant's fresh and/or de-ionized water supply to
the washer’s freshwater inlet.
High-Voltage Electrical Connections
Connect the washer to a power supply. Amperage is
marked on the nameplate affixed to the electrical panel.
WARNINGS
Although we make every effort to tighten
the high-voltage electrical connections at
the factory, some of them may have loos-
ened during transport. We strongly recom-
mend that the high-voltage electrical con-
nections be re-tightened prior to connecting
power to the washer.
All the motor breakers in the main control-
panel enclosure have been positioned to
“off” for washer transport.
Only qualified personnel should make or
modify electrical connections. High voltage
is present is the control enclosure when the
washer is powered.
Check motor rotation direction
Check the direction of a motor rotation. Be sure it matches
the arrow indicator on the motor.
1. Select a motor that has not been disconnected for
shipment; for example, the exhaust blower or pump
motor. Position its motor breaker to ON.
2. Move the main disconnect switch on the electrical
cabinet to its ON position.
3. Start the motor by manually activating its contactor.
Run the motor only long enough to verify the rotation
direction.
NOTE
Stay away from any moving parts when
verifying the motor rotation direction. Do
not wear jewelry or loose clothing.
4. If the rotation direction is incorrect, cut all power to the
washer, reverse any two main power leads to the main
disconnect switch in the control panel (the rotation of
all motors was checked at our factory before shipping).
5. All motors not disconnected for shipment should now
be running in the correct direction.
6. Check any motor disconnected for shipment. If the ro-
tation direction is incorrect, reverse the power leads at
the motor starter, not at the main disconnect switch in
order to retain proper rotation direction of the motors
not disconnected for shipment.
16. 17501-IA1 INSTALLATION BULLETIN
PAGE 4 OF 5 INSTALLATION INSTRUCTIONS FOR PROCECO RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
Activating the Stage Timers
The WASH STAGE, FRESHWATER RINSE & BLOW-OFF TIMERs on
the electrical panel were de-activated prior to shipment to
preserve their internal batteries. Before using the timers,
you must re-activate them as follows:
1. Remove the retaining screw at the bottom of the front
panel on each timer.
2. Remove the unit.
3. Locate the seven (7) miniature rocker switches located
inside the unit housing.
4. Position the 6th switch to ON to activate the battery.
5. Replace unit and screw.
Gas Heating
IMPORTANT
A gas-burner specialist should recommend duct-
ing size and type and make the final adjustments
on the gas burner according to your local codes
and regulations before it is operated. Proceco
Ltd. is not responsible for this work.
Gas burners are adjusted at our plant, but every
installation is unique and the burner normally re-
quires additional adjustments once the washer is
installed at your site. Failure to have these ad-
justments done may seriously impair burner effi-
ciency.
6. Install the gas burner if it was removed for shipment.
Make sure the gasket is between the connecting
flanges. Make electrical connections to the burner and
verify burner blower rotation.
7. Reassemble the gas piping to the burner at the pipe un-
ion with the proper sealant on the threads.
8. Connect your gas supply to the burner inlet using ap-
proved piping and sealant materials.
9. Duct the combustion exhaust pipes, located on top of
the washer, to the outside. The exhaust ducting must
conform to local codes and is generally one nominal
size larger than the combustion exhaust pipe.
WARNING
Exhaust temperature may be as high as
1000°F (538°C). Local codes may require
that the exhaust ducting be insulated. Con-
sult a gas specialist familiar with your local
codes.
10. To start the burner, refer to the burner documentation
in the SUPPLIER DOCUMENTS section of this manual. Only
a qualified combustion specialist should perform all re-
lated installation and maintenance.
Exhaust Blower Ducting
IMPORTANT
The following suggestions are provided as gen-
eral guidelines only. Consult a ventilation spe-
cialist for the most suitable information for your
specific installation.
Exhaust blower discharge should be ducted to the out-
side using the shortest distance possible using water-
tight joints. Install the ducting in such a way that con-
densate will return to the washer cabinet. The exhaust
duct should extend into the blower discharge opening to
eliminate leaks at the flange.
Recommended materials for ducting are stainless steel and
CPVC. Aluminum and galvanized steel ducting should not be
used unless otherwise specified and approved by Proceco.
Blower Outlet Dimensions
Your washer’s exhaust blower outlet dimensions are indi-
cated on the diagram in the DESCRIPTION section of this
manual.
Determining Ducting Diameter
Your exhaust ducting may involve a combination of straight
ducting and various 30°, 45°, 60°, or 90° elbows. The flow
rate of exhaust discharge in this ducting is affected by the
length of straight ducting and by the elbows.
To estimate the effect of each elbow on the flow rate, con-
vert it to the approximate straight length of ducting that
would have an equivalent effect on flow rate. Then add all
these equivalent lengths together with the real estimated
straight length. The total equivalent ducting length deter-
mines the best ducting diameter.
1. Estimate the total straight horizontal and vertical duct-
ing length required.
2. Determine a preliminary diameter for your ducting us-
ing the following table:
TOTAL ESTIMATED
DUCTING LENGTH*
RECOMMENDED EXHAUST
DUCT DIAMETER
0–7.5 metres 25 centimetres
7.5–23 metres 30 centimetres
23–46 metres 35 centimetres
*For values outside this range, consult a ventilation specialist.
3. Determine the type and quantity of ducting elbows re-
quired to complete the exhaust ducting.
17. 17501-IA1
INSTALLATION INSTRUCTIONS FOR PROCECO RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501 PAGE 5 OF 5
4. Use the following table to convert all elbows into
equivalent lengths of straight ducting according to the
elbow angle. (For other types of ducting elements, con-
sult a ventilation specialist for equivalent straight
lengths).
PRELIMINARY
DIAMETER
EQUIVALENT LENGTH FOR ELBOW ANGLES
90° 60° 45° 30°
10 cm 3.05m 1.83m 1.52m 0.91m
15 cm 3.65m 2.44m 1.83m 1.22m
20 cm 4.57m 3.05m 2.44m 1.52m
25 cm 6.10m 4.27m 3.05m 2.13m
30 cm 7.62m 5.18m 3.96m 2.44m
35 cm 9.14m 6.10m 4.57m 3.05m
40 cm 10.97m 7.32m 5.49m 3.65m
45 cm 12.50m 8.53m 6.40m 4.27m
5. Add all equivalent straight lengths to the estimated re-
quired total straight length.
ESTIMATED
LENGTH OF
STRAIGHT DUCT-
ING
+
TOTAL
EQUIVALENT
LENGTH FOR
ELBOW ANGLES
=
TOTAL
ESTIMATED
DUCTING
LENGTH
6. With this total estimated length, determine the final
recommended duct diameter as follows:
TOTAL ESTIMATED
DUCTING LENGTH*
RECOMMENDED EXHAUST
DUCT DIAMETER
0–7.5 metres 25 centimetres
7.5–23 metres 30 centimetres
23–46 metres 35 centimetres
*For values outside this range, consult a ventilation specialist.
NOTE
Be sure to use the final recommended diameter
calculated with the equivalent elbow lengths,
even if it is different from the preliminary diame-
ter calculated in step 2.
If the required length of straight ducting ex-
ceeds the lengths shown in the following tables
(or for more accurate information on exhaust-
ing), consult a ventilation specialist.
20. BIA-0005 START-UP BULLETIN
Revision 10
PAGE 2 OF 5 INITIAL STARTUP INSTRUCTIONS FOR PROCECO CONVEYOR WASHERS
SOLUTION TEMPERATURE controllers monitor the current
temperature in the solution tanks or heating blow-off
sections/dryers and start or stop heating according to
programmed values and display alarm indicators when
the temperature values are outside of programmedlimits.
PV
PV
SV
SV
PF
PF
SUB3
SUB2
SUB1
TUNE
MANU
OUT2
STOP
RSP
CMW
OUT1
START/STOP pushbuttons toggle devices on and off.
MOTORS
START/STOP
OPERATOR TOUCHSCREEN (machines equipped with a pro-
grammable logic controller) displays screen messages
and buttons for controlling most machine functions.
Other pushbuttons, selector switches, indicator lights,
etc., may be located on the control panel. These are la-
beled according to their function.
Loading/Unloading Stations
Some models also feature remote operator consoles or but-
tons located at loading and/or unloading stations. These may
include extra EMERGENCY STOP buttons,CONVEYOR START/STOP
buttons, LOAD DONE buttons, etc. For more information, see
the DESCRIPTION and OPERATION sections of this manual.
POWER UP
1. Connect current to the machine by moving the Main Dis-
connect to the ON position.
2. Retract any red EMERGENCY STOP push-pull buttons that
may be pushed in.
3. Press the SYSTEM START button on the electrical panel.
This signals the system to send power to the system con-
trols so that you can set up your equipment.
NOTE
Because you have not yet filled your solution
tanks or heated their contents, the low solu-
tion level alarm control will indicate an alarm
condition. For machines equipped with op-
erator touchscreens, an alarm message will
appear onscreen.
CHECK SAFETY CIRCUITS
WARNING
It is essential to make sure that your machine’s
safety circuits are functioning correctly. Injuries
to personnel may occur if a solution pump is able
to operate when an access door is open. Because
of high-pressure, chemical concentration, and
high heat, exposure to solution sprays may cause
blindness, burns, and other serious or fatal inju-
ries.
Machine safety circuits are set and verified at our factory but
must be checked again after the washer installation.
Machines without PLC/HMI touchscreen
1. Make sure the wash solution pump breaker is off.
2. Open each access door, cover, etc., one at a time and try
to start the wash solution pump using the appropriate
button or control.
3. If the pump contactor makes a noise as if it is trying to
activate the pump, the limit switch on the door or cover
currently open may have been damaged during transport
and may not be functioning properly. Check limit-switch
operation; look for a loose wire, etc.
4. When the cause of malfunction has been found and
corrected, repeat this test.
To prepare the machine for further testing, you have to first fill
the solution tanks with water only. Do not add cleaning deter-
gent until you’ve completed the tests outlined in this docu-
ment.
IMPORTANT
Before attempting to fill the solution tanks, make
sure any drain outlets are closed.
21. BIA-0005
Revision 10
INITIAL STARTUP INSTRUCTIONS FOR PROCECO CONVEYOR WASHERS PAGE 3 OF 5
Filling the Solution Tank (with Water Only)
To prepare the machine for further testing, you must first fill
the solution tanks with water only. Do not add detergent
until you’ve completed the tests outlined in this document.
IMPORTANT
Before attempting to fill the solution tanks, make
sure any drain outlets are closed.
1. Open any valve you have installed to control the water
inlet to begin filling the solution tanks.
2. The automatic solution make-up system fills the tanks
with water to the normal operating level as adjusted at
our factory.
IMPORTANT
During the normal operation of the machine,
leave your main water inlet valve open at all
times so that the solution losses may be re-
placed continuously by the automatic solution
make-up system.
3. Once the water level in the tanks reaches the minimum
required for operation, the solution heating process
starts.
4. Once the water level in the tanks reaches the minimum
required for operation, the solution heating process
starts.
You should allow sufficient time (1-4 hours depending on
the tank capacity) for the water to heat up before testing
the washer. During this heating period, any temperature
controllers installed on your machine that are monitoring
solution temperature may report that the current value is
out of range. This is normal and requires no intervention.
NOTE
Verify that the water level is indeed at the lev-
el indicated on the side of the tanks. If the wa-
ter is too high or too low, the solution level
make-up control adjustment may have moved
during transport. For adjustment
information, consult the MAINTENANCE
section of this manual.
Machines WITH PLC / HMI Touchscreen
1. Follow the directions in the previous section “Filling the
Solution Tank (with Water Only)”.
2. Wait until the operator touchscreendisplaystheMACHINE
IS READY message.
3. Open a cabinet door or cover.
4. Check the operator touchscreen for a message stating
that the door or cover is open.
This indicates that the safety circuit is working properly.
If not, check the safety circuit using the electrical sche-
matic provided in the SCHEMATICS & DRAWINGS section of
this manual.
CHECK FILTER DRAIN PLUGS
Verify that the drain plug at the bottom of each bag or car-
tridge filter housing does not leak. PROCECO technicians
drain filters at the factory before shipping and there is no way
to check the plug seal integrity until the customer fills up the
washer tanks with water and runs the pumps. If a plug leaks,
tighten the plug accordingly.
If the plug is tight and still leaks, remove the plug (a large
enough container should be positioned under the bag filter
body as it will empty its contents), redo the Teflon tape seal
on the plug threads and reinstall.
LEARN OPERATING PROCEDURES
Procedures for operating the machine are explained in the
OPERATING INSTRUCTIONS bulletin located in the OPERATION
section of this manual.
RUN TEST CYCLES
Before loading detergent that could leak, it is important to run
your equipment through a test cycle to ensure that all systems
are operating normally and that the equipment did not incur
any damage during shipping.
Wait until the solution reaches its operating temperature.
Machines WITHOUT a Programmable Logic Controller
1. In each of the stage timers, enter several minutes.
2. Follow the directions in the OPERATION section of this
manual to run a cleaning cycle through to its end.
3. While the machine is running, check for leaks in the sys-
tem plumbing. Since PROCECO must drain plumbing be-
fore shipment, there is no way to check seal integrity un-
til the customer fills up the solution tanks with water and
runs the pumps. Press the red EMERGENCY STOP button if
any problem occurs. Then identify the problem and cor-
rect it before attempting to run the machine again
4. If your washer is equipped with an oil skimmer, oil coa-
lescer or sludge conveyor, run it for several minutes to
ensure proper operation and no leaks. This may require
you to program the 7-day timer for the device to tempo-
rarily enter a period of activity. For the programming pro-
cedure, see the appropriate bulletin in the OPERATION or
PROGRAMMING SECTION of this manual.
22. BIA-0005 START-UP BULLETIN
Revision 10
PAGE 4 OF 5 INITIAL STARTUP INSTRUCTIONS FOR PROCECO CONVEYOR WASHERS
IMPORTANT
Be sure to change the 7-day timer settings
back to their default settings. Running these
devices during the hours of machine use can
adversely affect the cleaning process.
5. If all the washer components are functional, change the
stage timers by entering values for cleaning parts ac-
cording to your specific needs.
6. Run the washer through several additional test cycles.
7. If everything checks out, the washer is now ready for
normal operation and chemicals may be added to the so-
lution tanks.
Machines WITH a Programmable Logic Controller
The operator touchscreen displays the message MACHINE IS
READY.
1. Check the duration values on the SETUP and PROCESS SET-
TINGS screens to make sure there are values entered in
each.
NOTE
Access to some screens requires the system
password as explained in the PROGRAMMING
section of this manual. If you do not know the
password, speak with your administrator.
2. Start a cleaning cycle by pushing the START button on the
touchscreen. Let the cycle run to until it is complete.
3. While the machine is running, check for leaks in the sys-
tem plumbing. Since PROCECO must drain plumbing be-
fore shipment, there is no way to check seal integrity un-
til the customer fills up the solution tanks with water and
runs the pumps. Press the red EMERGENCY STOP button if
any problem occurs. Identify the problem and correct.
4. If your washer is equipped with an oil skimmer, oil coa-
lescer or sludge conveyor, run it for several minutes to
ensure proper operation and no leaks. This may require
you to program the 7-day timer for the device to tempo-
rarily enter a period of activity. For the programming pro-
cedure, see the appropriate bulletin in the OPERATION or
PROGRAMMING SECTION of this manual.
IMPORTANT
Be sure to change the 7-day timer settings
back to their default settings. Running these
devices during the hours of machine use can
adversely affect the cleaning process.
5. If all the washer components are functional, program
your machine with values for cleaning parts according to
your specific needs.
6. Run the washer through several additional test cycles.
7. If everything checks out, the washer is now ready for
normal operation and chemicals may be added to the so-
lution tanks.
LOAD DETERGENT
IMPORTANT
Check your washer’s model number on the en-
graved metal plate on the side of the electrical
panel. If the model number does not contain “SS”,
this important note applies to your washer.
Machines without the designation SS in their
model number are manufactured withmill-certified
carbon steel in accordance with ASTM standards.
PROCECO recommends the use of an alkalineparts
washer detergent formulated with built-in corro-
sion inhibitors. To protect steel surfaces from
premature rust and corrosion, you must maintain a
minimum concentration of 2-3% and a pH level
greater than 10.5.
Over time, the concentration of detergent in a solu-
tion decreases. To avoid corrosion in tanks con-
taining a detergent solution, be sure to check the
solution concentration regularly, preferably every
50 hours or weekly. If your incoming water is hard
(above 7 GPG), it will react with most alkaline de-
tergents, reducing their rust inhibiting properties.
Please contact your chemical supplier for more in-
formation.
PROCECO Ltd. is not responsible for any damage
to your equipment or lack of cleaning perfor-
mance if you do not follow these recommenda-
tions.
We recommend that you drain the solution tanks a few inches
or centimetres before adding the chemicals. This is a precau-
tion so the tanks are not overfilled by chemicals and costly
chemical is not lost in the tank overflow, located a short dis-
tance below the top of the tanks. After chemical addition, fill
the tanks to their correct level.
23. BIA-0005
Revision 10
INITIAL STARTUP INSTRUCTIONS FOR PROCECO CONVEYOR WASHERS PAGE 5 OF 5
WARNINGS
Basic safety measures should be observed
whenever personnel carry out work near or in
solution tanks containing chemicals. Wear
gloves, goggles, and appropriate clothing.
Refer to your chemical supplier's documenta-
tion for more information on this subject.
The use of any chemistry other than that identi-
fied for use in the equipment during the equip-
ment approval stage is not PROCECO’s respon-
sibility. To seek approval of the safe use of al-
ternate chemistry, please submit a written re-
quest for approval to PROCECO Service (ser-
vice@PROCECO.com) along with MSDS and
product data sheets.
If the detergent is supplied in liquid form, it can be poured or
pumped directly into the appropriate tanks through their ac-
cess cover. If the detergent is supplied in powdered form, it
can be added to the spray cabinet according to the manufac-
turer's recommendations. This ensures thatpersonnelwillnot
be exposed to adverse chemical reactions.
IMPORTANT
Never empty a solution tank before the power is
switched off. If the tank’s low-level solution level
control malfunctions or is disabled, the heating ele-
ments will no longer be fully submerged in liquid,
and will overheat and/or burn out.
REMOVE RUST INHBITING OIL
To protect against rust during transport and storage, the in-
side of carbon-steel washers (those without the designation
SS in their model number on the nameplate affixed to the
electrical panel) is sprayed with a rust inhibiting oil prior to
shipping. Some of this oil may accumulate in the bottom of the
tanks during transport. To remove this oil from the inside
walls, we suggest running the washer through a cycle with
the normal concentration of the detergent recommended for
your washer and at your normal operating temperature.
After running your washer to remove the oil, completely drain
the solution tanks and refill according to the instructions in
this bulletin.
26. 17501-OA1 OPERATION BULLETIN
PAGE 2 OF 4 OPERATING INSTRUCTIONS FOR RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
SYSTEM CONTROLS
The controls for your washer are located on the electrical panel door.
1
2
3 4 5 6
7
8 9 10 11 12
13 14 15 16 17
18 19 20
21
27. 17501-OA1
OPERATING INSTRUCTIONS FOR RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501 PAGE 3 OF 4
1. MAIN DISCONNECT SWITCH mounted in the upper right
corner of the panel serves as the main breaker for all
electrical power flowing into the machine.
2. WASH SOLUTION TEMPERATURE controller monitors
the current temperature in the wash solution tank and
initiates an alarm if this temperature does not fall with-
in preset limits.
3. WASH STAGE TIMER
4. FRESHWATER RINSE TIMER
5. BLOW-OFF TIMER
These timers all control the duration of their respective
operations.
6. HEATING/SLUDGE 7-DAY TIMER controls the start and
stop time on any given day of the week for solution
heating, and sludge conveyor/oil skimmer.
7. OSCILLATION TIMER determines the speed of the oscil-
lation.
8. CYCLE START launches the cleaning cycle after a part
is loaded and the doors closed.
9. EXHAUST BLOWER WITH/AFTER selector switch tog-
gles the exhaust blower mode between running during
the cleaning cycle or after the cycle has completed.
10. CYCLE FINISHED indicator light illuminates when the
cleaning cycle is complete and the workpiece can be
removed.
11. SLUDGE CONVEYOR START/STOP pushbutton toggles
sludge conveyor operation.
12. OSCILLATION COLLISION warning light signals that os-
cillating nozzle frame has encountered an obstruction.
Stop the cycle using the EMERGENCY STOP pushbut-
ton, and then open the doors with the OPEN DOOR but-
ton. You can then use the OSCILLATION LEFT & OSCIL-
LATION RIGHT buttons to move the frame away from
the obstruction.
13. CLOSE SLIDING DOOR (left hand) causes the cabinet
doors to close when pressed and held at the same time
as pushbutton 15. The requirement for both buttons to
be pressed at the same time is a safety measure.
14. OPEN SLIDING DOOR causes the cabinet doors to open
when pressed and held.
15. CLOSE SLIDING DOOR (right hand) causes the cabinet
doors to close when pressed and held at the same time
as pushbutton 13. The requirement for both buttons to
be pressed at the same time is a safety measure.
16. SLUDGE CONVEYOR READY indicator light.
17. OSCILLATION HOME indicator light illuminates when
the hose carrier is at the home position.
18. SYSTEM START sends power to the system controls
and launches the solution heating system.
19. OSCILLATION LEFT manually moves the oscillating noz-
zle frame to the left. This is useful during load-
ing/unloading as well as for maintenance and trouble-
shooting.
20. OSCILLATION RIGHT manually moves the oscillating
nozzle frame to the right. This is useful during load-
ing/unloading as well as for maintenance and trouble-
shooting.
21. EMERGENCY STOP push-pull button stops all machine
functions immediately.
OPERATING THE WASHER
Once all the control features have been properly pro-
grammed and selector switches positioned, you are ready
to operate your washer. Wait until the solution reaches its
operating temperature.
1. Once the washing solution has attained its operating
temperature, open the cabinet doors with the OPEN
SLIDING DOOR pushbutton.
2. Carefully load the part to be cleaned using an appro-
priate crane.
WARNING
Every precaution should be taken when
moving heavy loads. Only qualified person-
nel with adequate equipment should move
or lift such loads.
Use caution when loading and unloading
parts. Do not wear jewelry or loose clothing.
3. Close the cabinet doors by pressing and holding both
CLOSE SLIDING DOOR pushbuttons.
NOTE
The wash solution pump motor functions on-
ly when the door is closed with firm contact
on the door limit switch.
WARNINGS
Always make sure that the door opening
is clear before closing the door. Use two
people for the operation if necessary.
To avoid serious injury, keep all body
parts away from opening when operating
the door.
4. Push the CYCLE START button to start washing. The
washer automatically performs all active stages in the
washing cycle.
5. When the washing cycle is finished, the CYCLE FIN-
ISHED indicator lights up.
6. Open the cabinet doors with the OPEN SLIDING DOOR
pushbutton.
28. 17501-OA1 OPERATION BULLETIN
PAGE 4 OF 4 OPERATING INSTRUCTIONS FOR RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
7. Remove parts. Load more parts as explained above for
another washing cycle.
STOPPING THE WASHER
In any case of danger or problem, press the red CYCLE
STOP pushbutton or the red push-pull EMERGENCY STOP
button. The washer stops automatically.
INTERRUPTING THE CLEANING CYCLE
With the EMERGENCY STOP button
Press the EMERGENCY STOP pushbutton. When you pull
EMERGENCY STOP pushbutton and press the CYCLE START
pushbutton, the timers are reset and the washer starts a
new washing cycle.
AT THE END OF THE WORKDAY
A 7-day timer controls your washer’s solution heating and
sludge conveyor/oil skimmer. Therefore, you must not use
an EMERGENCY STOP button to stop the washer. At the end
of the last cleaning cycle, leave the power on. The timer-
controlled activity will then stop and start according to the
settings stored in the 7-day timer.
CAUTION
To avoid unauthorized use of the equipment out-
side work shifts, we recommend that the main
disconnect switch be locked in the OFF position.
Solution heating will be disabled.
30. BOA-0031 OPERATION BULLETIN
Revision 8
PAGE 2 OF 2 SLUDGE CONVEYOR OPERATION
OPERATION
IMPORTANT
Do not run the conveyor during pump operation as this
stirs up any dirt that has not completely settled. In
such a case, this dirt is sucked up by the pump and
redeposited on the parts to be cleaned!
Sludge conveyor operation is normally controlled by a
7-day timer. This timer should be programmed to start the
conveyor a few hours after the last washing cycle (allow
enough time for the dirt to settle). It should run for 1-2
hours and stop at least a few hours before the next work
shift to allow sufficient time for dirt to settle to the tank
bottom.
Controls
On machines equipped with a PLC (Programmable Logic
Controller), sludge conveyor timers and operating controls
are integrated with the controller and associated operator
interface. Machines without a PLC normally feature a
SLUDGE CONVEYOR START/STOP push-pull button, a SLUDGE
CONVEYOR AWAITING 7-DAY TIMER indicator light, and a sepa-
rate SLUDGE CONVEYOR 7-DAY TIMER.
NOTE
The exact wording of labels identifying these controls
and indicator lights may vary.
Sludge conveyor control integrated with PLC
For machines equipped with a programmable logic con-
troller, the sludge conveyor's 7-day timer settings are
normally entered using the operator interface. Program
the sludge conveyor's 7-day timer according to the in-
structions in the PROGRAMMABLE CONTROLLER section of
this manual.
Such machines also feature operator interface control
buttons to start or stop the sludge conveyor. If the 7-day
timer is currently in an active period (in a period during
which the sludge conveyor is scheduled to be active), the
conveyor will start immediately. If the timer is in an inac-
tive period (a period during which the conveyor is not
scheduled to be active), the conveyor will only start op-
eration once the timer enters an active period.
Sludge conveyor control on systems without PLC.
The sludge conveyor is normally run in automatic mode.
It can also be used in a manual override mode. To pro-
gram the SLUDGE CONVEYOR 7-DAY TIMER for automatic
mode, consult the appropriate bulletin in the PROGRAM-
MING or SUPPLIER DOCUMENTS section of this manual.
Automatic mode
1. Make sure the ON/AUTO/OFF switch on the face of the
7-day timer is in the AUTO position.
1. Activate the sludge conveyor by retracting the
SLUDGE CONVEYOR START/STOP button.
7-DAY TIMER CURRENTLY IN AN ACTIVE PERIOD The
sludge conveyor starts immediately and the SLUDGE
CONVEYOR START/ STOP button lights up.
7-DAY TIMER CURRENTLY IN AN INACTIVE PERIOD The
SLUDGE CONVEYOR READY* indicator light comes on and
the SLUDGE CONVEYOR START/ STOP button remains
dark.
* This light is labelled SLUDGE CONVEYOR AWAITING
7-DAY TIMER on some washers.
The sludge conveyor will start operating when the 7-
day timer enters an active period. The SLUDGE CON-
VEYOR START/STOP button lights up and the SLUDGE
CONVEYOR AWAITING 7-DAY TIMER indicator goes out.
2. Push in the SLUDGE CONVEYOR START/STOP button to
stop the sludge conveyor at any time.
Manual Override Mode
1. Position the ON/AUTO/OFF switch on the face of the
7-day timer on the control panel to the ON position.
2. Retract the SLUDGE CONVEYOR START/STOP button. The
sludge conveyor starts operating and the button
lights up.
3. Push in the SLUDGE CONVEYOR START/STOP button to
stop the sludge conveyor at any time.
34. BOA-0049 PROGRAMMING BULLETIN
Revision 8
PAGE 2 OF 2 DUAL 7-DAY TIMERS: PROGRAMMING INSTRUCTIONS FOR OMRON H5L MODELS
2. The currently programmed day of the week flashes. Move
the day indicator using the plus or minus keys. Press the
Write key when the indicator reaches the current day of
the week.
3. The hour digits flash. Increment or decrement the value
using the plus or minus keys. Press the Write key when
you reach the current time.
4. The minutes digits flash. Increment or decrement the val-
ue using the plus or minus keys. Press the Write key
when you reach the current time.
5. Press the Mode key to move to the next mode.
PROG 1 – First circuit activity start/stop times
1. After pressing the Mode key, the PROG 1 indicator re-
verses color.
Setting the activity start time
1. The hour value flashes. Increment
or decrement it using the plus or
minus keys until you reach the hour
value for the activity start time.
Press the Write key to store this
value in memory.
2. The minutes value flashes. Incre-
ment or decrement it using the plus
or minus keys until you reach the
minutes value for the activity start
time. Press the Write key to store
this value in memory.
3. The output status indicator 1
flashes. Set the indicator to ON
(closed circuit ) by pressing
the plus key. Press the Write key
to store this value in memory.
IMPORTANT
Be careful not to press the plus key more than once. A
second press will cause an invalid indication and then
the Write key deletes this program from memory.
Setting the activity stop time
1. The hour value flashes again. In-
crement or decrement it using the
plus or minus keys until you reach
the hour value for the activity stop
time. Press the Write key to store
this value in memory.
2. The minutes value flashes. Incre-
ment or decrement it using the plus
or minus keys until you reach the
minutes value for the activity stop
time. Press the Write key to store
this value in memory.
3. When output status indicator 1
flashes. Set the indicator to OFF
(open circuit ) by pressing the
minus key. Press the Write key to
store this value in memory.
IMPORTANT
Be careful not to press the minus key more than once.
A second press will cause an invalid indication and
then the Write key deletes this program from memory.
4. The hour value flashes again. Since you entered the ac-
tivity start and stop times for the first circuit, press the
Mode key to move to the next mode.
PROG 1+DAY SET – First circuit days enabled
1. The day of week indicators that are
reversed indicate the days on which
the first circuit's activity start and
stop times are enabled. To disable a
certain day's use of the times, move
the indicator to that day using the
Write key.
2. Use the minus key to disable and the plus key to enable
the times for each day. Press the Write key to move to the
next day.
3. When all days are set, press the Mode key to move to the
next mode.
PROG 2 settings
1. After pressing the Mode key, the PROG 2 indicator re-
verses color indicating that you are now entering values
for the second circuit. Set up the activity start/stop times
and the enable/disable timers for days of the week in the
same way as for the first circuit.
2. When all times and days are set, press the Mode key to
return the timer to RUN mode.
MANUAL OVERRIDE SWITCHES
The manual override switches for circuits 1 and 2 have three
positions as follows:
RUN Circuit controlled by timer
ON Circuit overridden ON
OFF Circuit overridden OFF
ADDITIONAL INFORMATION
For more information on the Omron H5L timer, see the Omron
documentation. Its location is listed in the SUPPLIER DOCU-
MENTS section of this manual's table of contents.
PROG 1
1
PROG 1
1
PROG 1
1
PROG 1
1
PROG 1
1
SUN MON TUE WED THU FRI SAT
PROG 1
1
DAY SET
PROG 1
1
36. 17501-MA1 MAINTENANCE BULLETIN
PAGE 2 OF 5 MAINTENANCE SCHEDULE FOR TYPHOON®
-RCP RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
RECOMMENDED LUBRICANTS
Check the Table of Contents at the front of this manual for material safety data sheets included in the SUPPLIER DOCUMENTS section of this
manual. These list the lubricants recommended by Proceco or by manufacturers of purchased components for maintaining your equipment.
TASKS TO CARRY OUT DURING INITIAL USE
Be sure to carry out the following tasks to ensure trouble-free operation.
During first 150 hours of use
_ Check turntable drive chain tension. Chain must not be too loose or too tight.
_ Measure the current drawn by the pump motor and make note of the readings. This information can be used for measuring spray nozzle
wear. If the current measured at the maintenance intervals listed in this schedule exceeds your initial measurements by 15% or more,
some spray nozzles may be worn out and should be changed. Replace nozzles with same quantity, type, and capacity. For nozzle order-
ing information, see the REPLACEMENT PARTS section of this manual.
During first 500 hours of use
_ Observe cleaning performance and the cleanliness of your solution to determine how frequently you need to change the solution. The
frequency of solution change always depends on your specific cleaning needs. Change the cleaning solution frequently. The cost of the
solution can be lower than the time spent removing soil accumulated over a long time.
TASKS TO CARRY OUT AT EVERY SOLUTION CHANGE
Whenever you change the cleaning solution, you can perform maintenance tasks on components normally submerged in solution.Beforerefilling:
_ Inspect immersed portion of all temperature sensors and clean with wire brush. Chemical cleaning may be more effective for your spe-
cific situation. Consult your chemical supplier to obtain a product compatible with your water hardness and the chemicals used in your
solution.
_ Inspect heating pipes in solution tanks for mineral deposit accumulation. If excessive, thoroughly pressure rinse or brush to maintain
proper heat transfer.
_ While tank is drained, verify the cleanliness of solution level control float balls and clean if necessary.
_ Inspect immersed sections of pump for deposit accumulation, wear, or damage. Service as required.
PERIODIC MAINTENANCE TASKS
Make sure the tasks listed below are carried out at the intervals listed. Further information is contained throughout the MAINTENANCE section of
this manual.
FREQUENCY COMPONENT TASKS
EVERY 10 HOURS OR
DAILY
CHIP FILTERS _ Remove and rinse.
OVERALL SYSTEM _ Perform a brief visual inspection of all system components, hos-
es, electrical connections, etc. If there are any signs of damage,
leaks, etc., perform whatever maintenance is required to resolve
the problem. Failure to repair such problems as soon as possible
can result in costly repairs and downtime later!
EVERY 50 HOURS OR
WEEKLY
BAG FILTERS _ Check bags for plugging by comparing pressure readings at filter
inlet and outlet while the pump is running. If the pressure differ-
ence reaches 15 psi (103 kPa or 1 bar) or higher, replace bags.
BLOW-OFF _ Check compressed air supply nozzles
COMPRESSED AIR SUPPLY _ Drain any filters present on compressed air supply lines.
37. 17501-MA1
FREQUENCY COMPONENT TASKS
MAINTENANCE SCHEDULE FOR TYPHOON®
-RCP RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501 PAGE 3 OF 5
EVERY 50 HOURS OR
WEEKLY
(Continued)
SOLUTION _ Check concentration of chemical cleaning agent.
CAUTION
Your washer is manufactured with mill-certified carbon steel in
accordance with ASTM standards.
Overtime,theconcentrationofchemicalcleaningagentsinasolutionde-
creases.Toavoidcorrosioninsolutiontankscontainingachemicalclean-
ing agent, be sure to check the solution concentration regularly, prefera-
bly every 50 hours or weekly.
Acceleratedcorrosionwilloccurwhensurfacesareexposedtoplainwa-
ter. PROCECO recommends the use of alkali-based cleaning chemistry
containingrustinhibitingpropertiesand/orrustpreventiveadditivessuch
as amines. To prevent corrosion of ferrous components, a suitable con-
centrationofsuchadetergentshouldbeusedandapHlevelgreaterthan
11 should be maintained.
Mildalkalinecleanersshouldnotbeusedwithoutrustinhibitingadditives.
SPRAY NOZZLES _ Check for plugging. Unscrew, inspect, and clean as required.
_ Check for proper alignment.
_ Replace missing nozzles with same type and capacity.
EVERY 150 HOURS
OR MONTHLY
GAS SOLUTION HEATING SYSTEM _ Inspect heating pipes in solution tanks for mineral deposit accu-
mulation. If excessive, drain tank and thoroughly brush or pres-
sure rinse. While tank is drained, Inspect solution level control
float balls for deposits or dirt and clean if required.
RECIPROCATING CARRIER HOSES _ Inspect the hoses for damage. Replace if necessary.
EVERY 500 HOURS OR
EVERY THREE MONTHS
EXHAUST BLOWER _ Lubricate the shaft's pillow block bearings.
_ Check belt tension and tighten if necessary.
HOSES _ Check all hoses circulating solution for wear, cracks, and cuts.
Replace any hose that is damaged.
WARNING
A damaged hose may rupture. Heated solutioncontain-
ing corrosive chemicals may cause severe burns and
loss of eyesight.
HYDRAULIC UNIT _ Check filters and clean or replace as required.
_ Clean tank and all strainers.
_ Check oil filter. Clean or replace as needed.
_ Check the oil level in the hydraulic power unit and add oil if nec-
essary.
RECIPROCATING HOSE CARRIER
SLUDGE CONVEYOR
SOLUTION PUMP
_ Lubricate bearings where fittings are provided.
CAUTION
Overpacking a bearing with grease may cause it to fail
prematurely.
Clean and inspect assemblies. Repair or replace components as
required.
38. 17501-MA1 MAINTENANCE BULLETIN
FREQUENCY COMPONENT TASKS
PAGE 4 OF 5 MAINTENANCE SCHEDULE FOR TYPHOON®
-RCP RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501
EVERY 500 HOURS OR
EVERY THREE MONTHS
(Continued)
SPRAY NOZZLES _ Check for wear by measuring the current drawn by the solution
pump motor (make sure that no nozzles are missing before carry-
ing out this procedure).
_ If the measured current is 15% above the initial measurements
taken during the first 150 hours of operation or amperage infor-
mation on the motor, the nozzles may be worn out and should be
changed. Replace nozzles with same quantity, type, and capacity.
See the REPLACEMENT PARTS section of this manual for ordering
information.
EVERY 1000 HOURS
OR EVERY SIX MONTHS
NOZZLE PLUMBING _ Remove any plugs from nozzle plumbing, manifolds, etc., and
flush thoroughly to remove any blockage or buildup.
SLUDGE CONVEYOR _ Check the chain tension of the sludge conveyor. The chain should
be adjusted with the take-up bearing units in such a way that the
chain will have very little slack at the bottom but not so tight as to
impede operation.
_ Lubricate drive chain and check its tension. The drive chain
should be tight enough to move the conveyor during normal op-
eration but loose enough to slip if conveyor movement is ob-
structed (if its load is blocked). If adjustment is necessary, use
the drive chain tension adjustment bolt.
SOLENOID VALVES _ Clean valves and verify operation.
WATER INLET STRAINER _ Clean.
EVERY 2000 HOURS
OR YEARLY
BAG FILTERS _ Change O-ring cover seals.
GAS SOLUTION HEATING SYSTEM _ Change burner spark plug and flame rod.
GEARMOTORS _ Check oil level. Replenish as required.
NOTE
Some small gearmotors have no plugs to check the oil
level or to add oil. These gearmotors do not require
their oil level to be checked. However, The oil should
be changed every 4000 hours or two years..
HYDRAULIC UNIT _ Replace the oil in the hydraulic power unit. Use a petroleum-
based hydraulic fluid with anti-wear additives corresponding to
100 to 250 SUS at 100°F (38°).
OIL SKIMMER _ Check condition of disk oil skimmer scraping blades. If wear does
not permit the blades to apply sufficient pressure against the
disk, replace them.
MOTOR BEARINGS _ Lubricate bearings where fittings are provided.
NOTE
Some motors may have no fittings. These models have
sealed, permanently lubricated bearings.
39. 17501-MA1
FREQUENCY COMPONENT TASKS
MAINTENANCE SCHEDULE FOR TYPHOON®
-RCP RECIPROCATING NOZZLE FRAME WASHER, SERIAL Nº 17-501 PAGE 5 OF 5
EVERY 4,000 HOURS
OR EVERY TWO YEARS
GEARMOTORS _ Change oil.
EVERY 10,000 HOURS
OR EVERY FIVE YEARS
ELECTRIC MOTORS _ Inspect and service as required.
SPRAY CABINET _ Change spray nozzles
40.
41. BEA-0001
MAINTENANCE BULLETIN Revision 6
EXHAUST BLOWER ADJUSTMENTS
PROCECO BELT-DRIVE MODELS
WARNINGS
Only qualified and trained personnel
should service this component according
to all applicable codes and safety prac-
tices.
When maintenance work does not require
the washer to be powered, the power sup-
ply to the washer should be cut and the
main disconnect switch locked in the OFF
position.
Two adjustments can be made on the exhaust blower as-
sembly: Blower speed and V-belt tension.
NOTE
When the blower speed is adjusted, the belt
tension must be adjusted at the same time. Ad-
just blower speed and then adjust V-belt ten-
sion before testing blower speed.
BLOWER SPEED ADJUSTMENT
NOTE
The blower has been adjusted to atmospheric
conditions prevalent in our plant. Re-adjustment
may be required on site by the customer.
The exhaust blower is equipped with an adjustable (vari-
able-pitch) pulley on the drive motor shaft. The blower
speed is varied by modifying the effective diameter of this
drive pulley. As you move the two faces of the pulley
closer together, the effective diameter of the pulley in-
creases, and as a result the blower turns faster.
Set the blower to the slowest speed that will minimize
escape of vapors through the spray cabinet seal (or at
the cabinet openings on conveyor washers).
1. Loosen belt tension moderately by unscrewing the
tensioning bolt.
2. Adjust the effective diameter of the drive pulley to
obtain the lowest blower speed. The pulley outer
face is held by a setscrew.
3. Remove slack from the V-belt with the tension bolt
(see “PULLEY V-BELT TENSION ADJUSTMENT” below).
4. Test the blower at the end of a cleaning cycle (batch
washer) or during the cycle (conveyor washer).
5. If there is steam escaping through spray cabinet seal
or at the conveyor openings, adjust the blower to a
slightly higher speed and test again.
6. Repeat speed adjustment until no steam escapes.
PULLEY V-BELT TENSION ADJUSTMENT
1. Adjust the V-belt tension by turning tension adjusting
bolt clockwise to tighten the belt, or counterclock-
wise to loosen the belt.
2. Tension is correct when you can lift the belt by 1/2"
to 5/8" (1.3 to 1.6 cm) when pulling strongly upwards
with your hand at the center of belt between the pul-
leys.
CAUTION
Do not overtighten the belt.
Blower Shaft
Pillow Block
Bearings
Impeller V-belt
Impeller
Gasket
Split Taper Bushing
Fixed Pulley on
Blower Shaft
Adjustable Pulley
on Motor Shaft
Electric Motor
V-Belt Tension Bolt
Impeller
