Accurex Grease Trapper ESP Operator’s Manual
Document 482584
Grease Trapper ESP™
Kitchen Exhaust Pollution Control System
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with these instructions will result in voiding of the product warranty and may result in personal injury
and/or property damage.
Grease Trapper ESP™
The Grease Trapper ESP™ is a pre-engineered electrostatic precipitator
type pollution control unit with integral exhaust fan (available without
exhaust fan as an option). The unit is designed to remove grease and
smoke particles as well as odor from the kitchen exhaust airstream.
This installation manual covers procedures for receiving, installing, and
maintaining the unit.
For additional instructions and maintenance information on the integral
exhaust fan, when applicable, refer to the fan nameplate to determine
model type and visit accurex.com to download the corresponding manual.
General Safety Information
Only qualified personnel should install this system.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards. Other
considerations may be required if high winds or seismic
activity are present. If more information is needed,
contact a licensed professional engineer before moving
forward.
DANGER
Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch or
breaker to prevent accidental power up.
CAUTION
To reduce the risk of fire, electric shock, and injury be
sure to follow the cautions below:
• Before servicing, make sure the unit is properly
grounded.
• When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
• Do not operate this unit in an explosive atmosphere.
• Keep all flammable materials (such as gasoline)
away from the unit.
• Do not use flammable cleaner on or near the unit.
• The unit should be inspected frequently and the
unit and cells should be manually cleaned at proper
intervals to prevent a fire.
• Operating temperatures of the airstream should not
exceed 130°F.
1. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC), the National Fire
Protection Agency (NFPA), where applicable. Follow
the Canadian Electrical Code (CEC) in Canada.
2. The rotation of the fan wheel is critical. It must
be free to rotate without striking or rubbing any
stationary objects.
3. Fan motor must be securely and adequately
grounded.
4. Do not spin fan wheel faster than maximum
cataloged fan rpm. Adjustments to fan speed
significantly affects motor load. If the fan RPM is
changed, the motor current should be checked to
make sure it is not exceeding the motor nameplate
amps.
5. Do not allow the wires to kink or come in contact
with oil, grease, hot surfaces or chemicals. Replace
immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open access doors to a duct while the fan is
running.
8. The precipitator contains safety electrical interlock
switches at all maintenance access doors. Do not
attempt to defeat these interlocks.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 1
Receiving
Upon receiving the product, check to make sure all
items are accounted for by referencing items shown
on the packing list. Inspect each crate for shipping
damage before accepting delivery. Notify the carrier if
any damage is noticed. The carrier will make a notation
on the delivery receipt acknowledging any damage
to the product. All damage should be noted on all the
copies of the bill of lading which is countersigned by
the delivering carrier. A Carrier Inspection Report should
be filled out by the carrier upon arrival and filed with
the Traffic Department. If damaged upon arrival, file
claim with carrier. Any physical damage to the unit after
acceptance is not the responsibility of manufacturer.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only
items on the packing list. Remove all other shipping/
packing materials including fan tie down straps.
Handling
Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged finish may reduce ability of unit to
resist corrosion.
Storage
Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.
INDOOR
The ideal environment for the storage of units and
accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain, or snow. Temperatures should
be evenly maintained between 30°F (-1°C) and
110°F (43°C) (wide temperature swings may cause
condensation and “sweating” of metal parts). All
accessories (including the main control panel and the
keypad/touchscreen user interface) must be stored
indoors in a clean, dry atmosphere.
Remove any accumulations of dirt, water, ice, or snow
and wipe dry before moving to indoor storage. To avoid
“sweating” of metal parts, allow cold parts to reach
room temperature. To dry parts and packages use a
portable electric heater to get rid of any moisture build
up. Leave coverings loose to permit air circulation and
to allow for periodic inspection.
OUTDOOR
Units designed for outdoor applications may be stored
outdoors, if absolutely necessary. Roads or aisles for
portable cranes and hauling equipment are needed.
The unit should be placed on a level surface to prevent
water from leaking into it. The unit should be elevated
on an adequate number of wooden blocks so that it is
above water and snow levels and has enough blocking
to prevent it from settling into soft ground. Locate parts
far enough apart to permit air circulation, sunlight,
and space for periodic inspection. To minimize water
accumulation, place all unit parts on blocking supports
so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
NOTE
The main electrical panel, if stored, shall be stored
indoors only in a dry environment protected from the
elements.
Inspection & Maintenance during Storage
While in storage, inspect equipment once per month.
Keep a record of inspection and maintenance
performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. Every three
months, the fan motor should be energized. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lintfree cloths. Polish any remaining rust from surface
with crocus cloth or fine emery paper and oil. Do not
destroy the continuity of the surfaces. Wipe thoroughly
clean with Tectyl
For hard to reach internal surfaces or for occasional
use, consider using Tectyl® 511M Rust Preventive or
WD-40® or the equivalent.
®
506 (Ashland Inc.) or the equivalent.
Removing from Storage
As units are removed from storage to be installed
in their final location, they should be protected and
maintained in a similar fashion, until the equipment goes
into operation. Prior to installing the unit and system
components, inspect the unit assembly to make sure it
is in working order.
1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for
tightness.
2. Rotate the fan wheel(s), where applicable, by hand
and assure no parts are rubbing.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System2
Table of Contents
Grease Trapper ESP System Function . . . . . . .3
System Components
Unit Body . . . . . . . . . . . . . . . . . . . . . . .4
ESP Cells . . . . . . . . . . . . . . . . . . . . . . .4
Impingement Filters / Mist Eliminator / Filters /
Carbon Trays . . . . . . . . . . . . . . . . . . . . .4
Component Quantities . . . . . . . . . . . . . . . .4
Remote Mounted Detergent Dispenser. . . . . . . .4
Remote Mounted System Control Panel . . . . . . .5
Fire Cabinet . . . . . . . . . . . . . . . . . . . . . .5
PCU Field Assembly
Unit Modules . . . . . . . . . . . . . . . . . . . . .5
Terminal Enclosure . . . . . . . . . . . . . . . . . .6
Attaching Fan . . . . . . . . . . . . . . . . . . . . .6
Installation
Rigging and Placing Equipment . . . . . . . . . . .7
Ductwork Connections . . . . . . . . . . . . . . . .7
Cells and Carbon Trays . . . . . . . . . . . . . . . .7
Plumbing Connections
Detergent Dispenser . . . . . . . . . . . . . . . . .8
Wash Manifolds . . . . . . . . . . . . . . . . . . . .9
Electrical . . . . . . . . . . . . . . . . . . . . . . .9
Fire System
Ansul® . . . . . . . . . . . . . . . . . . . . . . . 10
Initial System Start-Up . . . . . . . . . . . . . . . 11
Sequence of Operation
Normal . . . . . . . . . . . . . . . . . . . . . . . 11
Wash . . . . . . . . . . . . . . . . . . . . . . . . 12
Controller Setup and Tutorial . . . . . . . . . 13-14
A.
B. Input/Output . . . . . . . . . . . . . . . . . 15
C.
D. Manufacturer . . . . . . . . . . . . . . . . 21
Keypad Navigation . . . . . . . . . . . . . . . . . 22
Touch Screen Navigation . . . . . . . . . . . 23-26
Variable Frequency Drive Information . . . . 27-28
BMS Points List . . . . . . . . . . . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . 30-31
Unit Layout . . . . . . . . . . . . . . . . . . . . . 31
Field Wiring Diagrams . . . . . . . . . . . . . 32-33
Wash Water Plumbing Schematic
Drain Line Plumbing . . . . . . . . . . . . . . . . 34
Detergent Dispenser Assembly . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . . . 35
Maintenance Log . . . . . . . . . . . . . .Backcover
Our Commitment . . . . . . . . . . . . . .Backcover
Clock. . . . . . . . . . . . . . . . . . . . . 15
Service. . . . . . . . . . . . . . . . . . 16-21
Grease Trapper ESP
System Function
Grease Trapper ESP is an electrostatic precipitator
pollution control unit (PCU), with an additional carbon
filtration module designed for two specific functions:
• Remove smoke/grease particles from kitchen exhaust
• Remove odor from kitchen exhaust
NOTE
• Grease Trapper ESP must be connected to a listed
exhaust hood assembly and must be installed in
accordance with local building codes, NFPA 96
and NEC.
• The unit must be installed with a minimum 12 inch
clearance to combustible materials on top of unit
and six inches on the sides and bottom.
A mechanical impingement pre-filter removes large
airborne particles from the incoming airstream prior to
reaching the ionizer cell. The permanent electrostatic
collector section removes grease and smoke particles
from the airstream using a high voltage ionizer cell(s).
The ionizer imparts a positive charge on the grease and
smoke particles as they pass. These particles are then
repelled by positively charged plates and collected on
negatively charged plates. Upon completion of each
cooking day, a wash sequence is initiated for the selfcleaning function of the electrostatic cell via the remote
mounted control panel. The mesh mist eliminator filter
prevents wash water from entering the carbon filtration
section(s) of the unit.
NOTE
Do not use this unit for applications with high
concentrations of water vapor, or other matter, that
is highly conductive if condensed in the airstream.
Heavy water vapor can causing continuous electrical
shorting within the ESP cells, which does not allow
the unit to collect cooking particulate and perform
asdesigned.
There are two configuration options for the Grease
Trapper ESP PCU’s. The standard unit will have two
ESP modules and one carbon filtration section for use
with light, medium and heavy duty cooking. For solid
fuel applications which will contain a greater quantity
of grease, smoke and odors, the solid fuel unit should
be selected. The solid fuel unit will contain three ESP
modules and two carbon filtration modules.
NOTE
This unit should NOT be installed in applications
where incoming airstream at the inlet of the unit is
capable of exceeding 130°F.
NOTE
Grease Trapper ESP is designed to remove submicron, airborne particulate generated from cooking
processes. This system is NOT INTENDED to
eliminate regular hood and ductwork cleaning and
service. Improper care and maintenance of this
system and associated hoods and ductwork may
present a fire hazard.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 3
System Components
NOTE
The installation criteria for each of the system
components shown below should be considered
when selecting a site for install. For further detail on
installing the components, refer to the INSTALLATION
section on page 7.
Unit Body
The unit body is shipped on a mounting rails ready for
installation. If the unit was ordered with an exhaust fan,
typically the fan will also be mounted on the same set
of rails as part of the PCU assembly. Unless specified
and built for outdoor use, the PCU must be mounted
indoors and be protected from weather. The unit should
be easily accessible for service personnel. (1) One-inch
water supply line and (1) two-inch waste water drain line
is required at the unit for the system’s wash function.
Power packs (power supply boxes) are attached to
hinged cell access doors of the cabinet assembly which
are wired to the terminal enclosure (disconnect box)
mounted to the rail below. High voltage feed-through
pins safely transfer voltage from power supply to the
cells located inside the unit. Power supplies are selfprotecting against overloads (which can be caused
by contaminant build up that leads to short circuits in
ionizer and collector sections) and are self regulating
from AC input voltage variations from 108 - 264 VAC.
Impingement Filters / Mist Eliminator
Filters / Carbon Trays
Impingement filters and mist eliminator filters will ship
installed in the unit. Carbon trays will ship in a separate
container. Filter quantities for each stage are based on
unit size.
Each carbon filter is a 20 x 20 x 2 inch, 12 lbs, and
contains coconut shell carbon, standard. Max designed
velocity across each filter is 90 ft/min.
Component Quantities
STANDARD UNIT
Housing
Size
15 121 6
30 2 4 2 12
45 3 6 3 18
60 4 8 4 24
90 6 12 6 36
Impingement
Filter
ESP
Cell
Mist Eliminator
Filter
SOLID FUEL UNIT
15 1 3 1 12
30 2 6 2 24
45 3 9 3 36
60 4 12 4 48
90 6 18 6 72
2" Deep
Carbon
Trays
ESP Cells
ESP cells will ship in separate crate to protect them
during shipping. Cell quantities for each stage are based
on unit size.
Cells have an ionizer
section and collector
section. Ionizer section
includes spiked
ionizer plates that are
charged with 12,000
VDC. Collector section
includes alternating
plates between ground
(0 VDC) and 6,000VDC
potential. Cells are fed voltage through high voltage
feed-through pins that are insulated from the unit
housing. These pins
contact brass plungers
located on the side
of the cell near the
bottom. If a module has
multiple cells, power is
passed from cell to cell
through these brass
plungers coming into
contact with the pins on
nextcell.
The total current to both the ionizer section and
collector section is below 6 mA.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System4
Collector Section
Stamped
Airflow
Direction
Indicator
Collector
Brass Plunger
Ionizer
Brass Plunger
Airflow
Ionizer Section
Left Hand Access Unit Cell
Collector Section
Airflow
Ionizer
Ionizer Section
Brass Plunger
Right Hand Access Unit Cell
Stamped
Airflow
Direction
Indicator
Collector
Brass Plunger
Remote Mounted Detergent Dispenser
A 30 gallon remote mounted detergent dispenser
equipped with 1/2 hp pump is included as part of the
electrostatic collector self-wash system. Solenoid
valves, pressure gauge, ball valve, ystrainer, and
backflow preventer are to be provided by others.
The detergent dispenser must be mounted indoors
on a solid, level foundation, as close to the cabinet
assembly as possible, and in a freeze protected location
accessible to maintenance personnel. The 1/2 inch
line from the detergent dispenser must be connected
to the water supply line prior to the precipitator. Refer
to the PLUMBING section for details on plumbing
connections.
System Components - continued
Remote Mounted System Control Panel
The 115 VAC system control panel fed from a 30A
building breaker allows the user to interface with the
unit and controls operation, as well as monitors wash
and other functions. Field wiring connects the system
control panel to the terminal enclosures on the unit,
and works in conjunction with the unit’s power supplies
and high voltage ESP cells. The system control panel
is designed to be mounted indoors (NEMA-1) in an
area easily accessible to daily operational staff. Allow
adequate room from the face of the panels for door
swing clearance and servicing.
Fire Cabinet
The fire cabinet should be mounted as close to the
Pollution Control Unit as possible, typically within 5 feet.
Unless the fire cabinet was provided with an outdoor
cabinet and heater, the cabinet should be mounted
indoors and must be kept above freezing.
3. After rails and modules have been moved to desired
location, the modules and rails can be reassembled.
Control boxes, access doors, filters,
and ESP cells must be removed
before welding modules together
Each module is
attached to the rails
with (4) 5/16-inch fasteners
1/8
Liquid Tight
PCU Field Assembly - if applicable
If unit is shipped in sections, each section will need to
be welded in the field.
Unit Modules
1. Remove (4) 5/16 inch mechanical fasteners that
attach each module to the rails.
2. Remove 5/16 inch mechanical
fasteners that attach each
module to the next adjacent
module. PCU housing size
can be found in the model
number on tag on side of unit.
Housing
Size
15 3
30, 45 4
60, 90 6
Each module is attached
to the adjacent module
with 5/16-inch fasteners
Number of
Mechanical
Fasteners
4. It is recommended to reattach the fasteners from
step 2 to properly align the modules with each other,
but fasteners are not required when the modules are
welded together from the outside.
INTERIOR OF MODULES
5/16 inch X 1 inch SS bolt
PN# 417205
SS washer with neoprene gasket
Liquid Tight
PN# 417246
1/8
EXTERIOR OF MODULES
5/16 inch SS hex nut
PN# 415576
SS washer with neoprene gasket
PN# 417246
5. Make sure all control boxes, access doors, filters
and cells are removed from the modules before
welding modules together.
6. Fully weld modules together on all four sides on the
outside of the unit. Welds must be liquid tight.
NOTE
Doors will have to be opened and/or removed to
access fasteners inside of modules. A 1/2 inch socket
is required to remove door bolts.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 5
Terminal Enclosure
1/2 inch silicone gasket
1. The bottom of each terminal enclosure mount needs
to be attached to the rail with (2) 5/16 inch fasteners
(provided by factory).
2. The top of each terminal enclosure mount needs to
be welded to the side of the modules.
NOTE
Be sure terminal enclosures do not block module
drains or doors.
3. Refer to wiring diagram provided with the unit
control panel for more information. Limit switches
(mounted on each module) need to be wired to
terminal enclosures.
4. Plugs on power pack enclosure (ESP modules only)
need to be plugged into the terminal enclosures.
Limit
switch
Power pack
enclosure
1/8 2-3.5
Weld top of terminal enclosure
mount to modules
Attaching Fan
The ESP fan is shipped bolted to unit body and rails. If
the unit was requested to be disassembled in the field,
the unit body-to-fan connection has not been sealed.
1. To disassemble in the field, remove mechanical
fasteners that attach the companion flange and fan
to the unit body.
2. Remove mechanical fasteners that attach the fan to
the isolators on the rails.
After fan and unit body have been moved to desired
location, the fan can be sealed and reattached to
the unit body and rails.
3. To seal the fan to unit body connection, apply fire
rated caulk (3M Fire Barrier Sealant CP25WP+ or
equivalent) to
fan inlet flange.
Make sure to
apply caulk
1/2 inch
silicone gasket
around each bolt
hole. Caulk to be
located outside
of silicon gasket
Seam on gasket to be
located on side of unit
mounted during
step 4.
4. Attach 1/2 inch silicone gasket around fan inlet
flange. Silicone gasket
to be located inside
of caulk applied
in step 3 (seam
of gasket to be
located on the
side of unit).
Transition collar
Companion flange
5. To reassemble locate fan on isolators on rails.
6. Reattach fasteners for companion flange removed in
step 1.
7. Reattach fasteners attaching fan to isolators
removed in step 2.
Liberally apply
fire caulk to
outside portion
of companion
flange and
around each
individual
bolt hole
Fire rated caulk
Fan
Fasteners attaching fan to ESP
transition are evenly spaced
around fan inlet
Connect bottom of terminal
mounting bracket to rails with
(2) 5/16 inch fasteners each
(provided by others)
Terminal enclosure mount
Terminal enclosure
Fasteners attach the fan to
the isolators on each corner
of the fan
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System6
Installation
4 inches
Rigging and Placing Equipment
1. The unit is furnished with lifting lugs
at the four corners. For corner
weights, reference the unit’s
submittal drawings.
2. Use a crane and a
set of spreader
bars hooked to
all four factory
lifting lugs to lift
the unit.
3. Field weight will
vary depending
upon final
selections
such as fan
type, accessories, etc.
Approximate weights are
shown in the table.
4. The unit can be positioned
on a base or roof deck
suitable for this purpose.
5. The unit must be anchored
to its base/roof deck.
6. Alternatively, the unit may be suspended from
an adequate overhead structure, using suitable
undercarriage or hanging rods (by others). If
suspended a cradle or support structure must be
provided by others to support unit from bottom. All
hanger brackets/lifting lugs must be used to ensure
proper support. The unit must also be hung level to
ensure proper operation.
7. A service clearance of 36 inches must be provided
on the access door side of the unit.
8. A minimum 12inch clearance must be maintained
between the top and 6 inches on each side and
bottom of this unit and any combustible material.
Approximate Weight
Housing
Housing
STANDARD UNIT
Size
15 1410 641
30 1710 777
45 2120 964
60 2765 1257
90 3315 1507
Size
15 1860 845
30 2295 1043
45 2860 1300
60 3660 1664
90 4390 1995
36 inches
lbs kg
SOLID FUEL UNIT
lbs kg
Ductwork Connections
Ductwork must conform to IMC and SMACNA guidelines.
All factory-built grease duct needs to be constructed
in accordance with ANSI/UL 1978 and should be
manufactured and installed in accordance with their
listing.
All field-built grease ductwork must be constructed in
the following manner per NFPA 96, unless otherwise
specified by the local authority having jurisdiction (AHJ):
Materials - Ducts shall be constructed of and supported
by carbon steel not less than 1.37 mm (0.054 in.) (No.
16 MSG) in thickness or stainless steel not less than
1.09mm (0.043 in.) (No. 18 MSG) in thickness.
Installation - All seams, joints, penetrations, and duct-
to-hood collar connections shall have a liquid-tight
external weld.
Units intended for indoor mounting have an outlet
mounting flange provided on the outlet of the fan. Outlet
ductwork from the exhaust fan is required to be per the
above mentioned methods unless otherwise specified by
the local authority having jurisdiction (AHJ).
NOTE
Ductwork should be properly insulated to prevent
formation of condensation through temperature
change. Condensation that occurs in ductwork will
short circuit ionizing-collecting cells.
Cells and Carbon Trays
Open ESP cell and carbon
tray access doors using
1/2inch socket wrench to
remove all bolts.
Insert cells into the ESP
module(s) in the unit,
making sure the brass
plungers are on the
bottom facing towards
you and the airflow arrow
stamped on each cell is
pointing towards the fan.
ESP cells should be pushed
in by the one next in the row.
For example, the second cell pushes the first cell,
third cell pushes the second, etc. The last cell installed
should be no more than 4 inches (±1/8inch) from the
edge of the cell to the edge of the frame.
Insert carbon trays into the carbon module(s) in the unit.
Make sure trays are inserted where gasketing material is
orientated on the left and right hand side, NOT the top
and bottom, so there is a seal against the filter next to
them.
After all cells and filters are properly installed, refasten
unit doors. Torque the bolts to 60-70 in-lbs. Bolts should
be started by hand prior to using an impact driver or
socket.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 7
Plumbing Connections
NOTE
All water piping exposed to freezing temperatures
must be trace heated and insulated to prevent
damage to the unit.
Once all system components are installed, plumbing
connections for the system can be made. It is
recommended that plumbing connections be done prior
to making electrical connections.
From the building, a 1-inch (refer to drawings) hot
water line is required for connecting the wash system.
Recommended water temperature is 140-180°F at 40
psi pressure. Make sure water pressure does not exceed
50 psi. Refer to the chart for information on water and
detergent quantity requirements. Install the quarter
turn ball valve (by others) at the incoming water source
to allow the water to be turned off for servicing. Next,
install the strainer (by others), backflow preventer (by
others), pressure gauge (by others), and 24 VAC solenoid
valve (by others) respectively. Locate these items along
the incoming water line in a location convenient for
inspection/servicing.
Approximate Water and Detergent Used per Wash Cycle (gallons)*
Housing
Size
15 70 1 105 2
30 140 1 210 2
45 210 2 315 4
60 220 2 330 4
90 330 2 495 4
Water usage numbers shown above are assuming factory default
wash cycle times. Actual water and detergent required may be
different based on the cooking load, appliance type, and cooking
frequency/time.
*Assuming 40 psi water pressure
STANDARD UNIT SOLID FUEL UNIT
Water Detergent Water Detergent
Detergent Dispenser
The detergent dispenser supplies detergent to the wash
system during the WASH mode.
1/2-inch
Hot Water
Fill Line
(Recommended
To Make It
Easier For
Detergent
Dillution)
Y-strainer
With Sediment Trap
Detergent
Flow Switch
Detergent Tank
Detergent Pump
1/2-inch
Detergent
Injection
Line (Connect
To 1-inch
Water Line)
When the unit is washing and the wash sequence is
calling for detergent, a pump housed underneath the
detergent tank pumps the detergent into the hot water
line. A Y-strainer is responsible for removing debris
and sediment from reaching the pump. A flow switch
determines if detergent is flowing when detergent is
being injected (if the flow switch doesn't close within
a time period upon detergent pump running, this will
trigger a low detergent fault). A detergent flow valve is
responsible for diverting some detergent back into the
tank. Turning the flow valve knob clockwise (closing
the valve) will force more detergent into the hot water
line and to the unit during a wash. Turning the flow
valve knob counter-clockwise (opening the valve) will
force more detergent back into the tank during a wash.
A series of colored rings on the flow control valve
indicate how opened/closed
the valve currently is. This can
be adjusted as needed based
on the detergent required for
the wash cycle, but should
start with setting the valve so
that the red ring is visible,
(see Flow Valve image) which
should equate to roughly
0.6GPM. Adjustments to the
flow control setting should be
done in small increments over
a period of several wash cycles.
Flow Valve
This flow valve may be locked into place by a black
hex head set screw located on the bottom of the flow
valve, just below the adjustable knob. Loosen the set
screw before making an adjustment using a 2-mm
Allenwrench.
From the pump located on the base of the detergent
dispenser, connect a 1/2-inch piping connection for
the detergent supply to the 1-inch water supply line.
A quarter turn ball valve (by others) can be installed
on this line if necessary for servicing. The connection
of the 1/2-inch detergent supply line to the 1-inch
water supply line should be made within 10 feet of the
cabinetassembly.
NOTE
Upon the system detecting no detergent flow for
the detergent alarm delay time, the system will go
into a low detergent alarm and the detergent pump
will be immediately shut off. The low detergent fault
can be manually reset (see page 14 for details), or it
will automatically reset if detergent flow is detected
upon the next wash cycle when detergent injection is
takingplace.
Pump should be located as close to unit as possible,
on same floor. Maximum distance recommended from
detergent pump to unit is 10 feet.
Detergent Flow Valve
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System8
Plumbing Connections - continued
Electrical
Wash Manifolds
The unit is supplied with 1-inch wash headers located
at the top of each ESP module. Connect the hot water
supply line to the wash headers at the top of the
ESP module. Bring a 2-inch waste water drain piping
connection with P trap to the drain pipe on the side of
the ESP module. The trap drain line water column for
the drain should be sized for the total system resistance
plus 1 in. wg.
For more information, refer to the plumbing schematic
located on page 34.
The Grease Trapper ESP PCU will be supplied with
a detergent tank and pump and connection headers
on each module. All other plumbing components and
piping will be provided by others. Follow all applicable
plumbing codes and best practices when installing
system.
Required Plumbing Components
(Provided by Others)
Quantity Item Description
3 Ball Valve
1 Y Strainer
2 Backflow Preventer or Check Valve
1 Pressure Gauge
4 24 VAC Solenoid Valves - Standard Unit
5 24 VAC Solenoid Valves - Solid Fuel Unit
Once all system components are installed, electrical
connections for the system can be made. It is
recommended that plumbing connections be done prior
to making electrical connections.
CAUTION
RISK OF ELECTRIC SHOCK. All wiring to be done by
qualified personnel only.
NOTE
All wiring must be done according to the equipment
data plate information, NEC (National Electrical Code
NFPA 70), and local codes.
NOTE
All wiring must be permanently installed in conduit.
Under no circumstances should extension cords be
used to connect the source of electrical supply to the
equipment.
NOTE
An earth ground must be provided to the unit
assembly housing and main control panel. If shipped
loose for remote mounting, terminal enclosures must
be provided with earth ground. The detergent pump
motor and solenoid valve must also be appropriately
grounded.
The Grease Trapper ESP PCU will require additional field
wiring for proper installation. The main control panel
will be shipped loose and is designed to be mounted
indoors. A typical field wiring diagram is shown on page
32. Refer to the unit specific wiring diagram located on
the inside of the door of the system control panel for
unit specific wiring that is required.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 9
Fire System
The Pollution Control Unit (PCU) is furnished with factory pre-piped fire suppression nozzles. Field connection, tanks,
controls, fusible link detectors, and commissioning is provided and installed, based on specifications at time of
order. The Authority Having Jurisdiction (AHJ) may require additional protection.
The fire system must be installed and operational to maintain the UL Listing of the unit. Refer to the drawings below
for information on field piping the fire system to the unit. The release and tanks should be mounted no more than
5feet away from the PCU unit.
ANSUL
To duct nozzles
(duct nozzles by Distributor)
RELEASE
TANK TANK TANK
FIRE SYSTEM DISTRIBUTOR / FIRE SYSTEM INSTALLER:
There are two quik-seals on each module. Connection to
only one of the quik-seals on each module is required.
Multiple quik-seals are provided for situations where
there are obstructions to the connection point.
TYPICAL DRAWING
• Do not install fire piping in front of doors on module. Must have 36 inches of clearance.
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System10
Initial System Start-Up
1. Verify unit is installed properly and all field water
and electrical connections have been made.
2. Check that all ESP cells have been installed
properly. There is a directional arrow that indicates
the direction of the proper airflow. If cells are not
installed in the proper direction, the unit will not
operate correctly.
3. Close and properly fasten the doors on the unit to
ensure the door limit switches are closed.
4. Turn on electrical power to control cabinet and
exhaust fan.
5. Turn on fan disconnect.
6. Turn on the disconnect switch on the PCU terminal
enclosures to energize the power packs.
7. Press the fan button on the user interface to start
the fan. The green indicator lights on the terminal
enclosure(s) should illuminate indicating the power
supply is powering cells. Some electrical arcing
(audible snapping and cracking) is normal at
initial power up as leftover debris in the duct and
unit may occasionally get caught inside the cells.
When the ionizer section on an ESP cell is arcing,
the green indicator light on the terminal box will
shut off, and the red indicator light will illuminate
temporarily. When the collector section of an
ESP cell is arcing, the green indicator light on the
terminal box will shut off, and both the red and
green indicator lights will remain off temporarily.
Arcing should subside after a short period of
time. If arcing continues, reference page 35 for
troubleshooting assistance.
POWER SUPPLY OFF/FAULT
POWER SUPPLY ON
!
DANGER
High
Voltage
Housing Size
15, 30, 45
DO NOT REMOVE THIS PANEL
Unless electrical switch is in the OFF position.
Failure to do so will damage switch.
ON
OFF
POWER SUPPLY OFF/FAULT
POWER SUPPLY ON
POWER SUPPLY OFF/FAULT
POWER SUPPLY ON
!
DANGER
High
Voltage
Housing Size
60, 90
DO NOT REMOVE THIS PANEL
Unless electrical switch is in the OFF position.
Failure to do so will damage switch.
ON
OFF
• RED indicates an ionizer fault within a cell
• GREEN indicates normal operation
• NO LIGHTS indicates power supply is off OR
collector fault within a cell
8. The indicating lights on the terminal enclosure(s)
will indicate status of the power supplies. Terminal
enclosure indicator lights will remain off unless fan
is running.
9. Check for alarms on the system controller. Correct
any alarms that may be displayed (See page 14
fordetails).
10. System should now be ready for operation.
NOTE
As a safety precaution, the system will only operate
in the NORMAL mode when the access doors of
the unit are completely closed and the terminal box
disconnect switch is in the ON position.
If the plunger of the safety switch on all of the doors
is not fully depressed, the red FAULT light on the
main controller (PLC) will illuminate and the unit will
not start. Do not attempt to operate the unit with the
access doors open or bypass the safety.
Sequence of Operation
The operation of the Grease Trapper ESP system falls
into two main categories:
1. NORMAL: System collects smoke and grease
particulate from the airstream.
The unit can be started by pressing the fan button on
the user interface or by closing the remote run contact
(terminals RE-1A and RE-1B). The remote run command
is a contact that can be wired to the kitchen control
panel, timeclock, or any other contact closure desired to
call for the system to run.
NOTE
BOTH the keypad fan button needs to be disengaged
AND the remote run contact needs to be open in
order for the fan to shut off. A call for the fan to run
will not allow for a wash to start, which will prevent
the cells from being cleaned.
During normal operation, as the grease enters the
unit, it will pass through an impingement filter that is
designed to remove the large grease particles. After
passing through the impingement filter, it will enter the
ESP module(s) which will remove the grease particles
and smoke from the airstream through a process
of electrostatic precipitation. Upon leaving the ESP
modules, the air then passes through a mist eliminator
filter which stops water from entering the carbon filters
during the wash down process and also helps protect
the carbon filter section from grease build-up. The air
then enters the carbon filtration section which removes
the odors from the airstream.
Normal Mode
• Exhaust Fan - Running
• Terminal Enclosure Indicator Lights - Green
• Main Solenoid Valve - Closed
• Detergent Pump - Off
Grease Trapper ESP™ Kitchen Exhaust Pollution Control System 11
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