CaptiveAire CORE Installation Manual
Self Cleaning Hood System
Installation, Operation, and Maintenance Manual
Save these instructions. This document is the property of the owner of this equipment and is
required for future maintenance. Leave this document with the owner when installation or
service is complete.
RECEIVING AND INSPECTION
Upon receiving unit, check for any interior and exterior damage, and if found, report it
immediately to the carrier. Also check that all accessory items are accounted for and are
damage free.
WARNING!!
Installation of this module should only be performed by a qualified professional who has read
and understands these instructions and is familiar with proper safety precautions. Improper
installation poses serious risk of injury due to electric shock and other potential hazards. Read
this manual thoroughly before installing or servicing this equipment. ALWAYS disconnect
power prior to working on module.
March 2011 Rev. 10
A0019144
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TABLE OF CONTENTS
WARRANTY .................................................................................................................................................. 4
INSTALLATION ............................................................................................................................................. 5
Mechanical ................................................................................................................................................ 5
Plumbing Connections for Self Cleaning .............................................................................................. 5
Piping Loss Calculation for Wall Mount Self Cleaning System ............................................................ 6
Minimum Pressure Requirements for Lengths of Hood ....................................................................... 8
Self Cleaning System Overview ........................................................................................................... 9
Drain Assembly .................................................................................................................................. 11
Electrical ................................................................................................................................................. 12
Copper Wire Ampacity ....................................................................................................................... 12
OPERATION ............................................................................................................................................... 13
Start Up ................................................................................................................................................... 13
Special Tools Required ...................................................................................................................... 13
Start Up Procedure ............................................................................................................................. 13
Start Up Checklists ................................................................................................................................. 15
Self Cleaning Hood Start Up Checklist .............................................................................................. 15
Component Description .......................................................................................................................... 16
Self Cleaning Spray Bar ..................................................................................................................... 16
Water Manifolds .................................................................................................................................. 17
Self Cleaning Manifold ....................................................................................................................... 17
Self Cleaning Manifold Details ........................................................................................................... 18
Self Cleaning Wash Timers ................................................................................................................ 19
Surfactant Tank .................................................................................................................................. 20
Troubleshooting ...................................................................................................................................... 21
Self Cleaning Hood Troubleshooting Chart ........................................................................................ 21
MAINTENANCE .......................................................................................................................................... 22
General Maintenance ............................................................................................................................. 22
Every 3 months ....................................................................................................................................... 22
Every 6 months ....................................................................................................................................... 22
Every 2 Years ......................................................................................................................................... 22
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WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and
service, for a period of 12 months from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation
instructions shipped with the product,
2. The equipment is not installed in accordance with federal, state and local codes and regulations,
3. The equipment is misused or neglected,
4. The equipment is not operated within its published capacity,
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages
potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be
defective in material or workmanship within the 12-month warranty period, upon examination by the
MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The
BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall
not be returned without MANUFACTURER’S prior authorization and all returned equipment shall be
shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.
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System Nomenclature
System
Water Connection
W1
1 Hot Water
W2
1 Cold Water
W3
1 Hot, 1 Cold Water
INSTALLATION
Warning
All field connections between hoods and drain lines must be run with Steel, Stainless Steel, or
Copper pipe. Plastic pipe cannot be used for drains or field connections between hoods, as it
could fail and become hazardous.
It is imperative that this unit is installed and operated with the designed airflow and electrical supply in
accordance with this manual. If there are any questions about any items, please call the service
department at 1-866-784-6900 for warranty and technical support issues.
Mechanical
WARNING: APPLY THE APPROPRIATE WATER PRESSURE
AND TEMPERATURE TO ALL FITTINGS TO PREVENT
LEAKAGE AND COMPONENT FAILURE
ATTENTION: SYSTEM MUST BE INSTALLED IN CONDITIONED SPACE BETWEEN 32°F AND 130°F
Ensure there is 36 Inches of service clearance to the front of the panel.
Plumbing Connections for Self Cleaning
Several field plumbing connections are required for proper Self Cleaning hood operation. It is
recommended that all plumbing connections be sealed with Teflon tape or pipe thread sealant. Use care
not to contaminate the interior surfaces of the water lines when plumbing the unit, as small particulate can
clog the orifices of the spray nozzles.
1. All incoming plumbing connections are connected via ¾” quickseals at the top of the utility
cabinet. See Figures 1 and 2 for details.
2. Self Cleaning hoods with the W1 option (Hot Water Wash) require a hot water connection at
140°F to 170°F and 30 to 50 psi operating pressure. If the operating pressure is greater than 50
psi, a water regulator must be connected. Max water static pressure is 125 psi. Typical water
flow rate is 0.7 GPM per foot of hood. The spray lasts for a factory setting of 3 minutes every
time the fans are switched off.
3. Self Cleaning hoods with the W2 option (Constant Cold Water) require an unheated water
connection at an operating pressure of 10 to 20 psi. If the pressure is greater than 40 psi, a water
regulator must be connected. Max water static pressure is 125 psi. Typical water flow rate is 0.4
GPM per foot of hood. The spray runs constantly while the fans are turned on.
4. Self Cleaning hoods with the W3 option (Hot Water Wash and Constant Cold Water) require a hot
water connection at 140°F to 170°F and 30 to 50 psi operating pressure and an unheated water
connection at 10 to 20 psi operating pressure. If the pressure is greater than the max rating, a
water regulator must be connected. Max water static pressure is 125 psi. Typical water flow rate
is 0.4 GPM per foot of hood for cold water and 0.7 GPM per foot of hood for hot water. The cold
spray runs constantly while the fans are turned on and the hot water lasts for a factory setting of 3
minutes every time the fans are switched off.
5. If multiple hoods are arranged in an end-to-end or back-to-back arrangement, plumbing
connecting the hoods must be piped in the field. The plugged end of the spray bar is used to do
this. Remove the plugs on the main hood and the adjacent hood and simply pipe the two
together. The highest part of the connecting pipe must not exceed the height of the vacuum
breaker in the main utility cabinet. See Figure 1A for illustration.
6. There is also a non-pressurized 1-1/2 inch drain connection that must be piped. This allows
water to drain from the hood grease trough. It must be connected to the building grease trap. 30
inch tall hoods will have 2 drains and hoods 10 feet and longer will also have 2 drains. See
Figure 3 for details.
7. Once all supply and drain lines are connected, remove one of the nozzles and flush the lines.
8. The Ansul fire system duct detection bracket and fusible link are shipped loose to be installed in
the exhaust ductwork. The detector must be installed no more than 20 feet from the hood, and
installed per the Ansul fire system guidelines.
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Piping Loss Calculation for Wall Mount Self Cleaning System
Equivalent Pipe Length For Various Pipe Fittings
Pipe Size Inches
45° Elbow
90° Elbow
Tee Thru Run
Tee Thru Branch
3/4"
1.03
2.21
1.23
4.41
1"
1.31
2.81
1.56
5.62
1 ½
2.15
4.31
2.4
8.63
Pressure Drop (PSI) per Equivalent Foot of Waterline - Pipe Size
Gallons per Minute
Waterline Pipe Size (psi per foot of pipe)
3/4”
1”
1 1/2”
10
0.102
0.029
0.004
20
0.368
0.105
0.014
30
0.779
0.222
0.030
40
1.327
0.379
0.052
50
2.005
0.573
0.078
60
2.809
0.803
0.109
70
3.735
1.068
0.146
80
4.782
1.367
0.186
90
5.947
1.700
0.232
100
7.223
2.066
0.282
To ensure proper operation of the Self Cleaning System, a minimum of 30 PSI water operating pressure
during spraying must be achieved at the hood nozzles. For this to occur, proper sizing of the water line is
required. Use the following steps to calculate the piping minimum size.
1. Use the Minimum Pressure Requirements for Lengths of Hood chart and find the Self
Cleaning minimum PSI required at the hood inlet. Subtract this value from the available PSI at
the panel pressure gauge. Maximum panel operating pressure is 50 psi. This will be your
maximum allowable pressure drop for field installed pipes between the panel and the hood.
2. Most fittings add an equivalent pipe length to the total run. Use the chart below to calculate the
equivalent pipe length for installed fittings. If you have multiple fittings of one type, simply multiply
the number below by the total number of the fitting and add to the total run length.
3. To calculate the total flowing pressure drop between the panel and the hood, take the total
equivalent length found in step 2 and add the total linear field installed pipe length. Multiply this
number by the value found in the table below, Pressure Drop (PSI) per Equivalent Foot of
Waterline. (Gallons per minute is calculated by multiplying the length of the hood by 0.7 gpm)
This will be the friction pressure drop between the hood and the panel.
4. Add in the pressure drop due to gravity. This must be evaluated to overcome any rise in pipe
elevation between the panel and the hood. There is .43 psi/ft of vertical rise of pressure drop.
5. Now, compare the maximum allowable pressure drop from step 1 to the calculated pressure drop
from step 3. If the calculated pressure drop exceeds the maximum allowable pressure drop,
increase the pipe size and recalculate steps 2 and 3. Continue this step until the calculated
pressure drop is below the maximum allowable.
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Field Pipe Pressure Drop Calculation Example:
0.01
0.1
1
10
1 10 100 1000
Pressure Loss (PSI/Ft)
FLOW (GPM)
Pressure Loss Water Flow
3/4" pipe
1" Pipe
1 1/2" Pipe
Wall mount panel installed with 30 feet of ¾” linear pipe between panel and hood. (2) 90 degree elbows
are installed in the pipe run and the pipe run has a vertical rise of 5 feet. Length of end-to-en hood
system is 32 feet.
Hood System = 32 feet. Flow rate = 32 feet * 0.7 gpm = 23 gpm
Pressure required at hood = 45 psi.
Pressure at panel gauge = 50 psi.
Allowable pressure drop between panel and hoods: 50 psi – 45 psi = 5 psi
Equivalennt length of pipe = 30 + 2 * 2.21 = 34.42 feet
Friction Pressure Drop through pipe = 34.42 * 0.779 = 26.81 psi
Gravitational Pressure = 0.43 psi/ft * 5 feet = 2.15 psi
Total Pressure Drop in Field Pipe between panel and hood = 26.81 psi + 2.15 psi = 28.96 psi
Allowable pressure drop = 5 psi
This system will not work correctly because calculated pressure drop is greater then allowable
pressure drop. Pipe size will need to be change to 1-1/2 inch diameter.
Re-calculate with 1-1/2 inch pipe instead of ¾” pipe:
Equivalennt length of pipe = 30 + 2 * 4.31 = 38.62 feet
Friction Pressure Drop through pipe = 38.62 * 0.030 = 1.15 psi
Gravitational Pressure = 0.43 psi/ft * 5 feet = 2.15 psi
Total Pressure Drop in Field Pipe between panel and hood = 1.15 psi + 2.15 psi = 3.30 psi
Allowable pressure drop = 5 psi
This system will work correctly because calculated pressure drop is less then allowable pressure
drop.
Pressure Loss Through Typical Water Pipe Chart
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Minimum Pressure Requirements for Lengths of Hood
Length of Hood
(Ft)
Minimum Inlet Water
Pressure for Cold
Mist (PSI)
Minimum Inlet Water
Pressure for Self
Cleaning (PSI)
0
10
30 4 10
30 8 10
30
12
10
30
16
15
30
20
15
31
24
15
32
28
15
34
32
20
37
36
20
39
40
20
42
44
20
46
48
20
50
Table 1
Note: Water pressure may not drop below 30 PSI while the hood hot water is operating. Pressure
may not rise above 50 PSI when the hood is spraying. If the pressure is greater than 50 PSI, a
water regulator must be connected. The chart above is for continuous hood installations. If the
above length is exceeded, water line must be branched for adequate water supply.
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