Delfield Self Cleaning System Control Panel Installation Manual

Self Cleaning System Control Panel

Installation, Operation, and Maintenance Manual

WARNING!!

Installation of this control 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.

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.

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.

March 2011, Rev. 2

A0017476

TABLE OF CONTENTS

WARRANTY .................................................................................................................................................. 3

PIPING SIZE SELECTION ............................................................................................................................ 4

INSTALLATION ............................................................................................................................................. 7

Plumbing ................................................................................................................................................... 7

Site Preparation .................................................................................................................................... 7

Assembly .............................................................................................................................................. 7

Electrical ................................................................................................................................................... 7

OPERATION ............................................................................................................................................... 11

Special Tools Required ...................................................................................................................... 11

Start Up Procedure ............................................................................................................................. 11

Water Wash Cycle .............................................................................................................................. 15

Scheduling .......................................................................................................................................... 16

Special Functions ............................................................................................................................... 18

Alarms ................................................................................................................................................ 18

Diagnostics ......................................................................................................................................... 18

WEB INTERFACE ....................................................................................................................................... 19

Scheduling .......................................................................................................................................... 19

Hood Control ...................................................................................................................................... 21

MAINTENANCE .......................................................................................................................................... 22

Factory Service Department ............................................................................................................... 24

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.

PIPING SIZE SELECTION

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

1.31

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”

0.102

0.029

0.004

0.368

0.105

0.014

0.779

0.222

0.030

1.327

0.379

0.052

2.005

0.573

0.078

2.809

0.803

0.109

3.735

1.068

0.146

4.782

1.367

0.186

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 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.

Field Pipe Pressure Drop Calculation Example

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-end 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

Equivalent 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: Equivalent 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

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)

30 4 10

30 8 10

NOTE: Water pressure may not drop below 30 PSI while the hood is spraying hot water. 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 you exceed the lengths above, water line must be branched for adequate water supply.

Copper Wire Ampacity

Wire Size AWG

Maximum Amps

30 8 50 6 65 4 85

INSTALLATION

WARNING!!

Disconnect power before installing or servicing control. High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.

Refer to the project blueprints for proper plumbing and electrical hookup, located on the inside of the plumbing door. CAUTION: Do not apply power before plumbing and electrical installation is complete on the panel. Please see drawings for the panel on the following pages.

Plumbing

Site Preparation

1. Provide clearance around installation site to safely install equipment into its final position.

2. Consider general service and installation space when locating unit.

Assembly

1. Mount the panel on the wall, or recessed in the wall with an optional trim ring if ordered, approximately 42” from the finished floor to the bottom of the cabinet.

2. Open the cabinet and verify proper pipe size for the hot water connection. Route and connect the hot water supply piping to the manifold connection located at the bottom of the cabinet.

3. Connect piping from the top connection of the manifold and route to the ceiling. Connect a vacuum breaker at the highest point of the run to the hood connections.

4. Connect a tee fitting after the vacuum breaker and connect the ¼” NPT soap injection check valve.

5. Continue the pipe to the hood, and then connect to the wash manifold connection on the hood.

6. Connect the tubing to the check valve and route tubing to the cabinet. At the cabinet, connect tubing to the top connection on the clear block mounted on the surfactant pump.

7. Prime the surfactant pump as described under the Maintenance section of this document.

Electrical

Before connecting power to the control, read and understand the entire section of this document. As-built wiring diagrams are furnished with each control by the factory, and are attached either to the door of the unit or provided with a paperwork packet.

Electrical wiring and connections should be done in accordance with local ordinances and the National Electric Code, ANSI/NFPA70. Be sure the voltage and phase of the power supply and the wire amperage capacity is in accordance with the unit nameplate.

1. Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

2. Electrical termination points are located on the right hand side compartment of the panel. One side of these terminal blocks is internally wired. Field wiring is expected on the other side, directions shown below. Refer to the SCS Electrical Installation Diagram.

a. 120 VAC power to the panel on terminal blocks H1 and N1. b. Hood Lights on terminal blocks B and W. c. Exhaust fan starter coil on terminal blocks A1 and N1. Supply fan starter coil on terminal

blocks SF1 and N1. If an electrical pre-wire package controlling the fans is also provided by the same manufacturer in conjunction with the Self Cleaning panel, the pre-wire will contain terminal blocks identically labeled A1, SF1 and N1. Connect the terminal blocks together from

the Self Cleaning panel to the electrical prewire panel. d. Electrical Gas Valve if present on terminal blocks GS and N1. e. Fire system Microswitch on terminal blocks C1, AR1 and TR1. C1 is the common, AR1 is the

armed state, and TR1 is the triggered state. Verify connections on wiring schematic. If no fire

system is required, place a jumper between terminals C1 and AR1. f. PCU Pressure Switch if present on terminal blocks HD and P2. g. Building Management System Dry contact if present on terminal blocks HD and BMS.

3. Duct thermostats (if present):

A duct thermostat is comprised of one RTD (resistive temperature detector) sensor mounted in the riser and one digital temperature controller mounted in the cabinet. Each RTD is connected to its controller through a 3 conductor 18AWG thermostat wire. The temperature controller has two displays on it; the upper (PV) display is the current temperature in the riser. The lower (SV) display is the temperature at which the controller will turn on the exhaust fan. The UP and DOWN buttons are used to adjust the 85 degree default SV value up or down to the desired setting. The controller has a default 2 degree hysteresis value so that once the rising temperature reaches the SV value and the fan turns on, it will stay on until the temperature drops 2 degrees below the SV value. If 2 degrees proves undesirable it can be changed, see the changing the hysteresis example section of this document. The C1, AL1 and SV LEDs will all normally be illuminated. The C1 LED will go out when the temperature controller turns on the fans.

RTD Sensor Installation

RTD sensors are shipped factory installed in factory assembled hood risers. If the risers are field cut, the sensor and other components are shipped loose for field installation as shown below. A hole must be cut in the grease duct and the quick seal and sensor must be assembled as shown.

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