Gaylord C-6000-D Service Manual

EFFECTIVE DATE 05-10

THE

GAYLORD

TECHNICAL MANUAL

FOR THE C-6000-D CONTROL CABINET

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET • TUALATIN, OREGON 97062 U.S.A. 800-547-9696 • 503-691-2010 • FAX: [phone] • email: [e-mail]

GAYLORD INDUSTRIES

World Headquarters: 10900 SW Avery Street • Tualatin, Oregon 97062 U.S.A.

To Our Customers. . .

Congratulations on your recent purchase of a Gaylord kitchen exhaust hood system. We are proud to be able to provide you with a quality product that incorporates the latest engineering concepts and is a result of over 60 years of experience in the foodservice kitchen exhaust industry.

If you have other Gaylord equipment such as a Gaylord Ventilator, Utility Distribution System, Quencher Fire

Protection System, or RoofTop Air Handling Equipment, etc., please refer to the corresponding supplementary equipment manuals.

If you have further questions, please call us toll free at

1-800-547-9696 or email:[e-mail]. We are more than happy to help.

Sincerely,

Gaylord Industries

STREET ADDRESS: 10900 S.W. Avery Street, Tualatin, Oregon 97062 U.S.A.

PHONE: [phone] • 800-547-9696 • FAX: [phone] • email: [e-mail] • www.gaylordusa.com

COMMERCIAL KITCHEN EXHAUST SYSTEMS • FIRE PROTECTION • UTILITY DISTRIBUTION  • ROOF TOP UNITS • POLLUTION CONTROL

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TABLE OF CONTENTS

GENERAL DESCRIPTION__________________________________________________________ 5 MODEL NUMBER DESCRIPTION____________________________________________________ 6 STARTING THE C-6000-D COMMAND CENTER________________________________________ 7 MANUAL START__________________________________________________________________ 8 AUTOSTART_____________________________________________________________________ 9 REMOTE START_________________________________________________________________ 11

STOPPING THE EXHAUST/SUPPLY FAN(S) / STARTING WASH__________________________ 12 WASH MODES__________________________________________________________________ 13 EXTERNAL FIRE MODE__________________________________________________________ 17 INTERNAL FIRE MODE___________________________________________________________ 18 UV SAFETY____________________________________________________________________ 20 UV COMPONENTS______________________________________________________________ 21 UV SYSTEM ON_________________________________________________________________ 22 UV SAFETY INTERLOCKS________________________________________________________ 23 UV LAMP FAILURE______________________________________________________________ 24 FAN ON - UV SYSTEM OFF________________________________________________________ 25

UV LAMP LIFE_ _________________________________________________________________ 26 PROGRAMMING INSTRUCTIONS (MENU)___________________________________________ 27 PROGRAMMING INSTRUCTIONS (MENU) - CYCLE TYPE_______________________________ 28 PROGRAMMING INSTRUCTIONS (MENU) - DETERGENT_______________________________ 29 PROGRAMMING INSTRUCTIONS (MENU) - WASH LENGTH_____________________________ 30 PROGRAMMING INSTRUCTIONS (MENU) - DELAY TIME_______________________________ 31 PROGRAMMING INSTRUCTIONS (MENU) - SET CLOCK________________________________ 32 PROGRAMMING INSTRUCTIONS (MENU) - AUTOMODE________________________________ 33 PROGRAMMING INSTRUCTIONS (MENU) - SET WASH TIMES___________________________ 34 PROGRAMMING INSTRUCTIONS (MENU) - WASH TEST________________________________ 35 PROGRAMMING INSTRUCTIONS (MENU) - # OF WASHES______________________________ 36 GPC-6000 CABINET PARTS LIST___________________________________________________ 38 GPC-6000 PLUMBING PARTS LIST_________________________________________________ 39 C-6000-D PARTS LIST____________________________________________________________ 40 C-6000-D PLC STATUS LIGHTS____________________________________________________ 44 C-6000-D INTERNAL WIRING______________________________________________________ 46 C-6000-D.1 INTERNAL WIRING_____________________________________________________ 48 C-6000-D EXTERNAL WIRING_____________________________________________________ 50 C-6000-D WASH CONTROL WIRING________________________________________________ 52 C-6000-D TERMINAL VOLTAGES___________________________________________________ 53 C-6000-D-UV PARTS LIST_________________________________________________________ 55 C-6000-D-UV PLC STATUS LIGHTS_ ________________________________________________ 60 C-6000-D-UV INTERNAL WIRING___________________________________________________ 62 C-6000-D-UV.1 INTERNAL WIRING__________________________________________________ 64 C-6000-D-UV EXTERNAL WIRING__________________________________________________ 66 C-6000-D-UV TERMINAL VOLTAGES________________________________________________ 68 C-6000-D-UV WASH CONTROL WIRING_____________________________________________ 70

ALL RIGHTS RESERVED. NO PART OF THIS BOOK MAY BE REPRODUCED, STORED

IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY AN ELECTRIC, ME -

CHANICAL, PHOTOCOPYING, RECORDING MEANS OR OTHERWISEWITHOUT PRIOR

WRITTEN PERMISSION OF GAYLORD INDUSTRIES COPYRIGHT 2009.

© Copyright 2010, Gaylord Industries

The manufacturer reserves the right to modify the materials and specifications resulting from a continuing program of product improvement or the availability of new materials.

ADDITIONAL COPIES $15.00 iii

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GENERAL DESCRIPTION

The C-6000-D Control Cabinet is designed to control one or more of the following Gaylord products;

•CG3 Ventilators

•CG3-UV Ventilators

•CG3-UV-SPC Ventilators

•RSPC-ESP Pollution Control Units

•Gaylord Duct Sumps (GDS)

The C-6000-D Command Center will:

•Start/Stop Exhaust and Supply Fan(s)

•Control Wash system in Ventilators, Pollution Control Units, and/or Gaylord Duct Sumps

•Start/Stop Ultraviolet Lamps (UV)

•Start/Stop Electrostatic Cells (ESP or SPC)

•Interface with the Fire Protection (FP) system

•Interface with a Building Management System (BMS)

•Connect to an Autostart device, Gaylord model “TST”, if applicable

C-6000-D

COMMAND

CENTER

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MODEL NUMBER DESCRIPTION

The C-6000-D Command Center is typically installed in a Gaylord Plumbing Cabinet (GPC). The model number for the Gaylord Plumbing Cabinet is made up of an alphabetic prefix followed by a series of alphabetic and/or numeric suffixes to designate the type of control and various options. Sequence of model numbers is as follows.

1._____ 2._____ 3._____ 4._____ 5._____ 6._____ 7._____ 8._____ 9._____ 10.____ 11.____

Prefix	Control #	UV	#	Low	Cold	Light	Security	Trim	Pipe	220 Volts
			Sequences	Detergent	Water	Switch	Access	Ring	Size
					Mist

Explanation of Pre-Fixes and Suffixes

1.	GPC
	GPC............................	Gaylord Plumbing Cabinet

2.Control #

6000-D........................

Utilizes C-6000-D Control

3.UV (If Applicable)

UV..............................

Has inputs and outputs for Ultraviolet light control (UV)

4.# Sequences (# Wash Solenoids)

__...............................	Leave BLANK for 1 plumbing sequence
S#...............................	Has # of plumbing sequences indicated to wash at different times
	Ex) S2 – Has 2 plumbing sequences
S#/S#..........................	On Main Cabinet that has a Sub Panel. The first part (S#), indicates
	the Total number of plumbing sequences controlled by the control.
	The second part (S#), indicates the number of plumbing sequences
	in the Main Cabinet. Ex) S5/S2: Controls a total of 5 plumbing sequences.
	2 plumbing sequences in the main cabinet, and 3 plumbing sequences in
	the Sub Panel.

5.Low Detergent

LD...............................

If cabinet has a Low Detergent Flow switch installed

6.Cold Water Mist

CM..............................

If cabinet has a Cold Water Mist plumbing loop installed

7.Light Switch

LS...............................

If cabinet has a Light Switch installed

8.Trim Ring

TR...............................

If cabinet has a Trim Ring installed

9.Security Access

SA...............................

If cabinet has Security Access (Keyed Lift and Turn latch)

10.Plumbing Loop Size

1.00............................Indicates Plumbing Loop Size (diameter of pipe) in inches

11.220 Volts

220V...........................

Indicates Control is designed to be connected to 220VAC Supply Voltage

Model Number Example:

GPC-6000-D-UV-S3-LD-CM-LS-TR-SA-1.25-220V

Sub Panel Model Number Example:

GPC-SUB-S3-LD-1.25

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STARTING THE C-6000-D COMMAND CENTER

The C-6000-D can be started through one of three options:

1.	Manually -	-	-	Press the “F1” (FAN) button
2. Autostart -		-	- Autostart thermostats in the ventilator activate the C-6000-D
3. Remotely-		-	-	Remotely start the C-6000-D from a switch or BMS

* See the following pages for more details on each of these options

Typical Sequence of Operations for C-6000-D

	Mode	Electric	Exhaust Fan	Supply Fan	Wash
		Damper
	Fan Off (Stand by)	Closed	Off	Off	Off
	Fan On	Open	On	On	Off
	Wash On	Closed	Off	Off	On
	External Fire (Ansul)	Open	On	Off	On
	Activated				(After 60 Sec.)
	Internal Fire	Closed	Off	Off	On
	Thermostat Activated

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MANUAL START

To Start the Fan(s) press the “F1” (FAN) button.

Pressing the “F1” (FAN) button will result in:

1.Supply Fan On Starts immediately

2.The Electric Damper opens (after approximately 45 seconds)

After a 45 second delay:

1.Exhaust Fan Starts

2.UV Lamps On (if applicable)

3.ESP or SPC Cells On (if applicable)

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AUTOSTART

Description:

The C-6000-D is designed to start the Exhaust and Supply Fan(s) automatically when cooking starts, if the ventilator it is connected to is equipped with Autostart thermostats, Gaylord model “TST”. The Autostart thermostats (TST’s) are preset at the factory to 90°F, and may be adjusted in the field, if necessary.

Code Requirements:

Some municipalities require the exhaust fan to start automatically whenever cooking operations occur, to comply with IMC 507.2.1.1. This code requires the exhaust fan to be interlocked with the cooking equipment such that it will start whenever cooking operations occur. This can be accomplished with Temperature Sensing Thermostat(s) in the ventilator, Gaylord model “TST”.

Operation:

Whenever the temperature in the ventilator canopy is above 90°F, and the C-6000-D is OFF, the Exhaust and Supply Fan(s), UV Lamps (if applicable), ESP or SPC Cells (if applicable) will start automatically in “Autostart” mode, and display the text shown below.

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AUTOSTART

Automatic Shutdown:

Afterthetemperatureintheventilatorcanopydropsbelow90°F,theC-6000-D willstarttocountdownfrom 60 minutes. After 60 minutes the Exhaust and Supply Fan(s), and UV Lamps will shut off automatically. Once the countdown has started:

1.The Fan(s), UV, and ESP or SPC cells can be started by pressing the “F1” (FAN) button and cancel the countdown.

2.The Fan(s), UV, and ESP or SPC cells can be stopped by pressing the “F2” (WASH) button and cancel the countdown, and Start the Wash.

Note:

The Fans and UV should be started manuallynormally,bypressingthe“F1” (FAN) button. TheAutostartisprovided as a back-up when the user forgets to start the Fans before starting cooking. While in “Autostart” mode, pressing the “F1” (FAN ON) button will put the C-6000-D back into a normal“FAN ON” mode.

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REMOTE START

Description:

The C-6000-D can be started remotely, from a Fan On/Off Switch located elsewhere, or from a Building ManagementSystem(BMS). Thisisaccomplishedbyconnectingterminals“21” and“27” toa“Remote” switch. Please note that terminal “21” has 24VDC on it. Refer to the C-6000-D Internal Wiring diagram for more details.

Operation:

When the C-6000-D is Remotely Started, the Exhaust and Supply Fan(s), UV Lamps and ESP/SPC

Cells will start.

Note:

If the C-6000-D has been started “Remotely”, the Fan(s), UV, and ESP/SPC Cells cannot be shut off at the C-6000-D. The C-6000-D must be shut off “Remotely” by removing power from terminal “27”. When power is removed from terminal “27”, the C-6000-D will start to Wash.

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STOPPING THE EXHAUST/SUPPLY FAN(S) / STARTING WASH

To Stop the Fan(s) and Start the Wash press the “F2” (WASH) button. The C-6000-D can also be set to start the Wash Automatically. To do this set the C-6000-D to run in “AutoMode” and setting the times to Wash in the Menu. See “Programming Instructions” for information on setting up the “AutoMode”.

CAUTION: The cooking equipment must be shut off prior to shutting off the exhaust fan. Failure to do this will cause excessive heat buildup and could cause the surface fire protection system to discharge.

Pressing the “F2”(WASH) button will result in:

1.Exhaust Fan Off

2.Supply Fan Off

3.Electric Dampers Close (if applicable)

4.UV Lamps Off (if applicable)

5.ESP or SPC Cells Off (if applicable)

After a 45 second delay: 1. Wash Starts

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WASH MODES

	The C-6000-D can be programmed to control up to 13
		Recommended Wash
	Wash Sequences (solenoids). The C-6000-D can control
		Cycle Lengths
	“HOOD” wash cycles and “ESP” cycles, or a combination
	of both. The length of each wash cycle can be set from 3 to	Type of Cooking	Length of
	9 minutes. The delay between wash sequences can be set		Wash Cycle
	from 1 to 99 minutes. The delay is designed to allow time for
		Light-Duty	3
	the Hot Water to reheat if necessary and allow time for the
		Medium-Duty	5
	ESP or SPC cells to soak between wash cycles. To Start the
	Wash, press the “F2” (WASH) button. The Fan(s) cannot	Heavy-Duty	9
	be restarted until the entire wash cycle has completed, or

the wash cycle has been canceled. To Stop the Wash before the wash cycle has completed, press the “CANCEL” button. Refer to the “Programming Instructions” on how to adjust the times.

NOTE:Theventilatorwashsystemisdesigned toremovedailyaccumulationsofgreasewithin the extraction chamber. If the ventilator is not washed a minimum of once during a cooking day, a grease buildup could accumulate which the wash system cannot remove.If this occurs, it is recommended that the ventilator be put through several wash cycles by pushing the “F2”(WASH) button on the Command Center. If this does not remove the grease, it will be necessary to remove the grease manually by using a scraping tool, such as a putty knife, or retain the services of a commercial hood cleaning service to steam clean or pressure wash the system.

HOT WATER REQUIREMENTS

For proper operation of the wash system there must be adequate water pressure and temperature.There is a pressure/temperature gauge inside the control cabinet.

Water Pressure: 40 psi min. - 80 psi max.

WaterTemperature: 140°F min.- 180°F max.

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WASH MODES

“HOOD”Wash Description:

A “HOOD”Wash cycle is used for any water wash ventilator. It will wash using Hot Water and detergent. If there is more than one Sequence (solenoid), the C-6000-D will delay between each Sequence, then the 2nd Wash Sequence will start and run. After all of the washes are complete the C-6000-D will display a “FAN OFF” message. Refer to the table for a typical “HOOD” Wash.

“HOOD”Wash Cycle (Typical)

	Length of
Description	Wash Cycle
	(Minutes)
Wash #1	3
Delay	1
Wash #2	5

	Total Time		9
WASH SEQUENCE #1		DELAY

WASH SEQUENCE #2

FAN OFF

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WASH MODES

“ESP”Wash Description:

An“ESP”Wash cycle is used for CG3-UV-SPC ventilators or RSPC-ESP Pollution Control Units. An “ESP”Wash uses a “Wash-Delay-Wash-Delay-Rinse”cycle. This is designed to Wash the ESP or SPC cells with Hot Water and Detergent, allow to soak, then Wash again, allow to soak, then Rinse with Hot Water only. The length of the Wash cycles and the Delay are adjustable. The length of the Rinse is fixed at 3 minutes. After all of the washes are complete the C-6000-D will display a “FAN OFF” message. Refer to the table for a typical “ESP” Wash.

“ESP”Wash Cycle (Typical)

	Length of
Description	Wash Cycle
	(Minutes)
Wash - 1st Wash	3
Delay	1
Wash - 2nd Wash	3
Delay	1
Rinse	3

	Total Time		11
WASH #1		DELAY

WASH #2

DELAY

RINSE

FAN OFF

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WASH MODES

Low Detergent (Option)

Some control cabinets are equipped with a low detergent flow switch. The control cabinet model number would have the letters “LD” in the model number, if the it includes a low detergent flow switch

When the detergent is low:

Amessagewillflashindicating“LOWDETGNT” during the wash cycle. This indicates that the detergent is low and/or the detergent pump is not pumping

When the detergent is low:

Amessagewillflashindicating“LOWDETGNT” after the end of all of the wash cycles. This indicates that the detergent is low and/or the detergent pump is not pumping. To clear the “LOW DETGNT” message, fill the detergent, and run the C-6000-D through a Wash cycle. It may be necessary to prime the pump, refer to the “Detergent Pump Operation”.

Note:

If the detergent tank is filled with water or detergents other than Formula G-510, the detergent flow switch will act as if there is no detergent. The viscosity of water and other detergents is too low to be detected by the low detergent flow switch

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EXTERNAL FIRE MODE

Fire Protection System - Activated

Description:

The C-6000-D should be wired to the Fire Protection System for theVentilator(s) and/or Pollution Control Unit(s) it is controlling. A set of normally open contacts in the Fire Protection System needs to be wired to terminals “4” and “FS” in the C-6000-D, refer to the C-6000-D Internal Wiring Diagram for more details. Please note that terminal “4” has 120VAC on it. If the Surface Fire Protection System for the Ventilator(s) is activated the C-6000-D will be placed in an “External Fire” mode.

Operation:

In an “External Fire” mode, the C-6000-D will:

1.Start Exhaust Fan

2.Shut off Supply Fan

3.Run water in ventilator(s) and/or Pollution Control Unit(s) after a 60-second delay

4.Close Alarm Contacts “A1” & “A2” - refer to C-6000-D Terminals for more details

5.Open Alarm Contacts “Q1” & “Q2” - refer to C-6000-D Terminals for more details

Note:

The Fan(s) cannot be restarted until the microswitch in the Fire Protection System for the Ventilator(s) and/or Pollution Control Unit has been reset. After the microswitch has been reset, the Fan(s) can be restarted by pressing the “F1” (FAN) button.

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INTERNAL FIRE MODE

Thermostat - Activated

Description:

If the ventilator(s) connected to the C-6000-D are equipped with thermostat(s) at the duct/plenum to detect fire, and a fire is detected at the Exhaust Duct collar, or if the thermostat in the Pollution Control Unit detects a fire, the C-6000-D will go into an “Internal Fire” mode. Refer to the appropriate Gaylord Ventilator Technical Manual, or Gaylord Pollution Control Unit Technical Manual for thermostat location and temperature setting.

1st Screen

2nd Screen

3rd Screen

Operation:

In an “Internal Fire” mode, the C-6000-D will:

1.Shut off Exhaust Fan

2.Shut off Supply Fan

3.Run water in ventilator(s) and/or Pollution Control Unit(s) immediately

4.Close Alarm Contacts “A1” & “A2” - refer to C-6000-D Terminals for more details

5.Open Alarm Contacts “Q1” & “Q2” - refer to C-6000-D Terminals for more details

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INTERNAL FIRE MODE

Thermostat - Activated

Cool Down Cycle:

After the temperature at the thermostat(s) cools below its’ activation temperature, the C-6000-D will enter a “Cool Down Cycle” for 2 minutes. The C-6000-D will count down from 120 seconds.The water will continue to run until the end of the “Cool Down Cycle”, or until the “F5” (EXIT) button is pressed.

After the “Cool Down Cycle is complete, the Fan(s) can be restarted by pressing the “F1” (FAN) button.

Internal & External fire modes at the

same time:

It is possible that both the Internal and External Fire modes can be activated at the same time. If this occurs, the Internal Fire Mode will override the ExternalFiremodeuntilthethermostat(s)coolbelow the set point, refer to the appropriate Ventilator or Pollution Control Technical Manual for the set point. At this point the Cool Down Cycle will start counting down for 2 minutes. After the Cool Down Cycle, the External Fire mode will start.

Special Note: If the control is in the Cool Down Cycle when the External Fire mode is activated, the Cool Down Cycle will finish countingdownfor2minutes,beforeswitching to the External Fire Mode.

Summary of Both Fire Modes at the Same Time:

1.Internal Fire Mode (until thermostat temperature drops below the set point)

2.Cool Down Cycle (for 2 minutes)

3.External Fire Mode (until the External Fire Switch is reset)

FIRE MODE SUMMARY

			Cool Down Cycle
		INTERNAL Fire	(for Internal Fire	EXTERNAL Fire
			Mode Only!)
	Exhaust Fan	OFF	OFF	ON
	Supply Fan	OFF	OFF	OFF
	Electric Damper	FIRE	EXHAUST	EXHAUST
	Position (if applicable)
	Water Spray	ON	ON	ON

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UV SAFETY

Warning:

DO NOT defeat the purpose of the UV Safety Interlocks during Cleaning or Maintenance!

As with many types of technology if it is not used properly and/or proper precautions are not taken there is the potential for injury or harm. This is especially true with UVC light due to the fact that it does not physically hurt at the time of exposure.While UVC is very effective at breaking down grease molecules, direct exposure to large amounts is harmful to skin and eyes. The amount of UVC generated in these ventilators is greater than that what results from direct exposure to the sun. Under no circumstances is it acceptable to view the lighted lamps without proper eye protection or expose bare skin directly to the light.All interlocks and safety precautions called for in this manual must be followed to avoid the potential for harm to service personnel and/or operators. In addition, only trained and authorized personnel may perform some maintenance.

Personal Protective Equipment

Personal Protective equipment must be used at all times when working on any Gaylord “UV” ventilators, this includes:

1.Eye protection that prevents 100% of UVC being transmitted through the lens must be worn at all times when performing service work on any Gaylord “UV” ventilator that is energized and/or has the potential to be energized and expose personnel to UVC light.

2.Whenever service work is performed it is recommended that long sleeve shirts and long pants be worn to minimize the potential for inadvertent exposure of the skin to UVC.

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UV COMPONENTS

Description:

If the C-6000-D is controlling Gaylord “UV” ventilators, the model number will include “UV” in the model number. The C-6000-D-UV will include the following components:

1. UV Status Lights

•	Green	- “UV System On”
•	Yellow	- “UV Lamp Failure”
•	Red	- “UV Safety Interlock Activated”

2.UV Audible Alarm Cancel button

3.UV Hour Meter

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UV SYSTEM ON

Description:

When the C-6000-D-UV is running in the “Fan On”, “Autostart”, or “Remote Start” mode, the UV Lamps will turn on. Under Normal conditions, when the UV Lamps are running normally the “UV System On” Green light will illuminate. If either the Yellow or Red UV Lights are illuminated, refer to the following pages.

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