Gaylord CG3-UV, C-6000 Service Manual

EFFECTIVE DATE 4-2005

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET • TUALATIN, OREGON 97062-1149 U.S.A.

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1-800-547-9696 • 503-691-2010 • FAX: [phone] • email: [e-mail]

Sincerely,

Gaylord Industries

STREET ADDRESS: 10900 S.W.Avery Street, Tualatin, Oregon 97062-8549 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

"CG3-UV"VENTILATORDESCRIPTIONS ..............................................................................................	4–-5
"CG3-UV" SERIES PRINCIPLE OF OPERATION .....................................................................................	6–9

MODEL C-6000-UV SERIES CONTROL .......................................................................................	42
DAMPER CONTROL MOTOR AND CG3-UV-FDL WIRING ...........................................................	43
DETERGENTPUMP ....................................................................................................................	44
MISCELLANEOUS VENTILATOR PARTS ....................................................................................	45
UV MODULE ................................................................................................................................	46
WIRING DIAGRAMS ............................................................................................................................	47–51
STANDARDVENTILATORMODELS ........................................................................................................	52
METRICCONVERSIONCHART ................................................................................................................	53
START-UPINSPECTIONREPORT ...........................................................................................................	54
LIMITEDWARRANTY ........................................................................................................	Inside back cover

Patent Pending

© Copyright 2004, Gaylord Industries

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

STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM

BY AN ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING

MEANS OR OTHERWISE WITHOUT THE WRITTEN PERMISSION OF

GAYLORD INDUSTRIES COPYRIGHT 2004.

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

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"CG3-UV" VENTILATOR DESCRIPTIONS

There are 5 different types of "CG3-UV" “Classic Gaylord”, water-wash ventilators. The differences involve the type and location of fire damper and whether the ventilator has a fire

Summary of "CG3-UV" Ventilators:

The CG3-UV and CG3-UV-FDL are very similar. Both have a damper motor that closes the inlet damper during the wash

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"CG3-UV" VENTILATOR DESCRIPTIONS

CG3-UV-ND SERIES

NO DAMPERS

[NO DAMPER MOTOR, NO

THERMOSTAT(S)]

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"CG3-UV" SERIES VENTILATOR PRINCIPLE OF OPERATION

GREASE EXTRACTION

The Gaylord “CG3-UV” Series Ventilator extracts up to 95% of the grease, dust and lint particles from the airstream passing through it, when operated and maintained in accordance with

Baffle #3

This baffle is located on the back of the inspection doors. This baffle is also a grease collecting gutter, collecting grease, dust

TRANSITION AREA

UV LAMPS

PARTICULATE

SEPARATOR

BAFFLE #3

BAFFLE #2

OPTIONAL "CUSTOM AIR" BAFFLES

MAIN GUTTER

DRAIN LINE

BAFFLE #1 (3 POSITION DAMPER IN THE EXHAUST POSITION)

INLET SLOT

FIG. 1

GREASE EXTRACTION

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"CG3-UV" SERIES VENTILATOR PRINCIPLE OF OPERATION

WASH CYCLE

The wash cycle is activated each time the exhaust fan is shut off by pushing the “Start Wash” button on the Command Center or as programmed on the clock. When activated the UV

HOT DETERGENT

WATER SPRAY

PRE-FLUSH LINE

MAIN GUTTER

DRAIN LINE

FIG. 3

WASH CYCLE

HINGED UV

ACCESS DOORS

FULL-LENGTH HINGED

INSPECTION DOORS

DAMPER CLOSED FORWARD TO

THE WASH POSITION (N/A ON

CG3-UV-FDD, CG3-UV-ND, AND

CG3-UV-FDT)

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"CG3-UV" SERIES VENTILATOR PRINCIPLE OF OPERATION

INTERNAL FIRE MODE—For CG3-UV and CG3-UV-FDT only!

Automatic internal fire protection is accomplished by the action of the thermostat(s), which are located at the point

7.Then the digital display reads "Fire In Hood, Notify Fire Department". This display stays on until the thermostat cools down below 250°F.

FIRE QUENCHING

WATER SPRAY

WATER BARRIER

DAMPER CLOSED BACK TO

THE FIRE POSITION

DRAIN LINE

SURFACE FIRE PROTECTION NOZZLE (OPTIONAL)

FIG. 4

FIRE CYCLE

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"CG3-UV" SERIES VENTILATOR PRINCIPLE OF OPERATION

EXTERNAL FIRE MODE

An External Fire Mode is activated by the Ventilator’s Surface Fire Protection (Duct, Plenum, Surface/Appliance) system’s microswitch or contacts and/or an optional break glass fire

TESTING INTERNAL FIRE MODE –

FOR CG3 AND CG3-UV-FDT ONLY!

To test the Internal Fire Mode, a fire detected by the ventilator’s

Special Note: If the control is in the Cool Down Cycle when the External Fire mode is activated, the Cool Down Cycle will finish counting down for 2 minutes, before switching to the External Fire Mode.

BREAK GLASS FIRE SWITCH

C-1357A SERIES

Summary of Both Fire Modes at the Same Time

1.Internal Fire Mode (until thermostat temperature drops below 250°F)

2.Cool Down Cycle (for 2 minutes)

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

FIRE MODE SUMMARY:

	Note: The Damper Posi-	INTERNAL	COOL DOWN	EXTERNAL
	tion does not apply to
		FIRE	CYCLE (for Internal	FIRE
	CG3-UV-FDL, CG3-UV-
	FDD or CG3-UV-ND		Fire Mode only!)
	Exhaust Fan	OFF	OFF	ON
	Supply Fan	OFF	OFF	OFF
	Damper Position	FIRE	EXHAUST	EXHAUST
	Water Spray	ON	ON	ON
	UV Lamps	OFF	OFF	ON

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DAILY OPERATION

DAILY OPERATION

All functions of the ventilator, such as starting the exhaust fan, starting the wash cycle, etc., are controlled by the Command Center located on the control cabinet. Refer to Pages 16

6.The red “UV Saftey Interlock Activated” and the “UV Audible Alarm Cancel Button” lights will illuminate until the exhaust fans reaches operating speed.

7.Once the exhaust fan reaches operating speed, the UV lamps in the ventilator and the green “UV System On” light on the ventilator and the GPC-6000-UV cabinet will turn on.

8.The digital display then reads “Fan On 12:00” (current time) and “Start Wash> F2”.

Stopping the Exhaust Fan and Starting the Wash Cycle

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.

To start the wash cycle push the “Start Wash” button on the Command Center. If the Command Center is programmed to start the wash automatically, then the start button does not need to be pushed. When the wash cycle is activated the following occurs:

1.The UV lamps shut off.

2.The exhaust and supply fans shut off.

3.The damper begins closing forward to the wash position. (See Figure 3, page 7). This action takes approximately 45 seconds. (N/A on CG3-UV-FDD and CG3-UV-ND)

NOTE: Some control cabinets are equipped with a low detergent switch. If so equipped, the green light will flash if the detergent tank is empty or if the detergent pump is malfunctioning and detergent is not pumping. The digital display reads "Low Detergent" and the text alternates from "Fill Tank" and "Check Pump". If the detergent tank is filled with water the detergent switch will activate as if there is no detergent.

NOTE: The ventilator wash system is designed to remove daily accumulations of grease within 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 “Start 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.

WARNING: Some commercial hood cleaning services blow a fire retardant chemical into hood and duct systems. Fire retardant chemicals should never be applied to any portion of The Gaylord Ventilator. If retardant is applied to the ventilator, it must be removed.

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PREVENTIVE MAINTENANCE

PREVENTIVEMAINTENANCE

Some of the required maintenance can be performed by the	INSPECTION AND CLEANING REQUIREMENTS
operator. However, direct exposure to UV light is hazardous to	NFPA-96 (Standard for Ventilation Control and Fire Protection

Every Six Months

1.Exhaust fan(s) should be checked every six months for belt tightness, belt alignment, and lubrication of necessary moving parts.

NOTE: A blue lithium based grease is best suited for high heat and speed bearing lubrication.

2.Check for proper velocity at air inlet slot. Refer to Pages 24 through 26 for method of checking velocity.

3.Test the "Internal Fire Mode" to check for proper damper closure. Refer to Page 9 for instructions.

4.Detergent tank and foot valve should be cleaned every six months.

Particulate

Separator

Main Grease

Gutter

During clean-up		Inspection
procedures at		(Wash
the end of the		Access)
cooking period		Door(s)
special attention
should be given
to wiping clean
the damper at
the air inlet of
the ventilator

Actuator

Access"

Panel

Damper Actuator located behind this panel

During clean-up procedures at the end of the cooking period these areas should normally be wiped down

FIG. 7

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UV PREVENTIVE MAINTENANCE

CERTIFIED SERVICE AGENT MAINTENACE WARNING!

Warning: Do NOT defeat the purpose of the interlocks during cleaning and maintenance!

These items will need to be performed by a trained and quali-

Replacing UV Lamps

•An audible alarm on the C-6000-UV should come on

•The Red “UV Safety Interlock Activated” light on the ventilator and C-6000-UV control should come on

b.Open the UV Access door with the fan on

•The UV lamps should shut off

•An audible alarm on the C-6000-UV should come on

•The Red “UV Safety Interlock Activated” light on the ventilator and C-6000-UV control should come on

c.Turn off the breaker to the Exhaust Fan. Press the “Start Fan” button on the C-6000-UV control

•The UV lamps should shut off (stay off)

•An audible alarm on the C-6000-UV should come on

•The Red “UV Safety Interlock Activated” light on the ventilator and C-6000-UV control should come on

4.Check all gaskets for damage

a.Replace any gaskets that are worn or damaged

5.Check the Hour Meter

a.Record the hours.

b.Determine the approximate hours between inspection intervals.

c. Determine when the 8000-hour life of the lamps will occur and inform the operator of the approximate date when the lamps will need to be replaced

any other damage

12.Check all wires for damage

•Replace any wires showing damage

13.Lubricate each of the new UV lamp(s) before installing with a small amount of G-510 or similar detergent

14.Re-connect the lamp connectors on both ends of the UV lamps

•Each lamp connector should be labeled from 1 to 6) on both ends

•Lamp #1 is at the Front of the ventilator when the UV module is installed

•Lamp #6 is at the Back of the ventilator when the UV module is installed

15.Re-install the UV module end caps and torque the bolts to 7-10 in-lbs.

16.Re-install the UV module in the ventilator

17.Tighten all nuts holding the UV module to the ventilator

18.Re-connect the UV module power cord

19.Check for proper operation of UV lamps

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SAFETY CONCERNS WITH UVC

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

operation

All of these devices must be working and/or adjusted properly in order for the system to operate properly.

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DETERGENT PUMP OPERATION

The Gaylord Ventilator detergent pump is an integral part of the wash-down system of The Gaylord Ventilator. The pump is located within the control cabinet unless otherwise specified. (Refer to schematics on Pages 38 through 40.)

brass check valve should be clean and operating freely.

D. Detergent lines should be free and clear.

DETERGENT FLOW

Detergent flow is initially factory set according to the pipe size of the control cabinet (refer to chart). Generally, the factory setting will be sufficient to provide adequate cleaning of the ventilator. However, adequate cleaning is dependent upon a number of factors:

1. Temperature of hot water	4.	Wash cycle time
2. Water pressure	5.	Frequency of wash cycle
3. Daily grease accumulation	6. Type of detergent

Depending upon these factors, it may be necessary to adjust the detergent flow. Adjustment may be accomplished by changing the cam to a different size. To change the cam:

1.Loosen Allen set screw on brass cam.

2.Remove cam and replace with next size as required.

3.Cam #1 minimum setting. Cam #4 maximum setting.

NOTE: Cams are available from Gaylord Industries or your Gaylord Certified Service Agency.

PREVENTIVEMAINTENANCE

As with any piece of fine equipment, a reasonable amount of care must be taken to keep it in good working order:

FIG. 8

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DETERGENT FOR THE WASH SYSTEM

FORMULA G-510 is the only cleaner recommended by Gaylord Industries for use in the washdown system of The Gaylord Ventilator. FORMULA G-510 is a concentrated colloid cleaner specially formulated to remove the daily accumulation of

RESTROOMS...Add a disinfectant to clean all fixtures, walls, floors, etc.

Use a mixture of one part FORMULA G-510 to five parts water for extremely heavy grease build-up, such as on the floor and on equipment around deep-fryers. Spray on and rinse or wipe off. For extremely soiled areas, gentle agitation, followed by a soaking period, will result in more thorough cleaning.

DON’T be afraid to experiment with FORMULA G-510 because it contains no phosphates, nitrates, enzymes, sulfates, sulfonates or silicates.

LIMITED WARRANTY

IMPORTANT

If a cleansing agent other than FORMULA G-510 is used with The Gaylord Ventilator injection pump, it is recommended that a warranty similar to the above be obtained from the manufacturer of said product.

For name and address of the nearest FORMULA G-510 distributor contact:

20/10 Products Inc. P.O. Box 7609 Salem, OR 97303 Phone: [phone] FAX: [phone]

E-Mail: [e-mail]

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MODEL C-6000 SERIES COMMAND CENTER - INSTRUCTIONS

General Description:

The C-6000 Command Center is designed to start and stop the exhaust fan and wash up to 5 groups of ventilators in sequence with a delay period between each group. A sequence wash may

before the wash cycle starts, to allow the damper, if so equipped, to close to the "Wash" position. After closing, the timed wash cycle begins. Damper stays closed until "Start Fan" is pushed. Note: 24 hour kitchens must push "Start Wash" at least once a day, or as needed for proper cleaning.

3. To set the length of the time for the wash cycle, press "Menu", then press [F1] until "Wash Length" appears on the display. Follow the instructions on the display to edit the length of washes as necessary.

Note: Refer to the programming instructions on the inside of this cabinet for more information on programming the C-6000 Command Center.

LOW DETERGENT

The green light will flash and "Low Detergent" will be displayed on the C-6000 Command Center indicating the detergent is low.

FIRE CONDITION

1. A flashing red light and the message "Ext. Fire Active" indicates the control is in an External Fire Mode - exhaust fan on, damper open, and water wash nozzles on.

2. A continuous red light and the message "Fire In Hood" indicates the control is in an Internal Fire Mode - exhaust fan off, damper closed, and water wash nozzles on.

FIGURE 9

C-6000 COMMAND CENTER

3.Programming the length of the wash cycles and delay periods between the wash cycles. The maximum length of a wash cycle is 9 minutes. The maximum length of the

9.Number of Washes - Preset at factory and protected with a password. Allows the number of washes to be changed from 1 to 5 (S1 to S5).

Spanish (Español) Instructions:

The C-6000 Command Center has the ability to display its commands and messages in either English or Spanish (Español).

Press the "ENGLISH / ESPAÑOL" [F3] button to toggle the language displayed from English to Spanish (Español) or from Spanish (Español) to English.

NOTE: All messages displayed by pressing the "MENU" [F4]button only appear in English. They will not appear in Spanish (Español).

Using the Menu:

To Enter the Menu, press the MENU button [F4].

To navigate the Menu:

•Press [F1] to go to the Next menu item

•Press [F2] to go to the Previous menu item

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MODEL C-6000 SERIES COMMAND CENTER - INSTRUCTIONS

•Press [F5], the EXIT button to exit the Menu

•Press [F6], the ENTER button to select a Menu item

to cycle around if necessary

•Press [F5] [EXIT] to return to the menu

6.AutoMode [A or M]

•Used to select [M]anual or [A]utomatic mode. If [A] is displayed, the C-6000 is set to operate in Automatic

mode. If [M] is displayed, the C-6000 is set to operate in Manual mode.

•Press [F6] [ENTER] to display the “Set Mode” screen

•Press [F6] [ENTER] again to toggle between [M]anual or [A]utomatic mode

Setting Which Days of the Week to Run:

• Press [F1] to select which days to run the C-6000 in Automatic mode

• “Sun ON” or “Sun OFF” will display

•Press [F3] to set a day to “ON”. Set a day to “ON” in order for the C-6000 to run on that day

•Press [F4] to set a day to “OFF”. Set a day to “OFF” in order for the C-6000 NOT to run on that day

•Press [F1] to cycle through each day of the week [Sun

–Sat.]

•Press [F5] [EXIT] to return to the menu

7.Set WashTimes

•Only used when C-6000 is set to Automatic mode

•Press [F6] [ENTER] to display the Start time for the Fan on Sunday (Sun. Fan)

•Press [F3] to increase the Hour

Example: 1 = Sun. 2 = Mon. 3 = Tues, etc.

4.Turn AutoMode ON (Menu item #6)

Pressing (F6) Enter will toggle between [A]utomatic and [M]anual modes

After it is set to [A]utomatic mode, set which days of the week the Exhaust/Supply Fan will run - setting a day to "ON" means the Exhaust/Supply Fan will start on that

day, and the Wash will run. Example: Sun ON

Mon OFF

Tues ON

5.Set Wash Times, set start times for Fans & Wash (Menu item #7).

Set the time for the Fans to Start for each day of the week.

Example:	Sun. Fan	5:00
	Mon.Fan	5:00

Set the time for the Wash to Start for each day of the week.

Example: Sun.Wash 22:00 Mon.Wash 22:00

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MODEL C-6000 SERIES MENU FUNCTIONS

MENU FUNCTION			DISPLAY READS
1. Service - To obtain website address for a list
of service agencies
one wash)
Press [F3] to Increase the Delay Time up to		F3>Up	F4>Down (Toggles with)	F5>Exit
99 Minutes (Maximum
or
Press [F4] to Decrease the Delay Time down
to 1 Minute (Minimum)
Press [F5] [EXIT] to return to the menu
5. To Set Clock
Press [F1] until "(5)Set Clock" appears		(5) Set Clock
		F1>Next F2>Prev (Toggles with)		F5>Exit	F6>Enter
Press [F6] [ENTER] to display the current		Day 6	1=Sunday
Day of the Week (1=Sunday)		F3>Up	F5>Exit (Toggles with)	F1>Next	F2>Prev
Press [F3] to change to the next Day of the
Week (1=Sun, 2=Mon, 3=Tues, etc.), keep
pressing [F3] to cycle around if necessary
Press [F1] to go to the current Hour		Hour:	7
Press [F3] to increase the Hour, keep		F3>Up	F5>Exit (Toggles with)	F1>Next	F2>Prev
pressing [F3] to cycle around if necessary
Press [F5] [EXIT] to return to the menu

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