Gaylord CG3-UVi-SPC Service Manual
Rev 04
Technical Manual
Operation, Maintenance &
Installation
for
Model CG3-UVi-SPC Series
Ventilators
GAYLORD INDUSTRIE S
10900 SW Avery Street – Tualatin, Oregon 97062 USA
Email: info@gaylordventilation.com
www.gaylordventilation.com
Toll Free 800-547-9696 – Fax 503-692-6048
All rights 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 prior written permission of Gaylord
Industries.
©Copyright 2015, 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
Page iii
Page iv
TABLE OF CONTENTS
Chapter 1 – Introduction Page
About This Manual ………………………………………………………………………………………………………….............. 1-1
Ventilator Description …………….…………………………………………………………………………………………………… 1-2
Model Number Sequence …………………………………………………………………………………………………………….. 1-3
Explanation of Damper Options …………………………………………………………………………………………………… 1-5
Chapter 2 – Principles of Operation
Principle of Operation Overview …………..……………………………………………………………………………………… 2-1
Grease Extraction / Smoke Removal .…….…………………………………………………………………………………….. 2-2
Optional Continuous Cold Water Mist ..……………………………………………………………………………………….. 2-6
Wash Cycle ………………………… ……………………………………………………………………………………………………….. 2-8
Internal Fire Mode ..……………………………………………………...………………………………………………………………. 2-14
Fire Extinguishing Systems ……………………………………………….…………………………………………………………. 2-16
Chapter 3 - Daily Operation
Starting the Exhaust Fan ………………...…………………………………………………………………………………………… 3-1
Turning Off the Exhaust Fan and Starting the Wash Cycle …………………………………………………………. 3-6
Recommend Detergent ………………………………………………………………………………………………………………… 3-10
Chapter 4 – Maintenance
Operator Preventive Maintenance ……………………………………………………………………………………………… 4-1
Preventive Maintenance Required by Code ………………………………………………………………………………… 4-8
UV System - Scheduled Preventive Maintenance ……………………………………………………………………….. 4-9
Chapter 5 - Troubleshooting
Troubleshooting ………………………………………………………………………………………………………………………….. 5-1
Chapter 6 – Testing and Repair
Measuring Airflow ............................................................................................................................ 6-1
Make-Up Air Guidelines ……………………………………………………………………………………………………………….. 6-5
Replacing UV Lamps …………………………………………………………………………………………………………………….. 6-7
Replacing UV Lamp Sockets ………………………………………………………………………………………………………….. 6-13
Replacing UV Ballast ……….……………………………………………………………………………………………………………. 6-19
Main Electrical Raceway Ventilation Fan …………………………………………………………………………………….. 6-30
UV Module Ventilation Fans …………………………………………………………………………………………………………. 6-32
High Temperature Shutdown Controller ……………………………………………………………………………………….. 6-36
Safety Interlock Pressure Switch ……………………………………………………………………………………………………. 6-37
UV Ventilation Control Board …………………………………………………………………………………………………………. 6-37
Replacing UV Module Access Door Gasket ……………………………………………………………………………………. 6-40
Replacing UV Module Plate Gasket ……………………………………………………………………………………………….. 6-41
Damper Motor ……………………………………………………………………………………………………………………………… 6-42
Smoke Pollution Control System (SPC) – Overview ……………………………………………………………………….. 6-46
Testing Voltages at the Spark Plug Terminal Clips ………………………………………………………………………… 6-47
Testing ESP Cells …………………………………………………………………………………………………………………………….. 6-49
Replacing Ionizing Wires ………………………………………………………………………………………………………………… 6-51
Shorting Cell Plates ………………………………………………………………………………………………………………………… 6-52
Testing Plunger Safety Switch ……………………………………………………………………………………………………….. 6-52
Removing Electrical Chassis …………………………………………………………………………………………………………… 6-54
Transformer Voltage Test ………………………………………………………………………………………………………………. 6-55
Page vi
Page v
TABLE OF CONTENTS
Chapter 7 - Parts
Parts - Ventilator ............................................................................................................................... 7-1
Parts - UV Lamp Module ………………………………………………………………………………………………………………. 7-4
Parts – Main Electrical Raceway …………………………………………………………………………………………………… 7-5
Parts – Miscellaneous ……………………………………………………………………………………………………. 7-7
Parts – ESP Cells …………………………………………………………………………………………………………….. 7-8
Parts – Miscellaneous Smoke Pollution Control …………………………………………………………….. 7-9
Chapter 8 – Wiring Diagrams
Wiring Diagrams ………………………………………………………………………………………………………………………….. 8-1
Appendices
Sample Ventilator Nameplate ……………………………………………………………………………………………………… A-1
Installation Requirements ……………………………………………………………………………………………………………. B-1
Cell Rotation Log Sheet ………………………………………………………………………………………………… C-1
Ventilator Start-Up Inspection and Tests – Overview …………………………………………………………………… D-1
Pre Start-Up Check List …………………………………………………………………………………………………………………. D-1
Start-Up Inspection and Tests Report Forms ………………………………………………………………………………… D-3
Limited Warranty ………………………………………………………………………………………................ Inside Back Cover
Page vi
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__________________________________________________________Chapter 1- Introduction, Page 1-1
About this Technical Manual
The purpose of this manual is to provide the Operator, Maintenance and Service personnel instructions
for operating, maintaining, troubleshooting and repairing the Gaylord Ventilator Model CG3-UVi-SPC
Series. Ventilators incorporating UV Systems, most maintenance and all repairs must be performed by a
trained and certified service company. This manual also includes information and guidance to
contractors for initial installation of the Ventilator.
The manual is divided into chapters for easy reference to a particular subject. The pages in the chapters
are numbered with the chapter number, then a dash, and then the page number. So for example pages
in Chapter 2 are numbered 2-1, 2-2, 2-3 etc. Figures and Tables are numbered in a similar manor. For
example Figure 5-3-2 is on page 5-3 and is the second figure. Please keep your manual in a convenient
location for so it can be accessed easily.
If you have any questions or concerns with the installation, operation, maintenance or service of your
Gaylord Ventilator, please contact Gaylord Industries;
Web: www.gaylordventilation.com
E-Mail: info@gaylordventilation.com
Main Phone: 503-691-2010
Toll Free: 800-547-9696
Safety
It is important that the operator read Chapter 2, Principle of Operation, Chapter 3, Daily Operation and
Chapter 3, Maintenance, before operating the Ventilator for the first time. Particular attention should
be given to all the Caution and Warning statements.
Related Technical Manuals
CG3-UVi-SPC-SPC Series Ventilators are controlled by a Gaylord Command Center. The model number
of the Command Center is dictated by when the Ventilator was purchased. Typical models are C-6000
and C-7000 Series. The model number of your Command Center can be found on the nameplate located
on the back of the electrical compartment door. All Installation Operation and Maintenance Manuals
may be downloaded from the Gaylord website: www.gaylordventilation.com or be obtained by calling
Gaylord Industries.
Chapter 1- Introduction, Page 1-2__________________________________________________________
Ventilator Description Overview
The Gaylord Model CG3-UVi-SPC Series is a 3 stage Ventilator containing a high efficiency Grease
Extractor, Ultraviolet Light (UV) and Electrostatic Smoke Pollution Control (SPC) in one integral unit
(Refer to Figure 1-3-1). Stage 1, the primary Grease Extractor, removes the larger grease particulate, key
to the efficient operation of the UV and Smoke Pollution Control sections. Stage 2 is an Ultraviolet Light
System that dramatically reduces grease accumulation in the Pollution Control section, exhaust plenum,
ductwork and exhaust fans. This section contains UV Modules each having six high efficiency lamps
powered by high tech solid state ballasts. Stage 3, the Smoke Pollution Control section, contains
electrostatic precipitator ESP Cells to remove smoke particulate for the airstream.
The Ventilator incorporates six wash manifolds that connect to the Wash Control Cabinet. The Wash
Control Cabinet contains the Command Center that controls the exhaust fan and Wash Cycles. The
primary grease extractor, UV and SPC sections are automatically washed with hot detergent injected
water each time the exhaust fan is shut off, washing the accumulated grease and smoke particles out of
the Ventilator and into the building drain system.
UV and SPC Safety
The Ventilator has many safety features to ensure operators are not exposed to UV light or to high
voltage from the ESP Cell high voltage transformers. The access doors into the Extraction Chamber, UV
Lamp Modules, and the ESP Cells are monitored so if any door is opened the UV Lamps and the ESP Cells
immediately go off. In addition a pressure switch monitors the exhaust flow to shut off the lamp if the
airflow is below a minimum level.
Approvals
The Ventilator is ETL listed to UL Standard 710, 710C and 867. In addition the Ventilator has been tested
for UV light omissions, in compliance with the ACGIH (American Conference of Governmental and
Industrial Hygienist) requirements for exposure to UV light. The Ventilator is also listed by ETL to NSF
Standard Number 2.
__________________________________________________________Chapter 1- Introduction, Page 1-3
Stage 3 SPC
Section
Stage 2 UV
Section
Stage 1 Grease
Extractor Section
UV Module
Particulate Separator
3 Position Damper
Exhaust Inlet
UV Module Access Door
Drain
Sloping Grease Gutter
Figure 1-3-1
Extractor Access Door
Extractor Wash
Manifold
ESP Cell
Particulate Separator/UV
Module Wash Manifold
ESP Cell Access Door Shown
In Open Position
Lower SPC & Upper UV
Exhaust Duct Collar
Upper SPC Wash Manifolds
Description Overview – Cont.
Wash
Typical Section View of Model CG3-UVi-SPC
Series Ventilator
Chapter 1- Introduction, Page 1-4__________________________________________________________
1._____
2._____
3._____
4._____
5.______
6._____
7._____
8. ______
9. _______
Series
Damper
Style
Low
Style of
Custom
Cold
Autostart
Front to
Inlet damper is fixed and no damper motor, and has fuse link activated fire
Model Number Sequence
The CG3-UVi-SPC Series model numbers are made up of an alphabetic prefix followed by a series of
alphabetic and/or numeric suffixes to designate the style of ventilator and various options. Sequence of
model numbers is as follows.
Type
Profile
Design
(Option)
Built in
Make-up
Air If
Applicable
Air If
Applicable
Water
Mist, If
Applicable
If
Applicable
Back
Dimension
of the
Ventilator
in Inches
Explanation of Prefixes and Suffixes
1. Series
CG3-UVi-SPC ………… Water Wash Ventilator with ultraviolet light and smoke pollution control
feature.
2. Damper Type
Blank Space …………. Electrically activated three position damper located at air inlet slot (Refer to
Figure 1-5-1).
FDD ……………………… Same as CG3-UVi-SPC except inlet damper is fixed and has a fuse link activated
fire damper located at the duct collar (Refer to Figure 1-6-1)
FDT ……………………….
FDL ….………………….. Same as CG3-UVi-SPC except a bracket (Fire Damper Lockout) has been added to
ND ………….…………… Same as CG3-UVi-SPC except inlet damper is fixed and has no fire damper (Refer
3. Style
BDL ……………………... Wall mounted canopy.
BDL-BB ................. Island style for back-to-back cooking equipment using two extraction chambers
BBC ……………………… Island style for back-to-back cooking equipment using two extraction chambers
BDL-DS ………………… Island style for back-to-back cooking equipment using one extraction chamber
BDL-DS-CL …………… Island style for single line of cooking equipment.
4. Profile
LP ........................... Low Profile. Reduced height of front face of Ventilator and sloping end panels.
damper located at the duct collar with a thermostat to detect fire to send
notification (Refer to Figure 1-5-3)
prevent the damper from closing to the fire position (Refer to Figure 1-5-2)
to Figure 1-6-2).
and two separate exhaust ducts.
with one common exhaust duct.
with two inlet slots. Has common exhaust duct.
__________________________________________________________Chapter 1- Introduction, Page 1-5
Explanation of Prefixes and Suffixes – Cont.
5. Style of Built In Make-Up Air (If Applicable)
MAW ……………………. Front face make-up air using perforated stainless steel panels.
MAR ……………………… Front face make-up air using registers or grills.
MAI .......................... Internal short circuit make-up air.
MAW/MAI …………… Combination of MAW and MAI design.
MAR/MAI …………….. Combination of MAR and MAI Design.
6. Custom Air (If Applicable)
CA ………………...……… Additional baffles added to reduce the air volume over specific types of cooking
equipment.
7. Cold Water Mist (If Applicable)
CM ………………………… Addition of cold water manifold with spray nozzles at the air entry slot for
application over solid fuel burning cooking appliances (Refer to Figure 2-6-1).
7. Autostart Option
Blank Space ............. Indicates the hood section does not have Autostart system as required by IMC.
AS ……………………..…. Indicates the hood section has Autostart conforming with the IMC requirement.
8. Front to Back Dimension
In Inches ………………. Indicates front to back dimension of the Ventilator, or the overall width of an
island style.
Chapter 1- Introduction, Page 1-6__________________________________________________________
Figure 1-6-3
CG3-UVi-SPC-FDT
Figure 1-6-1
CG3-UVi-SPC
Figure 1-6-2
Explanation of Damper Options
1. CG3-UVi-SPC Ventilator – This is the standard Ventilator
and incorporates a damper at the air inlet slot that
during a wash mode closes forward by and electric
motor to seal off the inlet slot and opens to the exhaust
position when the exhaust fan is started. During a fire
condition a thermostat activates the damper motor
which closes the damper backwards to the fire position
and stays closed until the thermostat drops below its set
point and then closes to the wash position.
2. CG3-UVi-SPC-FDL Series – The FDL in the model number
stands for Fire Damper Lockout. This Ventilator
incorporates the same inlet damper as the CG3-UVi-SPC
that during a wash mode closes forward by and electric
motor to seal off the inlet slot and opens to the exhaust
position when the exhaust fan is started. The main
difference is the CG3-UVi-FDL has a Fire Damper
Lockout (FDL) bracket added that prevents the inlet
damper from closing to the fire position, so it does
NOT have a fire damper. This Ventilator includes a
thermostat so that in the event of a fire send a signal is
sent to the building fire alarm systems.
3. CG3-UVi-SPC-FDT Series – The FDT in the model
number stands for a fuse link Fire damper in the Duct
collar with a Thermostat. The fire damper is weighted
and when the fuse link reaches its melting point, the
damper closes. When the thermostat reaches its set
point, a signal is sent to the building fire alarm
systems.
Section View
Section View
CG3-UVi-SPC-FDL
Section View
__________________________________________________________Chapter 1- Introduction, Page 1-7
Figure 1-7-1
Figure 1-7-2
Explanation of Damper Options – Cont.
4. CG3-UVi-SPC-FDD Series – The FDD in the model
number stands for Fire Damper in the Duct collar. The
fire damper is weighted and when the fuse link
reaches its melting point, the damper closes. There is
no thermostat and no signal is sent to the building fire
alarm system.
5. CG3-UVi-SPC-ND Series – The ND in the model number stands
for No Damper.
Section View
CG3-UVi-SPC-FDD
Section View
CG3-UVi-SPC-ND
Chapter 1- Introduction, Page 1-8__________________________________________________________
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__________________________________________________Chapter 2 - Principle of Operation, Page 2-1
Figure 2-1-1
Typical Command Center
Figure 2-1-2
Principle of Operation Overview
The Gaylord Model CG3-UVi-SPC Series Ventilator is a high grease extraction efficiency Ventilator that
includes the additional feature of an Ultraviolet Light System that dramatically reduces grease
accumulation in the exhaust plenum, ductwork and exhaust fans, and includes a Smoke Pollution Control
system that will reduce smoke opacity levels below 20% (Refer to Page 2-5 for information on opacity
levels). The Ventilator incorporates a hot water Wash Cycle that automatically washes the accumulated
grease and smoke particles out of the Ventilator and into the building drain system. The standard CG3UVi-SPC Ventilator has a full length fire damper located at the air inlet slot, two models have a fire
damper in the exhaust duct collar and one model does not have a fire damper. Refer to Pages 1-6 and 17 for an explanation on fire damper options.
The operation of the exhaust fan and the Wash Cycle is controlled by the Gaylord Command Center
which is located on the face of the Wash Control Cabinet (Refer to Figure 2-1-2). All the plumbing
components, detergent pump and detergent tank are located inside the Wash Control Cabinet (Refer to
Figure 2-1-2 and Figure 2-11-2).
Typical Wash Control Cabinet
Chapter 2 - Principle of Operation, Page 2-2__________________________________________________
Grease Extraction/Smoke Removal
Overview
The Gaylord “CG3-UVi-SPC” 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 design
specifications. This high rate of grease extraction is accomplished by the use of grease extraction
baffles, Particulate Separators and UV lamps and ESP Cells. The following describes the function of each.
Grease Extraction Baffles
When the exhaust fan is started the hot, grease-laden air rising from the cooking surface merges with
the higher velocity air that wipes the front of the cooking equipment and extends, like an air blanket, from
the front edge of the cooking equipment to the air inlet slot of the
through the Ventilator’s extraction chamber at a high speed, it is forced to make a series of turns
around three baffles. As this high velocity air turns around each baffle, the
thrown out of the airstream by centrifugal force and collected on the baffles. The extracted grease,
dust and lint are collected in the interior of the ventilator, remaining out of the airstream until
removed daily by the Wash Cycle.
Baffle #1
Important Note: The following description of Baffle #1 is for the standard CG3-UVi-SPC series
Ventilator. For operation of Baffle #1 for series FDL, FDT, FDD, and ND refer to TableT-2-15-1).
This baffle, located at the air entrance of the ventilator, is a three position damper. Position #1
is the Exhaust Mode as shown in Figure 2- 3- 1, position # 2 is the Wash Cycle Mode as shown
in Figure 2-9-1, and position # 3 is the Fire Mode as shown in Figure 2-15-1. When the START
FAN button is pushed on the Command Center, the damper opens to the exhaust mode position
#1 to become the preliminary grease extraction baffle. There is a small sloped grease
collecting gutter on the back side of the damper which drains off liquefied grease to one end of the
Ventilator, preventing it from re-entraining into the airstream.
Baffle #2
This baffle is located on the interior back wall of the ventilator and is a stainless steel pipe,
equipped with brass spray nozzles on 8" to 10" centers (Refer to Figure 2-3-1 ). During the wash
cycle, hot detergent water is released through the nozzles.
Baffle #3
This baffle is located on the back of the inspection doors (Refer to Figure 2-3-1). This baffle is also a
grease collecting gutter, collecting the grease extracted by the ventilator preventing the contaminants
from dropping back into the high velocity airstream.
Optional Custom Air Baffles
Some Ventilators may be equipped with optional Custom Air baffles, shown dotted, which reduces
the exhaust volume where the baffles occur (Refer to Figure 2-3-1).
Particulate Separator
Once the larger particles of grease have been captured through inertial impaction by the baffles, the
smaller particles will be arrested in the Particulate Separator using the principles of diffusion and inertial
impaction (Refer to Figure 2-3-1). These collected particles will be washed away each day by the Wash
Cycle.
V
entilator. As the air moves
larger
particles of grease are
__________________________________________________Chapter 2 - Principle of Operation, Page 2-3
Figure 2-3-1
Baffle #2
Baffle #1
Air Inlet Slot
Baffle #3
UV Lamp
UV Lamps
Optional
ESP Cells
Exhaust Duct Collar
Particulate
Grease Extraction/Smoke Removal – Cont.
Separator
Custom Air
Baffles Shown
Dotted
Module
Exhaust Mode
Chapter 2 - Principle of Operation, Page 2-4__________________________________________________
Grease Extraction/Smoke Removal – Cont.
UV Lamps
Once the baffles and Particulate Separator have collected the grease particles larger than 1 micron, the
UV lamps will break down the remaining grease particles by direct exposure to 254nm light and by the
Ozone, Hydroxyl Radicals and Anionic oxygen created by the 187nm UV light and oxidizing the grease into
a light gray dust. The Ozone will carry down the ductwork and continue to break down the grease
particulate and odor molecules keeping the ductwork much cleaner. The byproducts of this process are
CO2, H20 and the base minerals from the grease and particulate matter coming off of the cooking
surface. The light gray dust that collects on the lamps is washed away each day during the Wash Cycle.
UV Systems are used to remove a high percentage of grease that the baffles and Particulate Separators
cannot remove, offering many benefits to the owner/operator.
The UV Lamps are mounted in an UVi Module which slide into a track downstream of the Particulate
Separator (refer to Figure 2-3-1). The Ballasts are mounted in the front portion of the module and other
electronics are mounted in the electrical raceway (Refer to Figure 6-7-1 and 6-15-1). The Command
Center monitors and displays text indicating the status of the UV System, and Safety Interlocks. Refer to
your Command Center Tech Manual for specific text displayed.
For proper UV operation, the Ventilators must be maintained in good working order. The UV system
must be inspected periodically and the lamps replaced as necessary. The Ventilator, ductwork and
exhaust fan must be inspected in accordance with NFPA-96 or local guidelines, though frequency of duct
cleanings should be significantly reduced. Refer to Chapter 4 for maintenance details.
UV Safety
Caution: Exposure to UV light is harmful to skin and eyes.
The CG3-UVi-SPC Series Ventilator is equipped with panels and Safety Interlocks to protect operators
from direct exposure to UV light. All safety precautions called for in this manual must be followed to
avoid the potential for harm to operators or service personnel. Refer to Page 4-9 for complete
description of safety precautions.
Smoke Removal
The Ventilator removes smoke particles by the use of Electrostatic Precipitator Cells (ESP Cells) located
after the UV section (Refer to Figure 2-3-1). The principle of operation of electrostatic precipitation is
actually quite basic. The Electrostatic Cell is made up of a series of aluminum plates spaced approximately
1/4” (6.35mm) apart (Refer to Figure 2-5-1). Every other plate is energized with 5000 volts of D.C. power
and the alternating plates are grounded. At the entry point of the Cell is a series of thin wires spaced
approximately 4” (101.60mm) apart (Refer to Figure 2-5-1). These wires, referred to as ionizing wires, are
energized with 10,000 volts D.C. and as the smoke particles enter the Cell and pass over the wires they
receive a positive charge. As the charged smoke particles continue through the Cell, the positive plate repels
them and the negative or grounded plate attracts them. Thus, the smoke particles are collected on the
negative plates. The action is efficient, safe and simple.
__________________________________________________Chapter 2 - Principle of Operation, Page 2-5
Figure 2-5-1
Side View
Figure 2-5-2
Isometric View
Grease Extraction/Smoke Removal – Cont.
Basic Facts About Smoke
Smoke particles are extremely small and not visible to the human eye unless thousands of them are
grouped together to form what we see as smoke. Individual particles are measured in units called
microns and one micron equals 1/25,400 of an inch (1/64,516 of a cm).
Smoke generated by commercial cooking equipment has a particulate size of 0.15 microns and it is
these very small particles that smoke abatement equipment must remove from the airstream. The
amount of smoke being discharged from a kitchen exhaust duct is measured in terms of its density,
referred to as opacity - the degree to which emissions block light. A 100% opacity level would be solid
black and 0% would be perfectly clear. Control agencies that have adopted smoke pollution ordinances
are requiring an opacity level of no more than 20%, which is a very light blue smoke.
Typically, heavy smoke producing cooking such as charbroiling creates an opacity level of 60% to 70%.
Opacity readings are taken by the human eye by viewing the smoke being discharged and then
assigning a percentage of opacity to what is seen. Though this method is quite subjective, it is the
method practiced by control agency inspectors who are trained and certified in determining opacity
percentages
Other more technical methods of determining opacity or particulate density are achieved through the
use of opacity meters and cascade impactors. This level of analysis is usually referred to as source
testing. Control agencies occasionally require this type of analysis and if so, the testing is conducted by
state certified contractors which can be quite costly and time-consuming. The efficiency of a pollution
control unit is based on how well it reduces the opacity level of a given airstream. The Gaylord ClearAir
unit will reduce the opacity level below 20%, thereby meeting the requirements of environmental control
agencies.
Electrostatic Cell
Electrostatic Cell
Chapter 2 - Principle of Operation, Page 2-6__________________________________________________
Figure 2-6-1
Cold Water Mist Nozzles
Optional Continuous Cold Water Mist
Overview
Some ventilators may be equipped with optional continuous cold water mist. NFPA-96 requires that all
hoods used over solid fuel burning appliances be equipped with a “spark arrester” to knock down any
embers, created by the burning of solid fuel, to reduce the possibility of embers or sparks being drawn
up into the exhaust duct and fan where it could ignite collected grease. Continuous cold water mist is
one of the acceptable spark arresters.
Continuous cold water mist ventilators incorporate a water manifold with spray nozzles, located at
the lower edge of the air inlet slot (Refer to Figure 2-6-1). The Wash Control Cabinet contains a Cold
Water Mist loop that contains a pressure regulator and pressure gauge (Refer to Figure 2-7-1). The
regulator is adjusted for a flow pressure of 40 PSI. When the exhaust fan is started, the solenoid
valve in the cold water loop in the Wash Control Cabinet opens (Refer to Figure 2-7-1), turning on the
mist nozzles which remain on as long as the exhaust fan is on. The nozzles produce a very fine mist and
are located so
that the entire air stream passes through the mist.
Optional Cold Water Mist
__________________________________________________Chapter 2 - Principle of Operation, Page 2-7
Figure 2-7-1
With Continuous Cold Water Mist Loop
Cold Water Loop
Cold Water Line to
Ventilator
Cold Water Inlet
Solenoid Valve
Pressure Regulator
Pressure Gauge
Shut Off Valve
Vacuum Breaker
Optional Continuous Cold Water Mist – Cont.
Engineering Notes
1. Water pressure: The optimal water flow pressure of the nozzle is 40 psi. There is a pressure
regulator and pressure gauge in the plumbing loop to accomplish this pressure.
2. Water Consumption: .66 GPH per lineal ft. of Ventilator at 40 psi.
Typical Wash Control Cabinet
Chapter 2 - Principle of Operation, Page 2-8__________________________________________________
Wash Time
in Minutes
1
4, 5 and 6
Upper ESP Cell Wash
3 2 All Off
Delay
20
3
4, 5 and 6
2nd Upper ESP Cell Wash
3 4 All Off
Delay
20
5
4, 5 and 6
Rinse
5
Extraction Chamber
Cell Wash
Table T-2-8-1
Wash Cycle
The Ventilator’s wash system is comprised of six wash manifolds with spray nozzles. (Refer to Figure 29-1). Manifolds #1 and #2 wash the Extraction Chamber, the Particulate Separators, and the
bottom of the UV Lamps (Refer to Figure 2-9-1). Manifold #3 washes the bottom of the ESP Cells
and manifolds #4, #5 and #6 washes the top of the ESP Cells (Refer to Figure 2-9-1). All the
components to operate the Wash Cycle, the detergent pump, detergent tank, solenoid valves and
other plumbing components are located in the Wash Control Cabinet (Refer to Figure 2-11-2). There are
two Solenoid Valves in the Wash Control Cabinet, one for manifolds #1, #2 and # 3 and one for manifold
# 4, #5 and #6 (Refer to Figure 2-9-1 and 2-11-2). The Wash Cycle is sequenced, first washing the top of
the ESP Cells in a sequence of Wash, Delay, Wash, Delay and then a Rinse. Then the Extraction Chamber,
Particulate Separator, UV Lamps and the bottom of the ESP Cells are washed. Refer to Table T-2-8-1 for
a typical Wash Cycle sequence.
The Wash Control Cabinet is piped to the building hot water system. The required temperature of the
water is 160°F. Min. - 180° F. Max. The required water pressure is 40 PSI Min. - 80 PSI Max.
The Wash Cycle sequence is activated each time the exhaust fan is shut off by pushing the START
WASH button on the Command Center or automatically at a specific time as programmed in the
Command Center (Refer to Figure 2-7-1). When activated the UV lamps shut off, the ESP Cells shut off,
and the exhaust and supply fans shut off. If the Ventilator is a standard GC3-UVi-SPC the electric
damper motor is energized and the damper begins closing forward to the wash position (Refer to
Figure 2-9-1). The damper takes approximately 45 seconds to close to the wash position. Refer to Pages
1-6 and 1-7 for an explanation of damper options.
Once the damper closes, the Wash Cycle sequence begins. If the Ventilator does not have an electric
damper, the Wash Cycle sequence begins immediately after pushing the START WASH button. There
are six sequences in the Wash Cycle as shown in Table T-2-8-1. When the wash is initiated the first
sequence begins; Solenoid Valve #1 opens and the Detergent Pump is energized, and hot detergent
water goes to the Upper ESP Wash Manifolds (#4, #5 and #6) for the length of time programmed in the
Command Center (Refer to Figure 2-9-1 and 2-11-1). The washes, delays and rinse continue as shown in
Table T-2-8-1. During the rinse cycle the detergent does not come on.
Typical Wash Cycle Sequence with Factory Recommend Times
Sequence # Manifold # Name of Wash
6 1, 2 and 3
Particulate Separator/UV
Lamp Wash/Lower ESP
See Table
T-2-10-1
__________________________________________________Chapter 2 - Principle of Operation, Page 2-9
Manifold #3
ESP Cells
UV Lamps
Particulate
Extraction
Damper in
Drain Line
Upper ESP Cell Wash
Sloping Gutter
Figure 2-9-1
Sloping Gutter
Wash Cycle – Cont.
Manifold #4
Manifold #5
Manifold #6
Manifold #2
Manifold #1
Extraction
Chamber/Particulate
Separator/UV
Lamp/Lower ESP Cell
Wash
Separator
Chamber
Wash Position
Wash Cycle Mode
Chapter 2 - Principle of Operation, Page 2-10_________________________________________________
Minimum Factory Recommended Wash Cycle Times for the
Extraction Chamber/UV Lamp Wash/Lower ESP Cells
Length of
(in min.)
Light Duty – Ovens, steamers and kettles
3
Light/ Medium Duty – braising pans, tilting skillets,
fryers, open burner ranges, hot top ranges, and
conveyor ovens.
Medium Duty – griddles and grooved griddles.
5
Heavy Duty – gas and electric char broilers, upright
broilers, woks and conveyor broilers.
Extra Heavy Duty – solid fuel broilers
9
Table T-2-10-1
Wash Cycle – Cont.
The Wash Cycle’s hot detergent water washes the day’s grease, dust and lint accumulation from the
Extraction Chamber baffles, the Particulate Separator, the gray dust from the UV Lamps, and the smoke
particles from the ESP Cells, flushing them down to the main gutter which slopes to a pre-flushed
drain which leads to the building drain system.
At the end of the Wash
Ventilator is clean and ready for the next day’s operations. If the Ventilator is a standard CG3UVi-SPC with electric damper the damper remains in the wash position until the exhaust fan is
restarted. This is to prevent conditioned air from going up the exhaust system during off hours.
The factory recommended length of the Wash Cycle, Delay and Rinses for the Upper ESP Cell Washes,
as shown in Table T-2-8-1, are the standard recommended times to be programmed into the Command
Center. If the Cells are not adequately cleaned the Wash Cycle time may have to be increased and/or
the delay time increased to allow more soaking time. The wash and rinse cycles may be programmed for
between 1-99 minutes. The delay time between the washes and rinses may be programmed for a length
of time necessary to allow the building’s hot water system to recover. The delay time may be
programmed for between 1-99 minutes however the minimum factory recommended delay is 20
minutes as shown in Table T-2-8-1. Refer to your Command Center Technical Manual for instructions on
programming wash, rinse and delay times.
The factory recommended length of wash time for the Extraction Chamber/Particulate Separator/UV
Lamp/Lower ESP Cell Wash is dependent upon the type of cooking equipment being used as shown in
Table T-2-10-1. However, adequate cleaning is dependent upon water pressure, water temperature,
daily grease accumulation, the length of the wash cycle, frequency of wash cycle and the type of
detergent being used. It may be necessary to increase the wash time for the Extraction
Chamber/Particulate Separator/UV Lamps above the factory recommended times to achieve proper
cleaning. Refer to your Command Center Technical Manual for instructions on programming wash
times. The water consumption for all the Wash and Rinse Cycles is shown on Table T-2-12-1.
C
ycle sequence, the water automatically shuts off, and the interior of the
Type of Cooking Equipment
Wash Cycle
4
7
_________________________________________________Chapter 2 - Principle of Operation, Page 2-11
Outlets to Ventilator
Detergent Pump
Figure 2-11-1
Detergent
Pressure
Detergent Container
Backflow Preventer
Command Center
Hot Water Inlet
Figure 2-11-2
Line Strainer
Solenoid Valve #2 to
Solenoid Valve #1
Wash
Shut Off Valve
Drain to Building
Shut Off Valve
Wash Cycle – Cont.
Command Center
Lower ESP Cell/
Extraction Chamber/
Particulate Separator/UV
Lamp Wash
to Upper ESP Cell
Injection Point
/Temperature
Gauge
Drain System
Typical Wash Control Cabinet with
Plumbing Door Open
Chapter 2 - Principle of Operation, Page 2-12________________________________________________
Extraction
ESP Cells Wash
60 PSI
80 PSI
60 PSI
80 PSI 4’-0”
10.9
13.2
3.51
4.05 1 4’-6”
11.8
14.2
3.51
4.05 1 5’-0”
12.5
15.2
3.51
4.05 1 5’-6”
13.4
16.1
3.51
4.05 1 6’-0”
14.1
17.1
7.02
8.10 2 6’-6”
15.0
18.1
7.02
8.10 2 7’-0”
15.5
19.1
7.02
8.10 2 7’-6”
16.4
20.0
7.02
8.10
2
8’-0”
17.1
21.0
10.53
12.15
3
8’-6”
18.0
22.0
10.53
12.15 3 9’-0”
18.7
23.0
10.53
12.15 3 9’-6”
19.6
23.9
10.53
12.15 3 10’-0”
20.3
24.6
14.04
16.20
4
10’-6”
21.2
25.9
14.04
16.20
4
11’-0”
21.7
26.9
14.04
16.20 4 11’-6”
22.8
27.8
14.04
16.20 4 12’-0”
23.5
28.8
17.55
20.25 5 12’-6”
24.2
29.8
17.55
20.25
5
13’-0”
24.9
30.8
17.55
20.25
5
13’-6”
25.8
31.7
17.55
20.25 5 14’-0”
26.5
32.7
21.06
24.30 6 14’-6”
27.4
33.7
21.06
24.30 6 15’-0”
28.1
34.7
21.06
24.30 6 15’-6”
29.0
35.6
21.06
24.30 6 16’-0”
29.7
36.6
24.57
28.35
7
Table T-2-12-1
Wash Cycle – Cont.
Engineering Notes
CG3-UVi-SPC Water Consumption in GPM
Ventilator
Length
1. Hot Water Pressure: 60 PSI Min. – 80 PSI Max.
2. Hot Water Temperature: 140° Min. - 180° Max.
Chamber/UV
Lamps/Lower
Upper ESP
Cell Wash
and Rinse
# of ESP
Cells
_________________________________________________Chapter 2 - Principle of Operation, Page 2-13
This Page Intentionally Left Blank
Chapter 2 - Principle of Operation, Page 2-14_________________________________________________
Internal Fire Mode
Important Note: The following description of the Internal Fire Mode is for the standard CG3-UVi-SPC
series Ventilator only. Refer to Table T-2-15-1 for a description of the Internal Fire Mode for series FDL,
FDT, FDD, and ND. Refer to Pages 1-6 and 1-7 for an explanation of fire damper options.
Automatic internal fire protection is accomplished by the action of the thermostat(s), which are located
at the point where the ductwork joins the ventilator (Refer to Figure 2-15-1). When the temperature of
the conveying airstream, which must pass over the thermostats, reaches 250°F, the system is activated,
and the following occurs:
1. Baffle #1 begins closing back to the fire position, position #3, stopping the combustion supporting
natural draft through the ventilator and creating a fire barrier to contain the fire in the kitchen (Refer
to Figure 2-8-1).
2. The UV lamps shut off.
3. The ESP Cells are shut off.
4. The exhaust fan serving the Ventilator is shut off. The supply fan is also shut off.
5. A fire signal is sent from the Command Center to the building fire alarm system (if wired).
6. The display on the Command Center will indicate a fire. Important Note: Refer to your Command
Center Technical Manual for specific text displayed during an Internal Fire Mode.
7. Upon cooling of the thermostat below 250°F, a 2 minute Cool Down Cycle begins and Baffle #1
moves to the exhaust position. Important Note: Refer to your Command Center Technical Manual
for specific text displayed during a Cool Down Cycle.
8. At the end of the Cool Down Cycle the damper closes to the wash position. Important Note: Refer to
your Command Center Tech Manual for specific text displayed upon completion of a Cool Down
Cycle.
9. The exhaust fan can now be restarted.
Important Note: The water sprays do not come on during an Internal Fire Mode
Chapter 2 - Principle of Operation, Page 2-15_________________________________________________
Signal sent to
(if wired)
CG3-UVi-SPC
Closes to Fire
Position
None
Yes
CG3-UVi-SPC-FDL
Baffle Fixed
None
Yes
CG3-UVi-SPC-FDT
Baffle Fixed
Closes if fuse link reaches
activation temp
Yes
CG3-UVi-SPC-FDD
Baffle Fixed
Closes if fuse link reaches
activation temp
No Thermostat
CG3-UVi-SPC-ND
Baffle Fixed
None
No Thermostat
Table T-2-15-1
Fire Detection
Baffle #1 Closed to the
Figure 2-15-1
Internal Fire Mode – Cont.
Thermostat - 250°F.
Internal Fire Mode Position
Internal Fire Mode
Internal Fire Mode (Thermostat Activated)
Series Baffle #1 Duct Collar Damper
building fire
alarm system
Chapter 2 - Principle of Operation, Page 2-16_________________________________________________
Fire Extinguishing Systems
The National Fire Protection Association Standard 96 (NFPA-96) and the International Fire Code (IFC)
requires the use of a Fire Extinguishing System to cover the cooking surfaces, Ventilator exhaust plenums
(the area above the ESP Cells), and the exhaust duct (Refer to Figure 2-17-1). Upon activation of the Fire
Extinguishing System the follow will occur:
1. Fire extinguishing agent will discharge through the cooking equipment nozzles, the plenum nozzles
and the duct nozzle(s) (Refer to Figure 2-17-1).
2. The protected cooking equipment and possibly other cooking equipment will shut off. Refer to the
above referenced codes for specific equipment that must shut off.
3. If the Fire Extinguishing System is wired to a building fire alarm system the alarm will activate.
4. If the Fire Extinguishing System is wired to a building management system it will notify of a fire
condition.
5. The Fire Extinguishing System should be wired to the Gaylord Command Center. If wired the
following will occur:
a) If the exhaust and supply fan were on, the exhaust fan would stay on and the supply fan would
shut off. It the exhaust and supply fans were off, the exhaust fan would come on and the supply
fan would stay off.
b) If the Ventilator Wash Cycle was on it would shut off.
6. After discharge, the Fire Extinguishing System must be recharged and certified by a fire system
contractor before the cooking equipment can be turned back on.
For Operation and Maintenance of the Fire Extinguishing System, refer to the system manufacture’s
Owner’s Manual.
Important: NFPA-96 requires inspection and certification of Fire Extinguishing Systems every 6 months.
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