Gaylord GX2-UV-FDD-BDL Service Manual

THE

GAYLORD VENTILATOR

EFFECTIVE DA TE 4-05

TECHNICAL MANUAL

FOR THE Ultima VentTM “GX2-UV” SERIES

NON WATER-WASH VENTILATORS

GAYLORD INDUSTRIES

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

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

“Undisputed World Leader in

Engineered Systems for

Commercial Kitchens”

tm

GAYLORD INDUSTRIES

World Headquarters: 10900 S.W . Avery Street • T ualatin, Oregon 97062-1149 U .S .A .

To Our Customers. . .
Congratulations on your recent purchase of a Gaylord

kitchen exhaust hood system. We are proud to be ab le
to provide you with a quality product that incorporates
the latest engineering concepts and is a result of over
50 years of experience in the foodservice kitchen
exhaust industry.

If you have other Gaylord equipment such as a Gaylord
Utility Distribution System, Quencher Fire Protection Sys-
tem, or Roof Top 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

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

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

2

TABLE OF CONTENTS

“GX2-UV” VENTILA TOR MODEL DESCRIPTION“ ..............................................................4

“GX2-UV” SERIES PRINCIPLE OF OPERA TION.......................................................... 5 – 7

MAINTENANCE AND CLEANING INSTRUCTIONS ............................................................. 8

UV PREVENTIVE MAINTENANCE .......................................................................................9

SAFETY CONCERNS WITH UV........................................................................................ 10

START-UP PROCEDURES .............................................................................................. 11

MEASURING INLET SLOT VELOCITY ....................................................................... 12 –14

TROUBLESHOOTING ............................................................................................... 15 – 20

MODEL CUV-100 SERIES CONTROL CABINET .............................................................21

MODEL CUV-100 SERIES CONTROL.............................................................................. 22

P ARTS LIST...................................................................................................................... 23

UV MODULE P ARTS ......................................................................................................... 24

GEM SYSTEM DIAGRAM...................................................................................................25

UV HOOD WIRING ............................................................................................................26

WIRING DIAGRAMS................................................................................................... 27 – 28

ST ANDARD VENTILA TOR MODELS.................................................................................29

METRIC CONVERSION CHART ....................................................................................... 30

START-UP INSPECTION REPORT ..................................................................................31

WARRANTY ............................................................................................... Inside back cover

PATENT NUMBERS

U.S.A.: 4,266,529

4,281,635
4,356,870

CANADA: 1,139,151

1,155,366

GERMANY: 8,034,240

ALL RIGHTS RESERVED. NO PART OF THIS BOOK MAY BE REPRODUCED, STORED
IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY AN ELECTRIC, ME­CHANICAL, PHOTOCOPYING, RECORDING MEANS OR O THERWISE WITHOUT PRIOR
WRITTEN PERMISSION OF GAYLORD INDUSTRIES COPYRIGHT 2004.

© Copyright 2005, 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 $10.00

3

“GX2-UV” VENTILATOR MODEL DESCRIPTION

There are 3 different types of “GX2-UV” “Grand Gaylord” non water-wash ventilators. The differences
involve the type and location of fire damper and whether the ventilator has a fire damper. The first part
of the model number indicates the type of ventilator, see below:

Explanation of Prefixes:

GX2-UV-FDD Non water-wash ventilator with removable extractor inserts and a fuse link

activated fire damper located at the duct collar (

[No Damper motor, No Thermostats]

GX2-UV-EDD Non water-wash ventilator with removable extractor inserts and a thermo-

statically activated (

With Damper motor and 1 or more Thermostat(s)]

GX2-UV-ND Non water-wash ventilator with removable extractor inserts and No Fire

Damper.

[No damper motor, No Thermostats]

electric

) fire damper located at the duct collar. [

weighted

).

4

“GX2-UV” SERIES PRINCIPLE OF OPERATION

The Gaylord “GX2-UV” Series Non Water-Wash Ventilator
offers simplicity, economy and performance that no other
ventilator can offer. The unique “extractor insert” gives a
grease extraction efficiency far superior to that of a typical
baffle filter. The Gaylord “GX2-UV” Series Ventilators are UL
Listed and meet all the requirements of NFPA #96 and the
International Mechanical Code.

EXHAUST FAN OPERATION

The exhaust fan is controlled by the Gaylord CUV-100 Control
Cabinet. The cabinet is usually located on a wall near the
ventilator. When the control is turned on, the exhaust fan and
UV Lamps will come on.

GREASE EXTRACTION

The Gaylord “GX2-UV” Series Ventilator extracts up to 99%
of the grease, dust, and lint particles from the airstream
passing through it. Grease extraction is accomplished by
unique, removable stainless steel “extractor inserts” which
incorporate a series of horizontal baffles. As the air moves
through the extractor at high speed, it is forced to make a
series of turns around these baffles, forcing the heavier-than-
air particles of grease, dust, and lint to be thrown out of the
airstream by centrifugal force. The sticky grease collects in
the extractor and the liquified grease drains down into the
main grease gutter which slopes to the grease cup. Note:

Some ventilators may be equipped with optional “Custom Air”
baffles (shown dotted) to reduce the exhaust volume over
specific light duty cooking appliances. The extractor inserts
come in two sizes15½" (5.6 lbs.) and 19½" (6.75 lbs.).

Particulate Separator

Once the largest particles of grease have been captured
through inertial impaction by the baffles. The smaller particles
of grease will be arrested in the particulate separator using the
principles of diffusion and inertial impaction.

UV Lamps

Once the baffles and particulate separators have collected the
grease particles larger than 1 micron. The UV lights will be
able to break down the remaining grease by direct exposure
to 254nm light and by the Ozone, Hydroxyl Radicals and
Anionic oxygen created by the 187nm UV light. This 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. There will be a light gray dust that
collects on the lamps, which will be need to wiped off. The
ductwork will need to be inspected per NFPA-96 schedules
but, will need much less frequent cleaning.

IMPORTANT NOTE: Never operate ventilator without extrac­tor inserts in place.

GREASE EXTRACTION

FIG. 1

5

“GX2-UV” SERIES PRINCIPLE OF OPERATION

CLEANING

At the end of the cooking day the exhaust fan is turned off at
the CUV-100 control. After the fan has been turned off, the
extractor inserts and particulate separators are removed and
can be washed either in a dishwasher or soaked and rinsed
off. The grease cup is also removed and emptied at this time.
To ease in the removal of the extractor inserts, an “Extractor
Removal Tool” is available which eliminates the need for
kitchen personnel to climb up on the cooking equipment, or
up a ladder.

The UV lamps will develop a coating of dust. This coating must
be removed for optimum performance. Therefore, once a week
while the cartridges are removed, inspect the lamps and clean
as needed. Use a clean dry cloth and if necessary wash with
mild detergent and water first.

FIG. 2

6

“GX2-UV” SERIES PRINCIPLE OF OPERATION

FIRE PROTECTION

NFPA-96 requires the use of Surface Fire Protection (Duct,
Plenum, Surface/Appliance) on all hoods. It is these systems
that are the first line of defense against equipment fires.

The “GX2-UV-FDD” Series ventilator incorporates a fuse link
damper at the duct collar. In the event of a fire, should the
fuse link at the duct collar reach 280°F, the fuse link melts
allowing the damper to close. (See Fig. 3) After the fire is
extinguished the fuse link(s) in the duct collar needs to be
replaced and the damper reset.

The “GX2-UV-EDD” Series ventilator incorporates an Electric
Damper at the Duct collar and thermostat(s), which are
located at the point where the ductwork joins the ventilator.

When the temperature of the conveying airstream, which
must pass over the thermostat(s), reaches 250°F, the
Electric Damper at the Duct collar closes and the Exhaust
and Supply fans and UV Lamps shut off, when the ventilator
and fans are wired according to Gaylord’s wiring diagram.
After the thermostat(s) cool below 250°F the damper will
reset automatically, and the Exhaust and Supply fans will
restart, if the CUV-100 control is turned “ON”.

The “GX2-UV-ND” Series ventilator does NOT have a damper.
The damper in the “GX2-UV-FDD” and the “GX2-UV-EDD”

prevent the flames from entering the ductwork and spread­ing to other parts of the building. The fire is contained in the
kitchen area where it can be properly fought.

FIG. 3

7

MAINTENANCE AND CLEANING INSTRUCTIONS

CLEANING

At the end of each cooking day, the exposed interior
surfaces of the ventilator should be wiped down and the
grease cup emptied. During the course of operation, grease
particles are gradually collecting inside the extractor inserts
and particulate separator. Daily, or at periodic intervals,
depending on the type of cooking, the extractor inserts and
particulate separators, must be removed and cleaned. To
clean, proceed as follows:

1. Remove extractor inserts by hand or by using the
extractor removal tool. CAUTION: Care should be
taken when removing extractors, especially over fryers.
It is recommended that the cooking equipment be
cooled down and the fryers be covered prior to removing
extractors. To remove, lift up slightly on extractor insert
and pull straight out.

2. Extractor inserts may be cleaned either by using a
dishwasher or by washing in a sink using hot water and
a degreasing detergent. Formula G-510 is highly
recommended for this application. For information
contact:

20/10 Products Inc.

P.O. Box 7609
Salem, OR 97303

Phone: [phone]
Fax: [phone]

E-mail: [e-mail]

3. With the extractor inserts and particulate separators
removed, wipe and clean the back wall and the grease
gutter with hot detergent water. NOTE: If a steam or hot
water pressure washer is used for periodic cleaning of
the interior, connect a hose to the gutter drain and lead
it to a floor sink or large bucket to drain off the water.

4. To replace the extractor inserts, care must be taken to
insure that point “A” rests in the rear clip as illustrated
in Fig. 4.

5. If the ventilator(s) has a fuse link operated supply duct
fire damper NFPA-96 requires inspection of the fuse link
every 6 months and replacement annually.

6. UV lamps must be wiped down
on a regular basis. This
may need to be done
as often as weekly
on some systems.

INSPECTION AND CLEANING REQUIREMENTS

The 2001 edition of NFPA-96 (Standard for Ventilation Control
and Fire Protection of Commercial Cooking Operations)
require that hoods, ducts and exhaust fans be inspected by
a properly trained, qualified and certified company or person(s)
in accordance with the following table.

Upon inspection, if found to be contaminated with deposits from
grease-laden vapors, the entire exhaust system shall be
cleaned by a properly trained, qualified, and certified company
or person(s) acceptable to the authority having jurisdiction.

When a vent cleaning service is used, a certificate showing
date of inspection or cleaning shall be maintained on the
premises. After cleaning is completed, the vent cleaning
contractor shall place or display within the kitchen area a
label indicating the date cleaned and the name of the
servicing company. It shall also indicate areas not cleaned.
Factory trained service agencies are certified by Gaylord
Industries, Inc. to perform these inspections. For the name
and phone number of your nearest agent call 800-547-9696
or www.gaylordusa.com and go to service.

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CAUTION: Care should be taken when removing extractors,
especially over fryers. It is recommended that the cooking
equipment be cooled down and the fryers be covered prior to
removing extractors.

EXTRACTOR INSERTS

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MAIN GREASE
GUTTER

DURING CLEAN-UP PROCEDURES AT
THE END OF THE COOKING PERIOD
SPECIAL ATTENTION SHOULD BE
GIVEN TO WIPING CLEAN THE AIR
INLET OF THE VENITLATOR

DURING CLEAN-UP PROCEDURES
AT THE END OF THE COOKING
PERIOD THESE AREAS SHOULD
NORMALLY BE WIPED DOWN.

FIG. 4

8

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 qualified
Certified Service Agency (CSA) on the same schedule as the
exhaust system inspection schedule described in NFPA-96 and
on the previous page in this tech manual. These tasks involve
potential exposure to high doses of UV light and live electrical
components. There is risk of injury to skin and eyes and in the case
of electrical shock, injury or death! For a list of CSAs go to
www.gaylordusa.com and go to "Service Agencies" for a list of
companies nearest you.

1. Inspection of the Lamps and Ballasts

a. Check the lamps for proper operation

1. Turn on the fan and look for the green "UV System
On" light on each hood section
a. If it is not on refer to "UV Troubleshooting",
pages 17, 18 and 20.

2. Open the UV Access door with the key

3. Turn on fan

4. Verify all of the Extractor Inserts are installed.

5. Depress the UV Access door safety switch

6. Check all indicator LEDs, 6 green and 3 red, to
ensure that they are all on. If they are not all on go
to "UV Troubleshooting", pages 17, 18 and 20.

2. Inspect the Plenum (around the UV lamps)

a. Disconnect the UV module power cord
b. Remove the nuts holding the UV module to the ventila-

tor with a nut driver

c. Remove the UV module from the ventilator
d. Check for build-up of deposits of grease, dust and/or lint.
e. Clean as necessary with a mild detergent, water and

a rag

f. Reinstall the UV module.

3. Test the Safety Interlock switches

a. Remove one Extractor Insert with the fan on

• The UV lamps should shut off

• An audible alarm on the CUV-100 should come on

• The Red “UV Safety Interlock Activated” light on the
ventilator and CUV-100 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 CUV-100 should come on

• The Red “UV Safety Interlock Activated” light on the
ventilator and CUV-100 control should come on

c. Turn off the breaker to the Exhaust Fan. Press the

“Start Fan” button on the CUV-100 control

• The UV lamps should shut off (stay off)

• An audible alarm on the CUV-100 should come on

• The Red “UV Safety Interlock Activated” light on the
ventilator and CUV-100 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

Replacing UV Lamps

Danger!

These items will need to be performed by a trained and qualified
Certified Service Agency (CSA). These tasks involve potential
exposure to high doses of UV light and live electrical compo­nents. There is a risk of serious injury to skin and eyes from UV
light. There is risk of shock, injury, and/or death from electrical.
For a list of CSA’s go to www.gaylordusa.com and go to the
“Service Agencies” for a list of certified companies nearest you.

1. Secure all power to the CUV-100 control

2. Secure all circuits that provide power to the UV lamps

3. Open the UV Access door with the key

4. Disconnect the UV module power cord

5. Remove the nuts holding the UV module to the ventilator
with a nut driver

6. Remove the UV module from the ventilator

7. Remove the bolts on each end of the UV module (2 on
each end) that hold the end caps on

8. Disconnect the lamp connector(s) on the UV lamp(s) to
be replaced

• 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

• Be sure to re-label the lamp connectors if necessary

9. Lubricate the lamps around the grommets on each end of the
UV lamp with a small amount of G-510 or similar detergent

10. Slide the UV lamp out one end, CAREFULLY!

11. Inspect the grommets around the lamps

• Replace any grommets that show cracks, checking,
or 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

9

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 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 hoods 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 See previous page for details.

Personal Protective Equipment

1. Eye protection that prevents 100% of UVC being trans-
mitted through the lens must be worn at all times when
performing service work on any Ultima Vent 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 pants and shirts be worn to minimize the
potential for inadvertent exposure of the skin to UVC.

Safety Interlocks

This product comes equipped with the following sensors to
verify that all access doors are in place and that the exhaust
fan is running:

1. Mechanical door switch on the UV Access door to ensure
that the door is closed

2. Gaylord Extractor Monitor (GEM) that ensures all of the
Extractor Inserts are installed.

3. Air Pressure switch to verify air flow and exhaust fan
operation

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

10

START-UP PROCEDURES

Before using the Ultima Vent a complete and thorough start-up of the Ultima Vent system must be performed by a qualified, and
authorized service technician. Because of this the UV modules will be shipped separate from the hood to an Certified Service
Agent(CSA). Contact Gaylord Industries to arrange for this service. It is normally included in the purchase price of the hoods.

Start-up requirements and activities

At the time of shipment a Certified Service Agent (CSA)will be
selected to perform the installation of the UV modules and the
start-up for the Ultima Vent system.

The Service agent should confirm the following prior to going
to the job site:

1. The Exhaust and Supply fan(s) are connected to the
ductwork

2. The fans have electricity and will run

3. The CUV-100 control panel is mounted and has the
following:

a. Power to the CUV -100
b. All necessary electrical connections between the CUV-

100 and the hood, surface fire protection system, and
fans.

4. All lighting wiring is connected to the hoods and light
switch

5. There is a 120 Volt, 20 Amp power circuit going to each
hood section, for UV lamps

6. Any personnel (Fire Marshal, owners rep., GC, FP
contractor, air balancer, etc) required to witness the start
up would need to be notified of time and date for start-up.

Field Start up directions

Allow about 1 hour per hood section, at the job site, for the
activities described below:

1. Check for power to the CUV-100 and wiring between the
CU V-100 and the hoods

2. Check that all Extractor Inserts are properly installed

3. Start the exhaust fan by turning the CU V-100 control on.
Both supply and exhaust fans should start. The green “UV
System On ” light should be on. If this does not occur refer
to "UV Troubleshooting" on pages 17, 18 and 20.

4. Turn CUV-100 control off. This will shut off the fans.

5. Open the UV Access door and remove the blank plate
from the UV light opening.

6. Install the UV light modules in the hood. Connect the plug
on the UV module to the hood.

7. Start the exhaust fan and check for the green “UV
System On” light at the hood(s) and control panel. Make
sure that all access doors are closed.

8. Check the air velocity at the inlet slot

9. Record the data on the start up form. Determine the
correct inlet slot velocity and record that in the design
velocity location. Then determine the percentage of de­sign that the actual air velocity represents

11. Remove an Extractor Insert

a. The red “Safety Interlock Activated” lamp should come on

and an audible alarm sound.

12. Check the UV Access door interlock

a. Open the UV Access door with the fan on.The red

“Safety Interlock Activated” lamp should come on and
an audible alarm sound.

Caution: Before any Fire tests are performed, check with
the building superintendent to see if the Surface Fire
Protection system is wired to the building alarm, monitor-
ing system, and/or fire department.

13. If the FP contractor is there have them trip the micro
switches on the FP system to verify that the Exhaust
Fan(s) starts and supply Fan(s) shut off.

14. Once all is working correctly demonstrate the following to
the end user

a. If the hood is interlocked with the FP system. Have the

FP contractor test it and confirm that the External fire
mode works properly.

b. Instruct them that if for any reason they can see the UV

light directly they must shut off the hood immediately
and call a CSA.

c. Check for proper damper operation if this hood has a

damper
d. How to remove, clean and replace the Extractor Inserts
e. That they need to perform the required end user main-

tenance described in the tech manual and hire CSA to

perform the UV maintenance as described in the tech

manual and have the duct system inspected/or cleaned

per the requirements of NFPA-96.
f. The frequency will need to be adjusted based on the

type, amount and duration of cooking done at this site.
q. Fill out the start up form completely with comments
r. Notify the Dealer/customer if the air volumes are more

than 5% low or 10% high and give the dealer and GC

a copy of the Start-up report.
g. Send a copy of the Start-up report to Gaylord and keep

a copy for your records.

11