Gaylord RSPC-TPF Service Manual
TECHNICAL MANUAL
FOR
INSTALLATION, OPERATION
Effective Date: 4-05
AND MAINTENANCE
OF
THE GA YLORD "ClearAir
TM
MODEL "RSPC-TPF" SERIES
POLLUTION CONTROL UNITS
WITH FM-100 SERIES MONITORING STATION
WARNING
Improper installation, adjustment, alteration service or maintenance can cause property damage, injury or death. Read
the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment. Only
trained and qualified service personnel should install or service this equipment.
"
GAYLORD INDUSTRIES
10900 S.W. A VERY STREET • TUALATIN, OR 97062-1 149 USA
PHONE: 503-691-2010 • TOLL FREE: 800-547-9696 • FAX: 503-692-6048
email:info@gaylordusa.com • www.gaylordusa.com
“Undisputed World Leader in
Engineered Systems for
Commercial Kitchens”
tm
GAYLORD INDUSTRIES
World Headquarters: 10900 S.W. Avery Street • Tualatin, Oregon 97062-1149 U.S.A.
T o Our Customers . . .
Congratulations on your recent purchase of a Gaylord
ClearAirTM Pollution Control Unit. W e are proud to be ab le
to provide you with a quality product that exemplifies our
long-standing dedication to quality engineering.
Your unit is assembled from some of the very finest com-
ponents available and is designed for years of efficient,
effective, and troublefree operation. In addition, this unit
has undergone rigorous quality control inspections and
was fully operationally tested prior to shipment.
If you hav e further questions, please contact us toll free at
1-800-547-9696, or info@gaylordusa.com. We are more
than happy to help .
Sincerely,
Gaylord Industries
PHONE: 503-691-2010 • 800-547-9696 • FAX: 503-692-6048 • email: ga ylord@ga ylordusa.com • www.ga ylordusa.com
COMMERCIAL KITCHEN EXHAUST SYSTEMS • FIRE PROTECTION • HEAT RECLAIM • UTILITY DISTRIBUTION • ROOF TOP UNITS • POLLUTION CONTROL • AIR HANDLING UNITS
STREET ADDRESS: 10900 S.W. Avery Street, T ualatin, Oregon 97062-8549 U .S.A.
2
TECHNICAL MANUAL
FOR
INSTALLATION, OPERATION
AND MAINTENANCE
OF
THE GA YLORD “ClearAirTM”
MODEL “RSPC-TPF” SERIES
POLLUTION CONTROL UNITS
WITH FM-100 SERIES MONITORING STATION
Published by:
GA YLORD INDUSTRIES
Tualatin, Oregon 97062-1 149
U.S.A.
First Printing: January , 2003
© Copyright 2005, Gaylord Industries
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 THE WRITTEN PERMISSION
OF GAYLORD INDUSTRIES, INC. COPYRIGHT 2003.
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
The Gaylord ClearAirTM Unit is designed and engineered by
GA YLORD INDUSTRIES
10900 S.W. A very Street, Tualatin, Oregon 97062-1 149.
3
TABLE OF CONTENTS
INTRODUCTION ..........................................................................................5
SPECIFICATIONS ....................................................................................6-7
MODEL NUBER EXPLANA TION.................................................................8
TYPICAL INST ALLA TION .............................................................................9
SAMPLE ClearAir
RECEIVING & INST ALLA TION ...................................................................12
EQUIPMENT LIFTING PROCEDURE ........................................................13
ASSEMBLING RSPC HOUSING ON UNITS SPLIT FOR SHIPMENT....14-15
FM-100 MONITORING ST A TION (P ARTS) ............................................16-17
ODOR CONTROL SECTION ................................................................18-21
TM
CONFIGURA TIONS .............................................10-11
EXHAUST F AN SECTION ....................................................................22-23
NAMEPLATE DATA...................................................................................24
OPERA TING MA TRIX ................................................................................25
PRESSURE SWITCH TUBING DIAGRAM .................................................26
MAINTENANCE.........................................................................................27
FM-100 TERMINAL VOL T AGES................................................................28
WIRING DIAGRAM.....................................................................................29
P ARTS-MISCELLANEOUS ......................................................................30
ST ART-UP INSTRUCTIONS.......................................................................31
CLEARAIR RSPC-TPF ST ART-UP INSPECTION REPORT ......................32
WARRANTY........................................................................Inside back cover
4
INTRODUCTION
ir quality is becoming a major concern in America’s large
A
cities and as a result, many commercial kitchens will require pollution control equipment in their exhaust systems to
comply with the increasing demands of environmental control
agencies. In addition, pollution control equipment is being used
for kitchens in high-rise buildings allowing the exhaust to discharge out the side of the structure which saves the cost of
running the duct up many floors to the roof.
Pollution control in kitchen exhaust systems has typically been
accomplished by any one of the following methods - gas fired
incinerators, scrubbers, filtration units or electrostatic precipitators. Incinerators and afterburners literally burn the pollutants
and, while effective, can be very costly and hazardous to oper-
ate. Scrubbers consist of a water bath and extraction baffles to
remove the pollutants and though quite effective on grease re-
moval, they typically require the addition of high efficiency fil-
ters to abate smoke below control agencies’ standards. Filtra-
tion units use a series of impingement filters to remove the
pollutants and if done properly can be quite effective on both
smoke and grease.
The Gaylord pollution control unit, trademarked “ClearAirTM”TM,
can be manufactured with either electrostatic precipitation
(ESP) or Filtration (TPF). Gaylord Industries, Inc. has been
manufacturing ESP’s specifically designed for commercial
kitchen exhaust systems since the early 1970’s, longer than
any other manufacturer. However , when initial cost is a greater
concern the TPF unit is a sound alternative.
The ClearAirTM TPF unit is available in several configurations,
as illustrated on the following pages, ranging in capacity
from 1000 to 32,000 CFM (472 to 15,102 L/s). Most models
can include an exhaust fan and odor abatement equipment
as an option.
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 mea-
sured 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 between 0.3 and 0.8 microns and it is
these very small particles that smoke abatement equipment
must remove from the airstream. The amount of smoke be-
ing 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 an TPF is based on
how well it reduces the opacity level of a given airstream.The
Gaylord ClearAirTM unit will reduce the opacity level below
20%, thereby meeting the requirements of environmental control agencies.
Basic Facts About Odor
Cooking odors (molecules) generated by the combustion of
animal and vegetable matter result in an extremely complex
mixture of reactive organic gases (ROG’s). A small percentage of
these odors may be absorbed by the grease particles but the
vast majority exist separately in the airstream. The ROG molecules are much too small to be removed by any type of filter and
therefore, other methods must be used. There are several meth-
ods with which to manage the odor. One method is to use a
media bed. The two most popular types of media bed are acti-
vated charcoal, which absorbs and retains the odor molecules,
and the use of an odor-oxidant media (potassium permanganate) which oxidizes the molecules to solids and then retains them.
The other method involves the use of a liquid delivered with a finely
atomized spray. This spray performs a similar function to potassium permanganate in that it adsorbs or chemically neutralizes
odors. This process has the benefit of the end user being able to
adjust the amount of spray and thus the effectiveness and cost of
the odor control.
The life of the media bed type of odor control is dependent
upon several factors such as how much media is used, type
of odor, amount of odor molecules, grease loading and air
temperature. Typically , any of the above mentioned types of
media can remove 85% - 90% of the molecules. Determining
the efficiency of odor control can be very subjective, as testing
is usually conducted by the human nose. More scientific testing is available through ROG analysis, but this involves considerable costs.
Grease Removal - The Important First Step
Grease particles are also measured in terms of microns and
grease generated by commercial cooking equipment has a
particulate size of 10 microns and up. Pollution control equipment is not limited to removing smoke particles, but will also
remove a majority of the grease particles remaining in the
airstream. Therefore, the grease extraction efficiency of the
exhaust hood plays an important role in the operation and
performance of pollution control equipment.
Removal of grease particles before they reach smoke and
odor control equipment will significantly increase the smoke
abatement efficiency and the life of the odor abatement media. It is highly recommended that a Gaylord CG3 Series
Ventilator be used with the ClearAirTM unit as it has a grease
extraction efficiency of 95%. Other high efficiency exhaust
hoods and standard filter type hoods may be used with the
ClearAirTM unit. Contact Gaylord Industries for details.
5
SPECIFICATIONS
General
Furnish one (1) Gaylord ClearAir Pollution Control Unit model
RSPC-TPF series as manufactured by Gaylord Industries Inc.
of Tualatin, Oregon in accordance with the following:
The pollution control unit shall consist of a smoke control
section, odor control section (optional) and an exhaust fan
section (optional) all built on a common base as an integral
unit. Smoke control shall be accomplished by a three stage
high efficiency filter section (TPF). The unit shall be ETL listed
and labeled.
Smoke Control Section
The smoke control section shall have three phases of filters
The filters shall consist of replaceable 30% pre-filter, 95%
bag filter and a replaceable 99% final filter. Replaceable fil-
ters shall be mounted in filter slide tracks to prevent air by-
pass around the ends of the installed filter bank. Filters shall
be accessed through removable side access panels with lift
and turn latches.
Phase one filters shall have an average efficiency of 25 to
30% and an average arrestance of 90 to 92% in accordance
with ASHRAE test standard 52.1-1992. Media support grid
shall be on 1" centers with an open area 96%. Filter enclos-
ing frame shall be a rigid, high wet strength beverage board,
with diagonal support members 4" deep.
Phase two filters shall have an average efficiency of 90 to
95% in accordance with ASHRAE test standard 52.1-1992.
Sealing surface and pocket retainers shall be configured to
provide 84% open area. Seams in bag filters shall be sealed
with foamseal adhesive to completely eliminate air leakage
through stitch holes.
Phase three filters shall be 95% efficient on .03 micron par-
ticles (DOP smoke test), 97% efficient on nebulized staphy-
lococcus aerosols, 99+% efficient on atmospheric test dust
(ASHRAE standard 52.1-92). The casing shall be 16 gauge
steel with corrugated aluminum separators to insure media
stability. Media shall be fine-fiber, high strength
microfiberglass paper. Media end cuts shall be encapsulated
in urethane potting adhesive.
Fire Detection
A thermostat, set at 250o F, shall also be located in the filter
section to shut down the exhaust fan in the event of a fire.
Optional Fire Damper for use in Canada
The unit shall include a UL listed fire damper, with a 280o F
fusible link, located downstream of the filters to prevent passage of fire to the duct downstream of the unit
Filter Monitoring Panel
A monitor panel, for remote location, shall be supplied for the
operation and monitoring of the unit. The panel shall be constructed of 18 gauge stainless steel, number 4 finish, and be
suitable for surface or recessed mounting. The panel face
shall be a hinged door with a lift and turn flush latch. The
panel shall include an air proving time delay , relays and indicator lights to continuously monitor the unit. Indicator lights
shall be “Fan On”, “Normal Air”, “Low Air”, “Replace Pre-Filters”, “Replace Bag Filters”, “Replace Final Filter”, “Missing
Filter”, and “Fire In Unit”. An audible alarm, with an alarm
cancel button, shall be included and shall activate whenever
the unit status is low air, replace filters, missing filters or fire
in the unit. Status other than “Fire In The Unit” shall not shut
down the exhaust fan.
Specifier Note: If the ClearAir unit is used in conjunction with
a water wash ventilator, the monitor panel is built into the main
water wash control cabinet model GPC-6000 series.
Odor Control Options
Media bed of 50/50 Blend Potassium Permanganate and
Carbon Blend
The unit shall be provided with odor control utilizing a media
bed of 50% potassium permanganate 50% carbon blend. The
odor removal media shall be housed in slide out reusable steel
modules. There shall be a 30% pleated media after filter lo-
cated immediately downstream of the odor control media. Re-
placeable filters shall be mounted in filter slide tracks to pre-
vent air bypass around the ends of the installed filter bank. The
odor control media and after filters shall be removable through
side access doors with lift and turn latches.
Spray Odor Control
The unit shall be provided with a spray odor control system
utilizing an odor neutralizer chemical. The odor spray con-
trol cabinet shall be mounted on the side of the unit and
shall contain a liquid spray compressor piped to the spray
nozzle in the fan plenum, adjustable delay timers with fuse
protected circuitry factory wired to the unit electrical panel.
The cabinet shall include one 5 gallon container of Gaylord
Formula GS-710 Odor Neutralizer. The cabinet shall contain
a heater to prevent freezing of the odor neutralizer,
Exhaust Fan Options
Exhaust Fan (Standard Centrifugal Fan)
The unit shall include a centrifugal exhaust fan. The exhaust
fan shall be an SWSI upblast arrangement #9 or #10 with a
non-overloading BI or AF wheel. The motor, drives, bearings
and fan mounting base shall be located out of the exhaust
air stream as required by the IMC (International Mechanical
Code) and NFP A-96. The fan shall be AMCA certified and
bear the AMCA seal for performance. The fan housing shall
be constructed of heavy gauge steel. The fan bearings shall
be heavy duty self-aligning pillow block type rigidly mounted
on heavy structural steel supports. The motor shall be ODP
three phase mounted on a common base with the fan and
shall be pre-wired to the electrical cabinet located on the
unit. The electrical cabinet shall include a disconnect switch,
motor starter, overloads and fuses. The factory provided drive
assembly shall be adjustable pitch on 5 HP and smaller,
fixed pitch on 7.5 HP and larger. It shall also be sized for a
minimum 1.5 service factor. After final system balancing,
fixed pitch sheaves shall be provided and installed by the air
balancing contractor to provide proper flow at actual installed
conditions.
Exhaust Fan (Optional Tubular Fan)
The unit shall include a tubular centrifugal exhaust fan. The
exhaust fan shall be an arrangement #10 with a non-overloading BI, AF wheel. The motor, drives, bearings and fan mounting
6
SPECIFICATIONS
base shall be located out of the exhaust air stream as required
by the IMC (International Mechanical Code) and NFPA-96. The
fan shall be AMCA certified and bear the AMCA seal for performance. The fan housing shall be constructed of heavy gauge
steel. The fan bearings shall be heavy duty rigidly mounted on
heavy structural steel supports. The motor shall be ODP three
phase mounted on a common base with the fan and shall be
pre-wired to the electrical cabinet located on the unit. The electrical cabinet shall include a disconnect switch, motor starter, overloads and fuses. The factory provided drive assembly shall be
adjustable pitch on 5 HP and smaller and fixed pitch on 7.5 HP
and larger. It shall also be sized for a minimum 1.5 service factor.
After final system balancing, fixed pitch sheaves shall be pro-
vided and installed by the air balancing contractor to provide
proper flow at actual installed conditions.
Exhaust Fan Housing
The exhaust fan section of the unit shall be enclosed with the
same material as the smoke control section. There shall be
a removable panel for access to the fan.
Unit Construction
The unit housing shall be constructed of a minimum of 16
gauge G90 bright galvanized steel. The perimeter base shall
be 12 gauge formed channel with lifting lugs at each corner
and along the length as required. The internal housing shall
be externally welded liquid tight for compliance to the Inter-
national Mechanical Code and NFPA-96 grease duct con-
struction requirements.
Fire Extinguishing System Options
Specifier Note: NFPA-96 requires a fire extinguishing sys-
tem for protection of the smoke and odor control sections
and protection of the duct down stream of any filters or damp-
ers. Not all authorities having jurisdiction require protection.
Check with your AHJ. If required, specify one of the following
systems.
Wet chemical system
Provide a complete factory mounted Ansul wet chemical fire
extinguishing system, including nozzles piping and detec-
tion runs. Pipe penetrating the unit cabinet shall use a UL
listed fitting. System shall be installed in accordance with
the systems listing and NFP A-96. The Ansul Automan cabi-
net shall be mounted on the side of the unit for easy access,
certification and service.
Water spray sprinkler fire system
Specifier Note: Units that are located indoors may be factory
pre-piped for a wet pipe building sprinkler system
.
Check Out and Demonstration
Upon completion of installation, the entire pollution control
system, including the kitchen exhaust hoods, shall be commissioned by factory certified personnel. Start-up shall include checking all filters, filter monitoring station, odor control and exhaust fan. The appropriate maintenance personnel shall be given a technical manual and a complete demonstration of the system, including operation and maintenance procedures. Upon completion of the commissioning,
a detailed start-up report shall be made available to the architect and owner certifying proper system operation. Changes
required in fan drive components shall be performed by the air
balancing contractor under the direction of the factory certified
person(s) performing the start-up.
FIL TER MONITORING ST ATION
FM-100
Green
Green
Clear
Clear
Clear
Clear
Red
Red
Red
Provide a pre-piped water spray fire system installed in accordance with NFP A-96. The unit shall be piped with one pendent type sprinkler nozzle located in the smoke control section, one in the odor control section, if equipped with 50/50
media bed, and one in the exhaust fan section for interconnection to the building sprinkler system by the appropriate trades.
Pipe penetrating the unit cabinet shall use a UL listed fitting.
Nozzles shall be the bulb type rated at 325o F.
7
MODEL NUMBER EXPLANATION
The assigned model number of a ClearAirTM RSPC-TPF unit will indicate the number of Filter Banks and if it has spray odor
control, single o r double pass odor control, if it has an exhaust fan plus other data. The following example shows the make-up of
a model number.
The model number of your ClearAirTM unit along with other data can be found on the nameplate which is attached to the
electrical control panel on the ClearAirTM unit. Refer to page 24.
Standard Prefix Series of ClearAirTM System (Remote Smoke Pollution Control)
Triple Pass Filter
Filter Configuration (W x H) - 1x1, 2x1, 3x1, 2x2, 3x2, 4x2, 3x3, 4x3, 3x4, 4x4
Odor Control Option:
SO = Single Pass Odor Control
DO = Double Pass Odor Control
SPO = Spray Odor
T otal CFM (1000 - 32,000)
Exhaust Fan Option:
EFS = Exhaust Fan, unhoused, spring isolated
EFN = Exhaust Fan, unhoused, not spring isolated
EFHS = Exhaust Fan, housed, spring isolated
EFHN = Exhaust Fan, housed, not spring isolated
(BLANK) = No Exhaust Fan
Fan Type = C (Centrifugal), T (T ubular)
Fan Size (ie. 100 - 490)
Fan Motor H.P. (ie. 1 - 75)
Hand - R = Right Hand
L = Left Hand
RSPC - TPF - 3x2 - DO - CFM - EFN - C - 300 - 15 - R
BLOCK 1 2 3 4 5 6 7 8 9
All Blank, if no exhaust fan
8
TYPICAL INSTALLATION
9
SAMPLE ClearAirTM RSPC-TPF CONFIGURATIONS
The ClearAir unit is available in sizes ranging in capacity
from 1000 to 32,000 CFM (472 to 15,102 L/s). Each unit
is equipped with Three Phase Filters for smoke control,
and may include an exhaust fan, odor abatement equipment and Quencher System, or Ansul System as an option. The following illustrations are examples of the most
common configurations.
RSPC-TPF
SMOKE CONTROL ONL Y
KEY
AF = 30% After Filter
BF = 95% Bag Filter
DO = Double Pass Odor
Kor48/Carbon blend
EF = Exhaust Fan–un-housed
EFH = Exhaust Fan–housed
FD = Optional Curtain Fire
Damper
FF = 99% Final Filter
PF = 30% Pre-Filter
SO = Single Pass Odor
Kor48/Carbon blend
SPO = Spray Odor Cabinet
AF
RSPC-TPF-SO
SMOKE CONTROL
WITH SINGLE P ASS MEDIA BED ODOR CONTROL
RSPC-TPF
SMOKE CONTROL
WITH PLENUM
RSPC-TPF-DO
SMOKE CONTROL
WITH DOUBLE P ASS MEDIA BED ODOR CONTROL
AND OPTIONAL FIRE DAMPER
O
RSPC-TPF-SPO
SMOKE CONTROL WITH SPRA Y ODOR CONTR OL
AND OPTIONAL FIRE DAMPER
(Remote Fan)
10
SAMPLE ClearAirTM RSPC-TPF CONFIGURATIONS
RSPC-TPF-EF
RSPC-TPF-SO-EF
KEY
AF = 30% After Filter
BF = 95% Bag Filter
DO = Double Pass Odor
Kor48/Carbon blend
EF = Exhaust Fan—un-housed
EFH = Exhaust Fan—housed
SMOKE CONTROL WITH EXHA UST FAN
AND OPTIONAL FIRE DAMPER
FD = Optional Curtain Fire
Damper
FF = 99% Final Filter
PF = 30% Pre-Filter
SO = Single Pass Odor
Kor48/Carbon blend
SPO = Spray Odor Cabinet
RSPC-TPF-DO-EFH
RSPC-TPF-SPO-EF
SMOKE CONTROL WITH SINGLE PASS MEDIA
BED ODOR CONTROL, EXHA UST F AN
AND OPTIONAL FIRE DAMPER
H
SMOKE CONTROL WITH DOUBLE P ASS MEDIA BED
ODOR CONTROL, EXHA UST F AN
AND OPTIONAL FIRE DAMPER
O
SMOKE CONTROL WITH SPRA Y ODOR CONTR OL, EXHA UST
F AN AND OPTIONAL FIRE DAMPER
11
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