Gaylord RSPC-TPF-H Installation Manual

TECHNICAL MANUAL

FOR

INSTALLATION, OPERATION

Effective Date: 1-03

AND MAINTENANCE

OF

THE GAYLORD "ClearAir"TM

MODEL "TPF" SERIES

POLLUTION CONTROL UNITS

WITH FM-100 SERIES MONITOR 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, INC.

10900 S.W. AVERY STREET • P .O. BOX 1149 • TUALA TIN, OR 97062-1149 USA

PHONE: [phone] • TOLL FREE: 800-547-9696 • FAX: [phone]

email:[e-mail] • www.gaylordusa.com

“Undisputed World Leader in

Engineered Systems for

Commercial Kitchens”

tm

GAYLORD INDUSTRIES, INC.

World Headquarters: P .O. Box 1149 • Tualatin, Oregon 97062-1 149 U.S.A.

T o Our Customers. . .
Congratulations on your recent purchase of a Gaylord

ClearAir Pollution Control Unit. We are proud to be able
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 com­ponents 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 have further questions, please call us toll free at
1-800-547-9696. We are more than happy to help.

Sincerely ,

Gaylord Industries, Inc.

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

TECHNICAL MANUAL

FOR

INSTALLATION, OPERATION

AND MAINTENANCE

OF

THE GA YLORD “ClearAir”™

MODEL “TPF” SERIES

POLLUTION CONTROL UNITS

WITH FM-100 SERIES MONITOR STATION

Published by:

GAYLORD INDUSTRIES, INC.

Tualatin, Oregon 97062-1149

U.S.A.

First Printing: January , 2003

© Copyright 2003, Gaylord Industries, Inc.

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, 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 ClearAir Unit is designed and engineered by

GA YLORD INDUSTRIES, INC.

P .O. Box 1 149, T ualatin, Oregon 97062-1 149.

TABLE OF CONTENTS

INTRODUCTION .............................................................................. 1

PRINCIPLE OF OPERATION ........................................................... 2

TYPICAL TPF MODELS ................................................................... 3

GENERAL INFORMATION ............................................................... 5

TYPICAL INSTALLATION ................................................................. 7

SAMPLE ClearAir CONFIGURATIONS ............................................ 8

NAMEPLA TE DATA........................................................................... 10

RECEIVING & INSTALLATION ......................................................... 12

EQUIPMENT LIFTING PROCEDURE.............................................. 13

ODOR CONTROL SECTION

GENERAL DESCRIPTION ........................................................... 14

ODOR CONTROL MEDIA............................................................. 14

SERVICE AND MAINTENANCE .................................................. 14

REPLACING THE MEDIA ............................................................. 14

FILTERS ........................................................................................ 16

EXHAUST FAN SECTION ................................................................ 18

MAINTENANCE ................................................................................ 20

PARTS LISTS ................................................................................... 21

WIRING DIAGRAM ........................................................................... 22

TERMINAL VOL T AGES..................................................................... 23

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

INTRODUCTION

Air quality is becoming a major concern in Americas large
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 operate. Scrubbers consist of a water bath
and extraction baffles to remove the pollutants and though
quite effective on grease removal, they typically require the
addition of high efficiency filters to abate smoke below con­trol agencies standards. Filtration 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 ClearAir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 ClearAir TPF unit is available in several configurations,
as illustrated on the following pages, ranging in capacity from
1000 to 24,000 CFM (472 to 11,328 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 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 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 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 an TPF 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.

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 methods with which to manage the odor.
One method is to use a media bed. The two most popular
types of media bed are activated charcoal, which absorbs
and retains the odor molecules, and the use of an odor-oxi­dant (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 is 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 ClearAir 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 ClearAir unit. Contact Gaylord Industries for de­tails.

1

PRINCIPLE OF OPERATION

ClearAir Unit - Principle Of Operation

Smoke Control Section

The smoke control section has three phases of filters
located prior to the odor control section. These filters
consist of replaceable 30% pre-filter, 95% bag filter and a
replaceable 99% final filter. Replaceable filters are mounted
in filter slide tracks to prevent air bypass around the ends
of the installed filter bank. Filters are accessed through
removable side access panels with lift and turn latches.

Phase one filters 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 is on 1" centers with an open area 96%. Filter en­closing frame is a rigid, high wet strength beverage board,
with diagonal support members 4" deep.

Phase two filters have an average efficiency of 90 to 95%
in accordance with ASHRAE test standard 52.1-1992.
Sealing surface and pocket retainers are configured to pro­vide 84% open area. Seams in bag filters are sealed with
foamseal adhesive to completely eliminate air leakage
through stitch holes.

Phase three filters are 95% efficient on .03 micron par­ticles (DOP smoke test), 97% efficient on nebulized sta­phylococcus aerosols, 99+% efficient on atmospheric test
dust (ASHRAE standard 52.1-92). The casing is 16 gauge
steel with corrugated aluminum separators to insure me­dia stability. Media is fine-fiber, high strength
microfiberglass paper. Media end cuts are encapsulated
in urethane potting adhesive.

All Gaylord ClearAir units include, as standard equipment,
a fan start stop switch and filter monitor panel. If a Gaylord
water-wash ventilator is used, a common control panel
which would wash the ventilator and provide the monitor
station for the Clear Air Unit is provided.

The ClearAir the unit includes a UL listed fire damper, with
a 280 degree fusible link, located down stream of the fil­ters to prevent passage of fire to the duct downstream of
the unit. A fire-stat, set at 250 degrees, is located in the
filter section to shut down the exhaust fan in the event of a

fire.

Model Application

The Gaylord ClearAir unit is available in various configura­tions, as shown on the following The simplest configura­tion is the Filtration unit alone with out a fan or odor con­trol. A second configuration includes the exhaust fan but
no odor control. This is used when smoke abatement is
the only concern. The third, and most common unit, is the
Model TPF-H- Series. This model would also be located
either in a mechanical room or on the roof and includes
odor control and the exhaust fan.

The size of each of the configurations varies with the air
volume, type of cooking equipment and options chosen.
Contact Gaylord Industries for complete details.

Construction

The housing is constructed of a minimum of 16 gauge
g-90 heat treated galvanized steel. The perimeter base is
12 gauge formed channel with lifting lugs at each corner
and along the length as required. The internal housing is
externally welded liquid tight for compliance to the Inter­national Mechanical Code grease duct construction re­quirements. The smoke control and odor control sections
all include a drain at the side bottom of the housings for
interconnection to a common drain to facilitate removal of
water from steam cleaning or pressure washing. The ex­haust fan includes a scroll drain with a grease receptacle.

Monitor Panel

A monitor panel, for remote location, is supplied for the
operation and monitoring of the unit. The panel is be con­structed of 18 gauge stainless steel, number 4 finish, and
is suitable for surface or recessed mounting. The panel
face has a gasketed hinged door with a lift and turn flush
latch. The panel includes an air proving time delay, relays
and indicator lights to continuously monitor the unit. Indi­cator lights are 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, is included and will activate when­ever the unit status is low air, replace filters, missing filters
or fire in the unit. Status other than Fire In The Unit will
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.

GAYLORD

®

TM

C

LEARAIR

POLLUTION CONTROL UNIT

CONTROL PANEL MODEL

FM-100

FAN ON

NORMAL AIR

LOW AIR

REPLACE PRE FILTERS

REPLACE BAG FILTERS

REPLACE FINAL FILTERS

MISSING FILTER

FIRE IN UNIT

THERMOSTAT ACTIVATION
AND / OR FIRE SYSTEM

FIL TER MONITORING ST A TION

FM-100

DISCHARGE

CANCEL ALARM BUTTON

The ClearAir Unit Model RSPC-TPF Series is ETL Listed under
the category Air Filtering Device, Report # 3028598-1

- CAUTION -

DO NOT OPERATE UNIT WITH MISSING
FILTERS OR WITH FILTERS THAT SHOULD
BE REPLACED AS INDICATED BY MONITOR­ING LIGHTS. THIS IS A SMOKE POLLUTION
CONTROL DEVICE AND WILL NOT OPER­ATE PROPERLY WITH MISSING OR DIRTY
FILTERS.

GAYLORD INDUSTRIES, INC.

TUALATIN, OREGON 97062-1149 U.S.A.

Phone: [phone] • 800-547-9696

Fax: [phone] • email: [e-mail]

Form No. TPF FP/19038

6(1625/,*+7

U.S.

42106

2

CLEARAIR TPF TYPICAL MODELS

MODEL TPF-H

Horizontal Style
The model TPF-H is a Filtration smoke abate­ment unit designed for use with a remote exhaust
fan and odor control unit(if required) which can
be supplied by Gaylord Industries as an option.

Model TPF-H-EF

Horizontal Style with Exhaust Fan

The Model TPF-H-EF is an Filtration smoke abate­ment unit that includes a built-in exhaust fan. The
primary feature of this unit is that the intercon­necting ductwork, transitions and fan are factory
installed in a single roof top package. The unit
comes pre-wired for single point electrical con­nection and includes a magnetic starter, fuses,
and a disconnect switch. This model is available
for both indoor and outdoor installations in sizes
from 1000 to 24,000 CFM (472 to 11,328 L/s).

PF

BF FF FDQM

PF

OUTLET TO FAN

BF FFQM

FAN DISCHARGE

EF

Model TPF-H-SO

Horizontal Style with Odor Control

The Model TPF-H-SO is an Filtration smoke
abatement unit that includes built-in odor con­trol and is designed for use with a remote ex­haust fan which can be supplied by Gaylord In­dustries as an option. The odor control section
includes a 30% pre-filter, and a single pass odor
control media. This model is available for both
indoor and outdoor installations in sizes from
1000 to 24,000 CFM (472 to 11,328 L/s).

Model TPF-H-SO-EF

Horizontal Style with Odor
Control and Exhaust Fan

The Model TPF-H-SO-EF is an Filtration smoke
abatement unit that includes built-in odor con­trol and exhaust fan. The primary feature of this
unit is that the interconnecting ductwork, transi­tions and fan are factory installed in a single roof
top package. The unit comes pre-wired for single
point electrical connection and includes a mag­netic starter, fuses and a disconnect switch. The
odor control section includes a 30% pre-filter,
and a single pass of odor control media. This
model is available for both indoor and outdoor
installations in sizes from 1000 to 24,000 CFM
(472 to 11,328 L/s).

PF

BF

PF

QM

FF

BF

QM

FF

SO FD

SO

AF

OUTLET TO FAN

FD

FAN DISCHARGE

EF

3

CLEARAIR TPF TYPICAL MODELS

Model TPF-H-DO-EF

Horizontal Style with Double Odor
Control and Exhaust Fan

The Model TPF-H-DO-EF is an Filtration smoke
abatement unit that includes built-in odor control
and exhaust fan. The primary feature of this unit
is that the interconnecting ductwork, transitions
and fan are factory installed in a single roof top
package. The unit comes pre-wired for single
point electrical connection and includes a mag­netic starter, fuses and a disconnect switch. The
odor control section includes a 30% pre-filter,
and a double pass of odor control media. This
model is available for both indoor and outdoor
installations in sizes from 1000 to 24,000 CFM
(472 to 11,328 L/s).

BF

FAN DISCHARGE

FF

QMPF

DO AF

FD

EF

Monitor Panel

Model FM-100

Every ClearAir unit comes complete with a re­mote monitor station, Model FM -100 Series.
The monitor panel contains switch for controlling
the exhaust fan, indicator lights for monitoring
the filters and internal fire protection system.
This monitor panel can be combined with the
ventilators wash and fire cycle functions if a
Gaylord water-wash type ventilator was used. The
cabinet is constructed of all stainless steel and
would typically be located within the kitchen.

GAYLORD

CLEARAIR

POLLUTION CONTROL UNIT

CONTROL PANEL MODEL

FM-100

FAN ON

NORMAL AIR

LOW AIR

REPLACE PRE FILTERS

REPLACE BAG FILTERS

REPLACE FINAL FILTERS

MISSING FILTER

FIRE IN UNIT

THERMOSTAT ACTIVATION
AND / OR FIRE SYSTEM

DISCHARGE

CANCEL ALARM BUTTON

The ClearAir Unit Model RSPC-TPF Series is ETL Listed under
the category Air Filtering Device, Report # 3028598-1

- CAUTION -

DO NOT OPERATE UNIT WITH MISSING
FILTERS OR WITH FILTERS THAT SHOULD
BE REPLACED AS INDICATED BY MONITOR­ING LIGHTS. THIS IS A SMOKE POLLUTION
CONTROL DEVICE AND WILL NOT OPER­ATE PROPERLY WITH MISSING OR DIRTY
FILTERS.

GAYLORD INDUSTRIES, INC.

TUALATIN, OREGON 97062-1149 U.S.A.
Phone: [phone] • 800-547-9696

Fax: [phone] • email: [e-mail]

Form No. TPF FP/19038

6(1625/,*+7

®

TM

U.S.

42106

4

General

GENERAL INFORMATION

The pollution control unit consists of a smoke control
section, odor control section and an exhaust fan all built
on a common base as an integral unit. Smoke control will
be accomplished by a three stage high efficiency filter
section and odor control by an odor oxidant media. The
unit is ETL listed and labeled. The unit should be used in
conjunction with a listed water wash or cartridge extractor
ventilator with a minimum grease extraction efficiency of
90%.

Smoke Control Section

The smoke control section has three phases of filters
located prior to the odor control section. These filters
consist of replaceable 30% pre-filter, 95% bag filter and a
replaceable 99% final filter. Replaceable filters are mounted
in filter slide tracks to prevent air bypass around the ends
of the installed filter bank. Filters are 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 is on 1" centers with an open area 96%. Filter
enclosing frame is a rigid, high wet strength beverage
board, with diagonal support members 4" deep.

Phase two filters have an average efficiency of 90 to 95%
in accordance with ASHRAE test standard 52.1-1992.
Sealing surface and pocket retainers are configured to
provide 84% open area. Seams in bag filters are sealed
with foamseal adhesive to completely eliminate air leak­age through stitch holes.

Phase three filters are 95% efficient on .03 micron
particles (DOP smoke test), 97% efficient on nebulized
staphylococcus aerosols, 99+% efficient on atmospheric
test dust (ASHRAE standard 52.1-92). The casing is 16
gauge steel with corrugated aluminum separators to
insure media stability. Media is fine-fiber, high strength
microfiberglass paper. Media end cuts are encapsulated
in urethane potting adhesive.

The unit includes a UL listed fire damper, with a 280 de­gree fusible link, located down stream of the filters to
prevent passage of fire to the duct downstream of the unit.
A fire-stat, set at 250 degrees, is located in the filter
section to shut down the exhaust fan in the event of a fire.

Odor Control Section

Odor control can be provided by either:

Carbon and potassium permanganate blend, Carbon
only or Chemical Spray Odor control

If an media bed type of odor control is selected. The odor
removal media is a 50% potassium permanganate 50%
carbon blend or 100% carbon and is housed in slide out
reusable steel modules. There is a 30% pleated media
after filter located immediately downstream of the odor
control media. The odor control media and after filters are

removable through removable side access doors with lift
and turn latches.

Chemical Spray Odor Control

The odor removal is performed through the injection of an
adsorbing chemical. This is done with a compressor push­ing air through an atomizing type nozzle that draws the
chemical from the resevoir. The 5 gallon resevoir is in the
cabinet on the side of the unit that houses the compres­sor. The spray system can be set for continuous spray or
intermittent spray with timers in the control cabinet. This
unit can be provided with an optional heater for cold cli­mates.

Exhaust Fan Section (Standard Centrifugal Fan)

The exhaust fan is an SWSI upblast arrangement #9 or
#10 with a non-overloading BI or AF wheel. The motor,
drives, bearings and fan mounting base are located out of
the exhaust air stream. The fan is AMCA certified and
bears the AMCA seal for performance. The fan housing is
constructed of heavy gauge steel and all seams are
continuously welded. The fan bearings are heavy duty
self-aligning pillow block type rigidly mounted on heavy
structural steel supports. The motor is OPD three phase
mounted on a common base with the fan and is pre-wired
to the electrical control cabinet. The factory provided drive
assembly is adjustable pitch on 7.5 HP and smaller, fixed
pitch on 10 HP and larger. It will also be sized for a
minimum 1.5 service factor. After final system balancing,
fixed pitch sheaves are to be provided and installed by
the air balancing contractor to provide proper flow at ac­tual installed conditions. The exhaust fan section is
equipped with removable panels for access to the fan.

Exhaust Fan Section (Optional Tubular Fan)

The exhaust fan is a tubular centrifugal or SWSI arrange­ment #9 or #10 with a non-overloading BI or AF wheel. The
motor, drives, bearings and fan mounting base are located
out of the exhaust air stream as required by the IMC
(International Mechanical Code) and NFPA-96. The fan is
AMCA certified and bears the AMCA seal for performance.
The fan housing is constructed of heavy gauge steel and
all seams are continuously welded. The fan bearings are
heavy duty self-aligning pillow block type rigidly mounted
on heavy structural steel supports. The motor is OPD three
phase mounted on a common base with the fan and is
pre-wired to the fan control cabinet. The fan control
cabinet includes the disconnect switch, motor starter,
overloads and fuses. The factory provided drive assembly
is adjustable pitch on 7.5 HP and smaller, fixed pitch on
10 HP and larger. It is sized for a minimum 1.5 service
factor. After final system balancing, fixed pitch sheaves
are provided and installed by the air balancing contractor
to provide proper flow at actual installed conditions.

5