Gaylord RSPC-TPF-SO User Manual

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TECHNICAL MANUAL

FOR

INSTALLATION, OPERATION

Effective Date: 4-11

AND MAINTENANCE

THE GAYLORD "ClearAir"

MODEL "RSPC-TPF" SERIES

POLLUTION CONTROL UNITS (PCU)

WITH COMMAND CENTER MODEL FM-1000-A

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 qualied service personnel should install or service this equipment.

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET • TUALATIN, OR 97062 USA

PHONE: 503-691-2010 • TOLL FREE: 800-547-9696 • FAX: 503-692-6048

email:info@gaylordusa.com • www.gaylordusa.com

GAYLORD INDUSTRIES

GAYLORD INDUSTRIESGAYLORD INDUSTRIES

Direct: 503.691.2010

Fax: 503.692.6048

Toll Free: 800.547.9696

Email: info@gaylordusa.com

To Our Customers. . .

Congratulations on your recent purchase of a Gaylord ClearAirTM 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 trouble free 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 contact us toll free at 1-800-547-9696, or info@gaylordusa.com. We are more than happy to help.

Sincerely,

Gaylord Industries

GAYLORD INDUSTRIES

10900 SW Avery Street • Tualatin, OR 97062 U.S.A

www.gaylordusa.com • 800.547.9696

TECHNICAL MANUAL

FOR

INSTALLATION, OPERATION

AND MAINTENANCE

THE GAYLORD "ClearAir"

MODEL “RSPC-TPF” SERIES

POLLUTION CONTROL UNITS (PCU)

WITH COMMAND CENTER MODEL FM-1000-A

Published by:

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET

TUALATIN, OREGON 97062 U.S.A

Phone: 503-691-2010 1-800-547-9696 Fax: 503-692-6048

email: info@gaylordusa.com

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. COPYRIGHT 2010.

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, engineered and manufactured by

GAYLORD INDUSTRIES

10900 SW Avery St., Tualatin, Oregon 97062

TABLE OF CONTENTS

INTRODUCTION …………………………………………………………………………..................... 5

SPECIFICATIONS …………………………………………………………………………………........ 6

MODEL NUMBER EXPLANATION ………………………………………………………….............. 8

TYPICAL INSTALLATION …………………………………………………………………………..…. 9

SAMPLE ClearAir CONFIGURATIONS ……………………………………………………………... 10

COMMAND CENTER CONTROL FUNCTIONS …………………………………………..………… 12

DAILY OPERATION – STARTING THE EXHAUST FAN …………………………………....……… 13

DAILY OPERATION – STOPPING THE EXHAUST FAN ……………………………….………….. 14

DAILY OPERATION – AUTOSTART ……………………………………………….........…………… 15

DAILY OPERATION – FILTER MONITORING ………………………………………….…………… 17

FIRE IN THE POLLUTION CONTROL UNIT …………………………………………….......……… 21

EXTERNAL FIRE CONDITION ……………………………………………………………….....….… 22

REMOTE START …………………………………………………………………………….…….....… 24

DAILY OPERATION – SPRAY ODOR CONTROL ……………………………...………………...... 25

SMOKE CONTROL SECTION …………………………………………………….…………..……… 26

ODOR CONTROL SECTION – MEDIA BED TYPE………………………………...……………..… 27

ODOR CONTROL SECTION – CHEMICAL SPRAY TYPE ………………………...……………… 29

EXHAUST FAN SECTION ………………………………………………………………...…………… 30

GENERAL MAINTENANCE ………………………………………………………………....………… 32

SYSTEM WIRING INTERNAL ..…………………………………………………………………..…… 33

SYSTEM WIRING EXTERNAL ..………………………………………………………………….…… 35

PCU PRESSURE SWITCH SETTINGS …….........................................…………………....…..… 37

PCU PRESSURE SWITCH TUBING DIAGRAM …………………............................……....…..… 38

NAMEPLATE SAMPLE ………………………………………………………………………………… 39

PARTS – COMMAND CENTER ………………………………………………………………….....… 40

PARTS – PCU ……………………………………………………………………………………….….. 41

PARTS – SPRAY ODOR CONTROL ……………………………………………………………….... 43

APPENDIX ....................................................................................................................... 44

RECEIVING AND INSTALLATION ……………………………….…………………………......…… A-1

START UP INSTRUCTIONS ………………………………………………………………….....……. B-1

LIMITED WARRANTY ………………………………………………………...… INSIDE BACK COVER

INTRODUCTION

ir 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 oors to the roof.

Pollution control in kitchen exhaust systems has typically been accomplished by any one of the following methods - gas red incinerators, scrubbers, ltration 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 bafes to remove the pollutants and though quite effective on grease removal, they typically require the addition of high efciency lters to abate smoke below control agencies’ standards. Filtration units use a series of impingement lters 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 has been manufacturing ESP’s specically 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 congurations, 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 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 certied 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 certied contractors which can be quite costly and timeconsuming. The efciency 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 lter 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 three most popular types of media bed are activated charcoal, which absorbs and retains the odor molecules, the use of an odor-oxidant media (potassium permanganate) which oxidizes the molecules to solids and then retains them, and a blend of the two. Another method involves the use of a liquid delivered with a nely atomized spray. This spray performs a similar function to potassium permanganate in that it adsorbs or chemically neutralizes odors. This process has the benet 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 efciency of odor control can be very subjective, as testing is usually conducted by the human nose. More scientic 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 0.1 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 efciency 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 signicantly increase the smoke abatement efciency and the life of the odor abatement media.

SPECIFICATIONS

General

Furnish one (1) Gaylord ClearAir Pollution Control Unit model RSPC-TPF series as manufactured by Gaylord Industries of Tualatin, Oregon in accordance with the following:

The pollution control unit (PCU) 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 efciency lter section (TPF). The unit shall be ETL listed and labeled.

Smoke Control Section

The smoke control section shall have three phases of lters The lters shall consist of replaceable 30% prelter, 95% bag lter and a replaceable .95 DOP nal lter. Replaceable lters shall be mounted in lter slide tracks to prevent air bypass around the ends of the installed lter bank. Filters shall be accessed through removable side access panels with lift and turn latches.

Phase one lters shall have an average efciency 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 enclosing frame shall be a rigid, high wet strength beverage board, with diagonal support members 4" deep.

Phase two lters shall have an average efciency of 90 to 95% in accordance with ASHRAE test standard

52.1-1992. Sealing surface and pocket retainers shall be congured to provide 84% open area. Seams in bag lters shall be sealed with foamseal adhesive to completely eliminate air leakage through stitch holes.

Phase three lters shall be 95% efcient on .03 micron particles (DOP smoke test), 97% efcient on nebulized staphylococcus aerosols, 99+% efcient 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 ne-ber, high strength microberglass 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 lter section to shut down the exhaust fan in the event of a re.

Optional Fire Damper Required in Canada

The unit shall include a UL listed re damper, with a 280o F fusible link, located downstream of the lters to prevent passage of re to the duct downstream of the unit

Control Panel A Gaylord Kitchen Exhaust System Command Center control panel, Model FM-1000-A, designed for remote location, shall be supplied for the operation of the exhaust fan and monitoring of the PCU. The control panel shall be constructed of 18 gauge stainless steel, number 4 nish, and shall be suitable for surface or recessed mounting. The panel face shall be a hinged door and with a lift and turn ush latch.

The control panel shall include a Programmable Logic Controller (PLC) and a LED display panel to operate and monitor all conditions of the PCU. The panel shall display text showing each PCU condition as it occurs. The control panel shall include push buttons for Starting and Stopping the exhaust fan, and control, monitor and notify of the following conditions; Fan On, Fan Off, Autostart (start the exhaust fan if the hood is provided with an Autostart system), Pre-Filter(s) dirty, Bag Filter(s) dirty, Final Filter(s) dirty, Missing Filter(s), Fire in the PCU, External Fire (chemical system in the hood or PCU discharged), and a Remote Start of the PCU. If the PCU is equipped with a Spray Odor Control system the Control Panel shall include a Low Spray Odor Chemical light. An audible alarm, with an alarm cancel button, shall be included and shall activate whenever the system detects a dirty Pre-Filter, Bag Filter, Final Filter, Missing Filter, Fire in the PCU or External Fire condition.

The Control Panel shall include terminals to allow interfacing with the make-up air system, a building management system (remote start and stop or the exhaust fan system), and a re alarm system.

(optional) Provide Remote Monitoring terminals to al-

low interfacing with the building management system to monitor all functions of the control panel.

(optional) Provide Hood Light Switch on the face of

the Control Panel.

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. There are two design methods of housing the media used in the ClearAir unit. One is called the Loose Fill type and the other is called the Media Panel type.

Loose Fill type – The odor control media shall be housed

in steel reusable Media Modules that can be replenished with Loose Fill media. There shall be a 30% pleated media After Filter located immediately downstream of the Media Models. The Modules and After Filters shall be mounted into slide tracks to prevent air bypass around the ends. The Modules and After Filters shall be removable through side access doors with lift and turn latches.

Media Panel type – The odor control media shall be

compressed into Media Panels that slide into Media Modules. The Modules shall be mounted into slide tracks to prevent air bypass around the ends. The Modules and shall be removable through side access doors with lift and turn latches.

(optional) The unit shall be equipped with a 30% pleated media After Filter located immediately downstream of the Media Models.

The unit shall be equipped with a Single Pass Media Bed

SPECIFICATIONS

The unit shall be equipped with a Double Pass Media Bed

The unit shall be equipped with a Triple Pass Media Bed

Spray Odor Control

The unit shall be provided with a spray odor control system utilizing an odor neutralizer chemical. The odor spray control 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, if mounted outdoors.

Exhaust Fan Options

Exhaust Fan (Standard Centrifugal Fan)

The unit shall include a centrifugal exhaust fan, Listed to U.L. 762. 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 NFPA-96. The fan shall be AMCA certied 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, xed pitch on 7.5 HP and larger. It shall also be sized for a minimum 1.5 service factor. After nal system balancing, xed pitch sheaves shall be provided and installed by the air balancing contractor to provide proper ow at actual installed conditions.

Exhaust Fan (Optional Tubular Fan)

The unit shall include a tubular centrifugal exhaust fan, Listed to U.L. 762. The exhaust fan shall be an arrangement #10 with a non-overloading BI, 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 NFPA-96. The fan shall be AMCA certied 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 xed pitch on 7.5 HP and larger. It shall also be sized for a minimum 1.5 service factor. After nal system balancing, xed pitch sheaves shall be provided and installed by the air balancing contractor to provide proper ow 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 International Mechanical Code and NFPA-96 grease duct construction requirements.

Fire Extinguishing System Options

Specier Note: NFPA-96 requires a re extinguishing system for protection of the smoke and odor control sections and protection of the duct down stream of any lters or dampers. 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 re extinguishing system, including nozzles piping and detection runs. Pipe penetrating the unit cabinet shall use a UL listed tting. System shall be installed in accordance with the manufacturer's recommendations, the systems listing and NFPA-96. The Ansul Automan cabinet shall be mounted on the side of the unit for easy access, certication and service. If mounted outdoors, a heater shall be provided.

Water spray sprinkler re system

Specier Note: Units that are located indoors may be factory pre-piped for a wet pipe building sprinkler system.

Provide a pre-piped water spray re system installed in accordance with NFPA-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 tting. Nozzles shall be the bulb type rated at 325o F.

Check Out and Demonstration

Upon completion of installation, the entire pollution control system, including the kitchen exhaust hoods, shall be commissioned by factory certied personnel. Start-up shall include checking all lters, lter 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 certied person(s) performing the start-up.

MODEL NUMBER EXPLANATION

(Required in Canada)

After-Filter (Optional) - Required if Loose Fill Type Media is Used)

Section (SO, DO, TO)

(DO shown)

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 or 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 38.

Standard Prex Series of ClearAirTM System (Remote Smoke Pollution Control)

Triple Pass Filter

Filter Conguration (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 TO = Triple Pass Odor Control SPO = Spray Odor

Total 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 (Tubular)

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

FIGURE 8-1

TYPICAL INSTALLATION

OPTIONAL SPRAY ODOR

CONTROL CABINET

OPTIONAL

FIRE EXTINGUISHING

SYSTEM CABINET

WIRES & GROUND FROM

COMMAND CENTER TO

CLEARAIR POLLUTION CONTROL UNIT

WIRES & GROUND FROM

COMMAND CENTER TO

FIRE EXTINGUISHING SYSTEM

120/60/1 PHASE 15AMP SERVICE

FOR COMMAND CENTER

IRES & GROUND FROM FIRE

GAYLORD COMMAND CENTER

SUPPLY FAN STARTER

BY OTHERS

FIGURE 9-1

SAMPLE ClearAirTM 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 ﬁre extinguishing system as an option. The following illustrations are examples of the most common conﬁgurations.

OUTLET TO FAN

BF FF

RSPC-TPF

SMOKE CONTROL ONLY

(REMOTE FAN)

FIGURE 10-1

KEY

AF = After Filter - optional Required if Loose Fill Type

Odor Control Media is Used

BF = 95% Bag Filter DO = Double Pass Odor EF = Exhaust Fan–un-housed EFH = Exhaust Fan–housed

SMOKE CONTROL WITH SINGLE PASS ODOR CONTROL

WITH SINGLE PASS MEDIA BED ODOR CONTROL

(REMOTE FAN)

SMOKE CONTROL

RSPC-TPF-SO

(REMOTE FAN)

FD = Optional Curtain Fire Damper Required in Canada FF = 95% DOP Final Filter PF = 30% Pre-Filter SO = Single Pass Odor SPO = Spray Odor Cabinet TO = Triple Pass Odor (not illustrated)

OUTLET TO FAN

FIGURE 10-2

RSPC-TPF

SMOKE CONTROL WITH PLENUM

SMOKE CONTROL WITH PLENUM (REMOTE FAN)

(REMOTE FAN)

FIGURE 10-3

OUTLET TO FAN

RSPC-TPF-DO

SMOKE CONTROL

WITH DOUBLE PASS MEDIA BED ODOR CONTROL

WITH DOUBLE PASS ODOR CONTROL (REMOTE FAN)

SMOKE CONTROL

(REMOTE FAN)

FIGURE 10-4

OUTLET TO FAN

BF FF

SMOKE CONTROL

WITH SPRAY ODOR CONTROL

(REMOTE FAN)

SPO

FIGURE 10-5

FAN DISCHARGE

SMOKE CONTROL WITH SINGLE PASS ODOR CONTROL AND EXHAUST FAN

SMOKE CONTROL WITH EXHAUST FAN

FAN DISCHARGE

FFBF

FAN DISCHARGE

SMOKE CONTROL WITH DOUBLE PASS ODOR CONTROL AND EXHAUST FAN

SMOKE CONTROL WITH SPRAY ODOR CONTROL AND EXHAUST FAN

FAN DISCHARGE

RSPC-TPF-EF

SAMPLE ClearAirTM CONFIGURATIONS

KEY AF = After Filter - optional Required if Loose Fill Type

Odor Control Media is Used

BF = 95% Bag Filter DO = Double Pass Odor EF = Exhaust Fan–un-housed EFH = Exhaust Fan–housed

FD = Optional Curtain Fire Damper Required in Canada FF = 95% DOP Final Filter PF = 30% Pre-Filter SO = Single Pass Odor SPO = Spray Odor Cabinet TO = Triple Pass Odor (not illustrated)

RSPC-TPF-SO-EF

RSPC-TPF-DO-EFH

WITH EXHAUST FAN AND OPTIONAL FIRE DAMPER

SMOKE CONTROL

FIGURE 11-1

SMOKE CONTROL

WITH SINGLE PASS MEDIA BED, ODOR CONTROL,

EXHAUST FAN AND OPTIONAL FIRE DAMPER

FIGURE 11-2

WITH DOUBLE PASS ODOR CONTROL

RSPC-TPF-SPO-EF

SMOKE CONTROL

AND EXHAUST FAN

FIGURE 11-3

SPO

SMOKE CONTROL

WITH SPRAY ODOR CONTROL

AND EXHAUST FAN

FIGURE 11-4

COMMAND CENTER CONTROL FUNCTIONS

The Kitchen Exhaust System Command Center, Model FM-1000-A, controls and monitors all functions of the Gaylord ClearAir pollution control unit (PCU). All functions are indicated on the LED display on the face of the Command Center. The Command Center is typically located in the kitchen area, near the ventilator and performs the following:

• Manually Starting and Stopping the exhaust fan.

• Automatically starts the make-up air system if the system is interfaced with the Command Center.

• Allows Autostart of exhaust fan if the ventilator includes optional Autostart feature.

• Notication that the exhaust is on via Autostart, if ventilator includes this option.

• Visual and audible notication that a Pre-lter(s) is dirty.

• Visual and audible notication that a Bag Filter(s) is dirty.

• Visual and audible notication that a Final Filter(s) is dirty.

• Visual and audible notication that a lter(s) is missing.

• Visual and audible notication that there is a re in the ClearAir pollution control unit.

• Terminals to interface with a building management system to allow Remote Starting and Stopping of the exhaust fan.

• Optional terminals to interface with a building manage ment system to monitor all functions of the control.

FIGURE 12-1

COMMAND CENTER

MODEL FM-1000-A

DAILY OPERATION - STARTING THE EXHAUST FAN

Starting the Exhaust Fan To start the exhaust fan press the F1 button.

Pressing the F1 button will result in:

1. There is a one minute delay, STAND BY, before the exhaust fan will come on.

2. The display panel will read as shown.

FIGURE 13-1

DISPLAY PANEL

FAN ON

STAND BY CONDITION

DAILY OPERATION - STARTING THE EXHAUST FAN

Starting the Exhaust Fan (continued)

At the end of one minute delay the following will occur:

1. The exhaust fan will come on.

2. The make-up air system will come on if interfaced with the control.

3. The display panel will read as shown.

FIGURE 14-1

DISPLAY PANEL

FAN ON CONDITION

DAILY OPERATION - STOPPING THE EXHAUST FAN

Stopping the Exhaust Fan To stop the exhaust fan press the F2 button.

Pressing the F2 button will result in:

1. The exhaust fan will shut off.

2. The make-up air will shut off if the make-up air system is interfaced with the control.

3. The display panel will read as shown.

Note:

If the ventilator(s) is equipped with optional Autostart controls the exhaust fan may continue to run after F2 is pushed. Refer to Page 16 for details.

FIGURE 15-1

DISPLAY PANEL

FAN OFF CONDITION

DAILY OPERATION - AUTOSTART

Countdown Clock

in Minutes

Code Requirements

Some municipalities require the exhaust fan to start automatically whenever cooking operations occur to comply with International Mechanical Code (IMC) paragraph 507.2.1.1. This can be accomplished by the use of Gaylord Autostart Model TST.

Description of Autostart Control

There is one or more Autostart Thermostats mounted in the canopy of the ventilator(s). The thermostat is factory set at approximately 90 degrees F +10. If the temperature of the thermostat reaches the set point, and the exhaust fan is off,

the exhaust fan will automatically start. The display panel will read as shown in Figure 16-1.

FIGURE 16-1

DISPLAY PANEL

FAN ON

STAND BY CONDITION

After the temperature of the thermostat drops below the set point, the Command Center starts a 60 minute shut off countdown, shown in the upper right hand corner of the display panel (refer to Figure 16-2). At the conclusion of the countdown the exhaust fan will automatically shut off.

Note: Once a countdown has started, the exhaust fan may be manually shut off by pushing F2.

FIGURE 16-2

DISPLAY PANEL

FAN OFF

COUNTDOWN CONDITION

DAILY OPERATION - FILTER MONITORING

Pre-Filters

If one or more Pre-Filters are dirty an audible alarm will come on and the display panel will read PRE-FILTER DIRTY – LOW AIR as shown in Figure 17-1. The audio alarm may be silenced by pushing F4, however if the dirty Pre-Filters are not replaced the audible alarm will come back on the next time the exhaust fan is started.

Note: Dirty Pre-Filters will cause low air in the ventilator typically causing smoke loss into the kitchen. Replace the lters as described on page 26.

FIGURE 17-1

DISPLAY PANEL

DIRTY PRE-FILTER CONDITION

DAILY OPERATION - FILTER MONITORING

Bag-Filters

If one or more Bag Filters are dirty an audible alarm will come on and the display panel will read BAG FILTER DIRTY, LOW AIR as shown in Figure 18-1. The audible alarm may be silenced by pushing F4, however if the dirty Bag Filters are not replaced the audible alarm will come back on the next time the exhaust fan is started.

Note: Dirty Bag Filters will cause low air in the ventilator typically causing smoke loss into the kitchen. Replace the lters as described on page 26.

FIGURE 18-1

DISPLAY PANEL

DIRTY BAG FILTER CONDITION

DAILY OPERATION - FILTER MONITORING

Final Filters

If one or more Final Filters are dirty an audible alarm will come on and the display panel will read FINAL FILTER DIRTY, LOW AIR as shown in Figure 19-1. The audible alarm may be silenced by pushing F4, however if the dirty Final Filters are not replaced the audible alarm will come back on the next time the exhaust fan is started.

Note: Dirty Final Filters will cause low air in the ventilator typically causing smoke loss into the kitchen. Replace the lters as described on page 26.

FIGURE 19-1

DISPLAY PANEL

FINAL FILTER CONDITION

DAILY OPERATION - FILTER MONITORING

Missing Filters

If one or more lters are missing an audible alarm will come on and the display panel will read MISSING FILTER, HIGH AIR as shown in Figure 20-1. The audible alarm may be silenced by pushing F4, however if the missing lters are not replaced the audible alarm will come back on the next time the exhaust fan is started.

Note: Missing lters in the ClearAir Unit will cause inefcient operation and smoke loss into the atmosphere. It will also cause high exhaust air in the ventilators resulting in reduced grease extraction efciency, and unbalanced air in the kitchen. Install required lters as described on pages 26.

FIGURE 20-1

DISPLAY PANEL

MISSING FILTER CONDITION

FIRE IN THE POLLUTION CONTROL UNIT (PCU)

Fire Condition

A re thermostat, factory set at approximately 250 degrees F., is located in the lter section of the PCU. Upon activation, the following will occur:

1. The exhaust fan will shut off.

2. An audible alarm will come on.

3. The make-up air system (supply fan) will shut off if the system is interfaced with the Command Center.

4. A Fire signal is sent to the building re alarm or building management system if interfaced with the control.

5. The display panel will read as shown in Figure 21-1.

Note: The audible alarm may be canceled by pushing F4.

Once the thermostat drops below the set point the following will occur:

1. The audible alarm shuts off.

2. The system goes to a FAN OFF condition, as shown in Figure 15-1, and the exhaust fan may be restarted.

FIGURE 21-1

DISPLAY PANEL

FIRE IN THE PCU CONDITION

EXTERNAL FIRE CONDITION

External Fire Condition

An External Fire Condition is when a chemical re extinguishing system, such as an Ansul or Amerex system, discharges either in the PCU or in the ventilator. An External Fire Condition may occur if the building management system or other building re system noties the Command Center of a re. When an External Fire Condition is initiated the following occurs:

1. The exhaust fan stays on.

2. An audible alarm will come on.

3. The make-up air system (supply fan) will shut off if the system is interfaced with the Command Center.

4. A Fire signal is sent to the building re alarm or building management system if interfaced with the Command Center.

5. The display panel will read as shown in Figure 22-1.

Note: The audible alarm may be canceled by pushing F4.

FIGURE 22-1

DISPLAY PANEL

EXTERNAL FIRE CONDITION

EXTERNAL FIRE CONDITION - CONTINUED

External Fire Condition

After a discharge of a chemical re extinguishing system, the system must be recharged before the exhaust fan can be restarted. Contact your re extinguishing system company to recharge and recertify the re system. The display panel will read as shown in Figure 23-1 until the system is recharged. It may be necessary to reset the re protection system to start the Make Up Air and stop the exhaust fan.

FIGURE 23-1

DISPLAY PANEL

EXTERNAL FIRE CONDITION

RESET SYSTEM

REMOTE START

Remote Starting and Stopping the PCU

The Command Center, Model FM-1000-A, has terminals for interfacing to a remote start and stop control, such as a building management system, to allow starting and stopping the exhaust fan remotely and automatically. This method of control causes identical actions as pushing F1 (FAN ON) and F2 (FAN OFF). When started or stopped remotely the display panel will read REMOTE START as shown on Figure 24-1, or REMOTE STOP (not shown).

FIGURE 24-1

DISPLAY PANEL

REMOTE START CONDITION

LOW ODOR CONTROL CHEMICAL

Low Odor Control

Chemical Light

Spray Odor Control Option

The PCU may be equipped with a Spray Odor Control option instead of a media bed odor control system. The Spray Odor Control system is mounted in a panel mounted on the PCU (refer to Figure 9-1 on page 9). The Command Center monitors the presence of the Spray Odor Chemical in the chemical container. If the Spray Odor Chemical is low the red Low Spray Odor Chemical light on the face of the Command Center will illuminate and continue to illuminate until the container is lled (refer to Figure 25-1). Refer to Page 29 for instructions and where to purchase the Spray Odor Chemical.

FIGURE 25-1

COMMAND CENTER

LOW SPRAY ODOR CHEMICAL CONDITION

Air Flow

TRIPLE PASS FILTERS SMOKE CONTROL SECTION

Air Flow

General Description

Smoke particles are removed from the airstream by the smoke laden exhaust air passing through a series of three high efciency lters. The rst set of lters are called PreFilters (PF), the second set are called Bag Filters (BF) and the third are called Final Filters (FF). The lters are installed in Racks and the number of lters in a Rack is determined by the amount of exhaust air (CFM) the PCU is designed to handle. The model number of the PCU incorporates numbers to identify the quantity of lters in each rack. Refer to Model Number Explanation on page 8.

The life of each of the three types of lters vary considerably depending upon the type of cooking equipment, the type of food being cooked, the amount of smoke being generated and the number of hours and days of operation. Generally the greater amount of grease and smoke generated the fewer days of life the lters have. Table T-26-1 below shows an approximate number of lter changes per year, for each type of lter, based on the duty of cooking. This Table is a starting point and is not to be considered as accurate for cost purposes. Your results will vary.

Table T-26-1

Filter Replacement

To replace any of the three types of lters, Pre-Filter, Bag Filter, or Final Filter, proceed as follows:

1. Turn off exhaust fan.

2. Open Filter Access Door.

3. Remove the wing nuts and the Filter Clamp Panel.

4. Slide Filters out of the Racks.

5. Slide in the new lters making sure the arrow on the end of the Pre-Filter or Bag Filter is facing in the direc tion of air ow. Important Note: The Final Filter is installed with the arrow on the lter facing towards the direction of air ow.

6. Replace the Filter Clamp Panel and wing nuts.

7. Replace the Filter Access Door.

8. The exhaust fan can now be turned on.

Approximate Number of Filter Changes Per Year

Total

Pre-

Bag

Final

Type of Cooking Equipment

Light Duty

Ovens, steamers and kettles

Medium Duty

Braising pans, tilting skillets, fryers, griddles, grooved griddles, open burner ranges, hot top ranges, and conveyor ovens

Heavy Duty

Gas and electric char broilers, upright broilers, woks and conveyor broilers

Extra Heavy Duty

Solid fuel broilers

Filter

17 2 1.5 20.5

26 3 2 31

52 6 4 62

122 8 6 136

Filter

Filters

Changed

per Year

Operation

To achieve maximum smoke removal it is necessary to have clean lters. The lters are monitored by a series of pressure switches mounted near each of the three lter Racks. As the lters build up with grease and smoke particles the pressure switches react to the increased pressure and send a signal to the Command Center. If the lters are clean within design parameters the display will read NORMAL AIR FLOW. If any of the three types of lters are dirty, the display will read either PRE-FILTERS DIRTY – LOW AIR, BAG FILTERS DIRTY – LOW AIR, OR FINAL FILTERS DIRTY – LOW AIR. If the lters are not changed when the display indicates, the result will be reduced grease extraction efciency and smoke loss at the ventilator. If a lter is missing, the pressure switch(s) will feel a low pressure and send a signal to the Command Center, and the display will read MISSING FILTER.

FIGURE 26-1

PRE-FILTER

FIGURE 26-2

BAG FILTER

FIGURE 26-3

FINAL FILTER

ODOR CONTROL SECTION - MEDIA BED TYPE

Table T-27-2

General Description

ClearAir units that include media bed odor control have a sufx in the model number of “SO” for single pass, “DO” sufx for double pass and “TO” for triple pass odor control. Refer to the Nameplate on the unit. (see page 39 for a sample Nameplate).

ODOR CONTROL MODULES

RACKS

FIGURE 27-1

The odor control media utilizes a blend of 50% potassium permanganate and 50% activated carbon. The media is housed in Odor Control Modules as shown in Figure 27-1. As the air is drawn through the Modules the potassium permanganate oxidizes the lighter odor molecules and chemically changes them into harmless solids which remain in the media, and the carbon absorbs the heavier odor molecules. The Odor Control Modules are mounted into slide tracks for easy removal and replacement and to prevent air bypass around the ends.

The life of the odor control media is dependent upon several factors such as the type of odor, amount of odor molecules, grease loading and the exhaust air temperature. The media has a at efciency curve, meaning that the efciency, or effectiveness, stays constant until the media has expended and then the efciency drops off rapidly. The carbon portion of the media’s efciency drops continually during its life. Thus a regular schedule of change out of odor control media needs to be established and followed.

There are two types of Odor Control Media Modules used in the ClearAir unit. One is called the Media Panel Type and the other is called the Loose Fill type.

With the Media Panel type the odor control media is compressed into 18” x 24” x 1.25” Media Panels which slide into a Module (see Figure 28-1). The Module(s) then slide into the Racks in the PCU (refer to Figure 27-1). As an option the unit may be equipped with a 30% pleated media After Filter located immediately downstream of the Media Models.

With the Loose Fill type the odor control media is housed in steel reusable Media Modules that can be replenished with Loose Fill media (refer to Figure 29-1). With Loose Fill media a 30% pleated media After Filter located immediately downstream of the Media Models is required.

Service and Maintenance

Generally the life of the Odor Control Media is the number of days shown in Table T-27-1. However every cooking condition varies and therefore it is important to establish

Odor Control Media Bed Inspection

Frequency Chart

Type of Cooking Equipment

Light Duty

Ovens, steamers and kettles

Medium Duty

Braising pans, tilting skillets, fryers, griddles, grooved griddles, open burner ranges, hot top ranges, and conveyor ovens

Heavy Duty

Gas and electric char broilers, upright broilers, woks and conveyor broilers

Extra Heavy Duty

Solid fuel broilers

Frequency In

Days

120

TABLE T-27-1

ODOR CONTROL

MEDIA MONITORING

TUBE

(USE GREASE PENCIL)

LAST REFILL

DATE INITIAL

LAST INSPECTION

FIGURE 27-2

ODOR CONTROL MEDIA

MONITORING TUBE

DATE INITIAL

FORM NO. OCMM 797

FIGURE 27-3

the frequency of inspection and replacement of the media. If the unit has Double or Triple Pass Odor Control the life expectancy between the rst, second and third pass will vary. To assist in determining if the media has expended an Odor Control Media Monitoring Tube is provided (see Figure 27-2). This tube is mounted in the odor control plenum of the PCU so that it is exposed to the odor molecules in the exhaust air, the same as the Media Modules. The tube is identied by the label shown in Figure 27-3. The label includes an area where the date of the last inspection and Media Panel installation can be lled in with a grease pencil.

To inspect the Media Monitoring Tube, using an open end wrench, turn the tube nut counter clockwise and remove the Monitoring Tube assembly. The Media starts off a dark purple so if the media in the Monitoring Tube is Dark Purple it is still good. If the Media is dark brown, break a granule open and if the inside is light tan there is very little life left and the Media should be replaced. If the outside of the granules are light tan the Media is completely expended and the Media must be replaced. If you are unable to determine the status of the Media send a small sample, one teaspoon, to Green Ladder Technologies if the unit uses the Media Panel type or Cameron Great Lakes if the unit has the Loose Fill type. Note the date of installation on the sample. They will conduct a life test and advise the results by e-mail, fax or phone. Refer to pages 28 and 29 for contact information.

Once the media in the Monitoring Tube has expended, and you wish to continue checking with the Media Monitoring Tube it must be replaced with a new one. To order new Media Monitor Tube contact Gaylord Industries.

ODOR CONTROL SECTION - MEDIA PANEL TYPE REPLACEMENT

Media Panel

Locking Clip Module

Ordering New Media Panels

The Media Panels slide into Modules, and there are two Media Panels per Module (see Figure 28-1). To order new Medial Panels contact Green Ladder Technologies.

Green Ladder Technologies, LLC 1502 Louis Bork Drive Batavia, IL 60510

E-mail: info@greenladdertech.com

Phone: 630-457-1872 Fax: 630-482-2760

Replacing Media Panels

Caution: Each Module weighs approximately 28 lbs. and may be awkward to handle, particularly from the upper racks.

It is highly recommend that a heavy duty steel wheeled ladder be used when removing the upper modules.

Caution: Exhaust Fan must be off before opening the Odor Control Media Access Door

To replace the Media Panels proceed as follows:

1. Turn off the exhaust fan.

2. Open the Odor Media Access Door on the PCU.

3. Carefully slide out the Modules.

4. Place the module on edge with the open side up, “V” side down (refer to Figure 28-1).

5. Flip the Locking Clip up (refer to Figure 28-1).

6. Pull out both Media Panels (refer to Figure 28-2)

7. Slide in the new Media Panels make sure the label stating “Inlet Side” is facing out. The two stiffening rods on the back of the panel should be facing the inside of the “V”.

8. Flip the Locking Clip down.

9. Carefully slide the Modules, with the label facing you, back into the Racks making sure the “V” of the Module is facing the airow as shown in Figure 28-1.

10. Replace the Odor Media Access Door.

11. Dispose the used Media Panels. The used panels are not recyclable.

FIGURE 28-1

BOTH MEDIA PANELS

IN PLACE

FIGURE 28-2

LIFTING OUT ONE

MEDIA PANEL

FIGURE 28-3

ONE MEDIA PANEL

REMOVED

ODOR CONTROL SECTION – MEDIA BED LOOSE FILL TYPE

Replacing Loose Fill Media

There are two methods of replacing the media, the “Advancing Program” or Site Rell.

Advancing Program - This is a program offered by Cameron/Great Lakes, Inc. where they will ship recycled prelled Modules in exchange for used Modules. The pre-lled Modules are shipped two to a box, box size 25" x 25" x 13", which weigh approximately 90 lbs. The boxes are palletized, 36 to a pallet, and are shrink wrapped. Three primary advantages of the “Advancing Program” are: 1) virtually no requirement for storage except for the short period of time needed to switch the new modules for the expended ones

2) minimizes unit down time and 3) avoids lling on site. Cameron Great Lakes

2335 NW 29th Portland, OR 97210 800-777-4044 630-377-0711

To participate in the “Advancing Program” proceed as follows:

1. Contact the local Cameron/Great Lakes distributor and

order the number of Modules required.

2. Upon receipt, remove the depleted Modules and replace

with the new Modules.

3. Empty the media from the depleted Modules into contain

ers for disposal.

4. Pack the empty used Modules into the boxes the new

ones came in and ship back to the distributor.

Site Rell - Site rell involves the purchase and storage of new media, emptying and relling the modules and disposing of the spent media. New media may be purchased from your local Cameron Great Lakes distributor. For the name and phone number of the local distributor call Cameron/Great Lakes.

New media comes in standard ve gallon buckets which weigh 40 lbs each. One bucket will rell approximately 1.33 modules. It is recommended that new media is purchased no more than 2 weeks in advance of its use. The buckets should be protected against physical damage as KOR48/carbon will begin to oxidize any odor molecule when exposed to atmosphere. The buckets should be stored in a cool dry area.

Removing and Relling the Modules Caution - each Module weighs approximately 30 lbs. and

may be awkward to handle particularly in the upper racks. It is highly recommended that a heavy duty steel wheeled ladder be used when removing the upper Modules.

Caution - Exhaust fan must be off before opening the odor control media access door.

Relling the Modules is a relatively simple task not requiring any special tools. Follow steps 1-13:

1. Turn off exhaust fan.

2. Open Media Access Door

MEDIA MODULE

FIGURE 29-1

3. Carefully slide out the Modules

4. Set the Module on end so the securing screw is on top.

5. Remove the securing screw and slide the cover plate

off.

6. Place the lling jig over opening.

7. Pour the media into the Module.

8. To eliminate voids, shake or vibrate the Module to en-

sure that the media settles.

9. Continue adding media until Module is full.

Caution: Do not overll as it may cause the

sides to bulge.

10. Replace cover plate and install securing screw.

11.

Optional - some dusting may occur on initial start up of the unit. To minimize this, vacuum or blow out the Modules.

MEDIA MODULE

FIGURE 29-2

Slide the Modules back into the rack being cautious

12. that the airow label is matching the airow of the unit.

FIGURE 29-3

MEDIA MODULE - SECTION VIEW

13. Replace the Odor Media Access Door.

ODOR CONTROL SECTION - CHEMICAL SPRAY TYPE

CYCLE TIMER

SECONDS

TIMER

SPRAY

100

120

140

160 1

100

120

140

160

OVERVIEW

The Spray Odor Control system is housed in a cabinet mounted on the PCU (refer to Figure 9-1 on page 9). The major components are a spray nozzle, air compressor, timers and a 5 gallon tank to hold the Spray Odor solution (refer to Figure 43-1 on page 43). The compressor pulls the solution up through the pick-up tube in the tank by creating a vacuum, and then pushes it out through an atomizing nozzle into the plenum after the Final Filters. The spray is not on constant, but is timed on and off, the length of time on dependent upon the amount of odor created by the cooking process.

SETTING THE TIMERS

The Spray Odor Unit operates on spray-on and spray-off timed cycles while the PCU unit is in the “Fan On” mode.

The Spray Odor Control includes two (2) timers, one (1) for the “Cycle Timer” (this is the spray ”OFF” timer) and one (1) for the “Spray Timer” (this is the spray “ON” timer). Both timers are calibrated and can be set between 5 and 600 seconds. The factory/setting is always 15 seconds “ON” and 15 seconds “OFF”.

CAUTION: Always de-energize the PCU before opening the Electrical and Timer Control Panel inside the Odor Spray Cabinet.

pressor unit to the compression tting and threaded into the air inlet side of the nozzle, for any leakage.

2. Check the liquid suction line, which is connected to the liquid inlet side of the nozzle, and ensure that it is immersed in the odor control solution.

3. If it appears that the nozzle is only blowing air and does not lift up the odor control solution out of the container, do the following:

Remove the cleanout plug from the nozzle body and, using a very thin pin or wire, clean the hole in the uid cap (orice) and replace the cleanout plug. Remove the foot valve from the liquid container and inspect screen for clogging. Brush clean if clogged.

SPRAY ODOR CHEMICAL

In order for the spray odor system to work correctly the system must be supplied with a chemical solution. This solution in conjunction with the delivery nozzle system that nely atomizes the spray is what makes the system work. We recommend the use of FORMULA GS-710. This material has been effective at removing between 80% and 90% of the odors from the kitchen exhaust in many applications. For the contact information of the nearest distributor of

FORMULA GS-710:

ADJUSTING THE TIMERS

To adjust the spray odor cycle and timers, open the Spray Odor Cabinet, and remove the screwed-in-place timer control cover plate. Adjust as necessary for satisfactory odor control.

Cycle Timer

To set the “Off” period, turn the dial to the desired off time interval.

Spray Timer

To set the “On” period, turn the dial to the desired on time interval.

COMPRESSOR

The air pressure is factory set at 20 psi. If the solution is not being pulled up through the pick-up tube adjust the pressure slightly up or down until the climbs up the tube.

SPRAY ODOR CONTROL SPRAY NOZZLE ASSEMBLY

NOZZLE MAINTENANCE

To obtain the best performance from your nozzle, it may become necessary to clean it periodically.

The nozzle may become clogged and cease spraying due to factors such as dust, foreign particles accumulated in the orice, and/or leakage in the air or liquid section of the nozzle.

The following procedure should be done to maintain the nozzle’s performance:

Gaylord Industries 10900 SW Avery Street Tualatin, OR 97062 Phone: (800) 547-9696 Fax: (503) 692-6048

Website www.gaylordusa.com

FIGURE 30-1

CYCLE AND SPRAY TIMER

1. Check the air line, which is connected from the com-

EXHAUST FAN SECTION

GENERAL

The exhaust fan in the ClearAirTM Unit is a heavy duty type. The size of the fan, motor, and drives have been chosen for the most efcient operation.

FAN PREVENTIVE MAINTENANCE

Every six months conduct the following maintenance:

1. Check for condition and tension of belts. Replace cracked, glazed or frayed belts. Re-check tension after 48 hours and re-tension if necessary. Do not over-tighten belts or bearing damage may result. Belt should depress its width when pressed rmly inward at midway point between the pulleys and belt should be tight enough to prevent slippage. When replacing worn belt, replace motor pulley if “shoulder” has a worn-in groove.

2. Check fan and motor bearings for possible binding, noise or overheating. Lubricate fan in accordance with instructions on fan housing.

3. Motors generally used are of the sleeve bearing type and require periodic oiling. A good grade of ASE No. 10 lubricating oil should be inserted into the oiler connections on each end of the motor about every two months. Not more than a teaspoonful should be used; over-oiling will result in oil drip.

TROUBLESHOOTING

1. Reduced Airow:

a. Blower impellers operating in wrong direction. b. Belt slippage or belts broken. c. Overload, starter cutout.

2. Noise in Blower:

a. Bad bearings. b. Loose tie rods or blades. c. Blower wheels loose on shaft, wheels rubbing on

housing. d. Drive pulley loose on shaft. e. Foreign object located in blower wheel or blower

housing.

Necessary Action - Correct situation found immediately, as continued operation can shorten life of component parts and result in poor airow and eventual general shut-down of system until needed repair is made.

GENERAL MAINTENANCE

Daily Maintenance

The Command Center should be looked at once a day to check if notication of dirty lters is displayed. If the display reads DIRTY FILTERS, they should be replaced. A scheduled should be developed, based on the operation of this kitchen, to replace the lters on a regular basis. Refer to page 26 for details.

Six Months

Remove the lters and inspect the interior of the unit for grease build up. If needed the unit should be cleaned to the same standards as the grease duct as described in NFPA 96.

Annually

The exhaust fan belts should be checked for wear and tension. If the belt is cracked, frayed, or other wise displaying signs of damage it should be replaced.

Fire Damper

The ClearAir unit may be equipped with a re damper on the outlet side of the nal lter. There are fusible links on the dampers that will sense a re. NFPA-96 requires these fuse links be replaced annually. Replace with a 280°F (138°C) link of the same type.

Fuse Link Replacement

1. Open the plenum access door.

2. Remove the defective link.

3. Replace with a new link by wrapping the link support

across the blades and securing at the clip on the other

side of the frame.

4. Replace the plenum access doors

5. Start the fan.

SYSTEM WIRING - INTERNAL

Socket

Fuse - Spray Odor

LT1

Low Chemical Light - Red

Table T-33-1

FM-1000-A Componant Schedule

Tag Description Size

PLC Programable Logic Controller HMI Human Machine Interface CBL HMI Cable AL1 Sonalert CR6 Control Relay

Socket

CR7 Control Relay

Socket

CR8 Control Relay

Socket

CR9 Control Relay

F1 Fuse - Main

F3 Fuse - PLC Power F4 Fuse - PLC Outputs F5 Fuse - Remote Outputs F6 Fuse - TX Primary F7 Fuse - TX Secondary

120VAC 19319

120VAC 19318

Gaylord

Part No.

20110 20111

6.56 Ft. 20107

DPDT 30828

SPDT 30837 SPDT 30827 SPDT 30836 SPDT 30827 SPDT 30836 SPDT 30827 SPDT 30836

6.3A 17061

6.3A 17601

0.5A 18153 4A 16822 4A 16822 7A 16508

3.5A 16504

"ON" & "OFF" applies to the LED light status for each PLC channel, Input and Output

Input Side Ouput Side

X = Input Channel Number Y = Output Channel Number

Signal Source - Description

Autostart Thermostat(s) Activates

Pre-Filter Dirty

Bag Filter Dirty

Final Filter Dirty

Missing Filter

PCU Thermostat Activates (Internal Fire)

Fire System Discharges (External Fire)

PCU Started From Remote Source

Table T-33-2

PLC Input /Output TABLE

Exhaust Fan

Y0 Y1 Y2 Y3 Y4 Y5

ON ON OFF ON NA

ON ON ON OFF ON NA

OFF ON ON OFF OFF NA

ON OFF ON OFF ON NA

Audible Alarm

OFF

System

Make-Up Air

External)

Fire Mode

(Internal or

Control

Spray Odor

Spare

SYSTEM WIRING - INTERNAL

SYSTEM WIRING - EXTERNAL

CUV-1000 Terminal Voltages

N.O. Dry Contacts for Interface to Building

Table T-36-1

FM-1000-A Terminal Voltages

Terminal Description Fan Off Fan On Int. Fire Ext. Fire

L1 Main Power Connection : Hot 120 VAC 120 VAC 120 VAC 120 VAC L2 Main Power Connection : Neutral 31 Output - Supply Fan Motor Starter 0 VAC 120 VAC 0 VAC 0 VAC 33 Input - Thermostat Return (N.C. Stats) 120 VAC 120 VAC 0 VAC 120 VAC 34 Fused Supply to Fire Switch, etc. 120 VAC 120 VAC 120 VAC 120 VAC 35 120vac Neutral Leg 36 Output - Spray Odor Power (optional) 0 VAC 120 VAC 0 VAC 0 VAC

38 Output - Exhaust Fan Motor Starter 0 VAC 120 VAC 0 VAC 120 VAC P1 Input - Pressure Switch #1 0 VAC 0 VAC P2 Input - Pressure Switch #2 0 VAC 0 VAC P3 Input - Pressure Switch #3 0 VAC 0 VAC

P4 Input - Pressure Switch #4 0 VAC

SF3 SF4 EF3 EF4 A11 A12 Q11 Q12

FS Input From External Fire Sw. 0 VAC 0 VAC 0 VAC 120 VAC

AS Input - Autostart Thermostat in Hood

RF1 120 VAC 120 VAC 120 VAC 120 VAC

RF2

N.O. Dry Contacts for Supply Fan Remote Control N.O. Dry Contacts for Exhaust Fan Remote Control

Fire Alarm / Monitor System N.C. Dry Contacts for Interface to Building Fire Alarm / Monitor System

Remote On/Off Switch Terminals Wired to N.O. Switch

Open

Open Closed Open Closed

Open Open Closed Closed

Closed Closed Open Open

120 VAC when Autostart Thermostat(s) rise above temperature setpoint

120 VAC when Remote N.O. On/Off Switch is closed ("ON")

Common

120 VAC

if filter is

dirty 120 VAC if filter is missing

Closed Open Open

0 VAC

120 VAC

if filter is

dirty

120 VAC

if filter is

missing

RS Remote Start Active

FM External Fire Mode Active 0 0 0 BMS

AA Autostart Mode Active

MF Missing Filter

FF Final Filter Dirty BF Bag Filter Dirty PF Pre-Filter Dirty

F1 Output - Exhaust Fan Motor Starter 0 BMS 0 BMS

COM Common

Optional "RM" Terminals (Remote Monitoring)

BMS when Remote N.O. On/Off Switch is closed ("ON")

BMS when Autostart thermostats above temperature setpoint

BMS Voltage (0-220VAC)

PCU PRESSURE SWITCH SETTINGS

PRESSURE SWITCHES

There are four Pressure Switches as show on Figure 37-1, Figures 38-1, and 38-2. The Pressures Switches are used to detect a dirty or missing lter and send a signal to the Command Center. Pressure Switches PS1, PS2 and PS3 are factory set to a static pressure as shown on the Table T-38-1. Pressure Switch PS4 is used to detect a missing lter and must be set after the PCU is installed. To set PS4 proceed as follows:

SETTING THE MISSING FILTER PRESSURE SWITCH

To set the Missing Filter Pressure Switch, PS4, proceed as follows:

1. Open each of the three Filter Access Doors on the PCU and check to make sure all lters are in place. If a lter is missing you cannot proceed with the adjustment until the missing lter(s) is installed.

2. Close and latch all Filter Access Doors and push F1 on the Command Center. After the one minute STAND BY delay the exhaust fan will start.

3. Look at the Command Center display panel. If the display panel reads FAN ON, NORMAL AIR, proceed to step num ber 4. If the display reads FAN ON, MISSING FILTER HIGH AIR, adjust Pressure Switch PS4 as follows: (NOTE: during a MISSING FILTER condition the Command Center audible alarm is on. To silence the alarm push F4)

4. Look at the Command Center display panel. If the display reads FAN ON, NORMAL AIR, proceed as follows: a) Open the Pre-Filter Access Door, remove one lter, and replace and latch the access door. b) Loosen the Cover Plate Hold Down Screw and remove the Cover Plate (refer to Figure 37-1). c) Turn the Pressure Switch Adjusting Screw (refer to Figure 37-2) counter clockwise until the display panel reads FAN ON, MISSING FILTER - HIGH, and then turn the screw another 1/2 turn counter clock wise. (NOTE: the Command Center audible alarm will come on during a MISSING FILTER condition. To silence the alarm, push F4)

d) Replace the missing lter. e) Double check the display panel to make sure it reads FAN ON, NORMAL AIR. f) Adjustment of PS4 is now complete. Replace the Cover Plate and tighten the hold down screw. g) Using a crescent wrench, turn the Safety Disconnect door shaft counter clockwise to de-energize the Electrical Panel. h) Close the Electrical Panel Door and turn the Safety Disconnect Switch clockwise to energize the panel. The adjustment is complete.

CAUTION: Do not touch live electrical terminals. Contact with live power will result in immediate injury or death to personnel.

a) The Pressure Switches are located inside the Electrical Panel (refer to Figure 38-2). Turn the Safety Disconnect Switch and open the panel door. b) Using a crescent wrench, turn the Safety Disconnect door shaft clockwise to energize the Electrical Panel. c) Push F1 on the Command Center to start the exhaust fan. d) On Pressure Switch PS4 loosen the Cover Plate Hold Down Screw and remove the Cover Plate (refer to Figure 37-1). e) Wait for the one minute STAND BY delay until the exhaust fans starts. f) Turn the Pressure Switch Adjusting Screw (refer to Figure 37-2) clockwise until the display panel reads FAN ON, NORMAL AIR, and then turn the screw another 1/2 turn clockwise.Proceed to step 4.

COVER PLATE HOLD DOWN SCREW

FIGURE 37-1

PRESSURE SWITCH

COVER ON

PRESSURE SWITCH ADJUSTING SCREW

FIGURE 37-2

PRESSURE SWITCH

COVER OFF

PCU PRESSURE SWITCH TUBING DIAGRAM

Table T-38-1

Pressure Switch Settings

Pressure

Factory Pressure

Sensing Pressure For

Sw. No.

Setting

PS1 Pre-Filter .50" W.G. (.124 KPA) PS2 Bag Filter 1.25 W.G. (.310 KPA) PS3 Final Filter 2.00" W.G (.497 KPA) PS4 Missing Filter (not set)

FIGURE 38-1

TUBING DIAGRAM

FIGURE 38-2

SENSOR LOCATION

NAMEPLATE SAMPLE

The ClearAirTM nameplate is located on the electrical compartment access door of the unit. If inquiring on service or ordering parts, please have model number and serial number available.

ENGINEERING DATA

FILTER SECTION

CFM

SMOKE POLLUTION CONTROL UNIT

MODEL NUMBER

RSPC -TPF -

SERIAL NUMBER

INT. STATIC PRESSURE "W.G.

VOLTS PHASE HERTZ AMPS WATTS

MAX. FUSE SIZE AMPS

MAX. BREAKER SIZE AMPS

SUITABLE FOR USE WITH CONTROL

MODEL NO.

FOR EITHER INDOOR OR

OUTDOOR INSTALLATION

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET TUALATIN, OREGON 97062

FOR NAME OF THE NEAREST SERVICE AGENCY CALL:

800-547-9696

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

FORM NO. CATPFNP 902/19039

Or Visit www.gaylordusa.com

OPTIONAL FAN SECTION

CFM TOTAL STATIC PRESSURE "W.G.

EXHAUST FAN POWER CIRCUIT:

VOLTS PHASE HERTZ AMPS

MIN. CIRCUIT AMPACITY

MAX. FUSE SIZE AMPS

MAX. BREAKER SIZE AMPS

THE FILTER INDICATOR LIGHTS SHOULD BE INSPECTED FREQUENTLY TO ENSURE THAT COLLECTED GREASE IS BEING

42106

FIGURE 39-1

ClearAirTM NAMEPLATE

REMOVED BY THE FILTER. REFER TO THE TECHNICAL MANUAL FOR SPECIFIC INSTRUCTIONS.

FLA

-CAUTION-

Figure 39-1

Command Center

7 3

10 11

4 5

8 9 12

PARTS - COMMAND CENTER

FIGURE 40-1

COMMAND CENTER

MODEL FM-1000-A

Table T-40-1

No.

1 Human Machine Interface (HMI) Shown from back 20111 2 Low Odor Control Chemical Light Shown from back 19318 3 Lift and Turn Latch Shown from back 11118 4 Fuse – 6.3A For F1 & F2 17061 5 Fuse – 0.5A For F3 18153 6 Fuse – 4.0A For F4 16822 7 Control Relay DPDT 30828 8 Control Relay (three required) SPDT 30827

9 Fuse – 4.0A For F5 16822 10 PLC (Programmable Logic Control 20108 11 PLC Remote Monitoring Module Optional 20113 12 Sonalert Alarm 19319 13 Spare Fuses NA

Description Comments

Gaylord Part

Number

PARTS - PCU

PCNo.

1 30%Pre‐Filter 30074

2 90%BagFilter 30515

Description GaylordPartNo. Illustration

TableT‐41‐1

PCUParts

3 95% DOPFinalFilter 30514

OdorControlMedia

MonitoringTube

SafetyInterlockPressure

Pre‐Filter,SP=0.50WG BagFilter,SP=1.25WG 19664 FinalFilter,SP=2.00WG 19666 MissingFilter,SPNotSet

30913

19663

FireThermostat(15"long,

250deg.F.N.O.

Latch‐ForPre‐FilterAccess

Door

PARTS - PCU

TableT‐41‐1(continued)

PCUParts

18782

19821

Latch‐ForBagFilterand

FinalFilterAccessDoor

Latch‐ForFanHousing

AccessDoor

19771

19547

PARTS - SPRAY ODOR CONTROL

SPRAY ODOR CONTROL CABINET

FIGURE 43-1

Table T-43-1

Spray Odor Component Schedule

Pc. No. Description

2 1/4" I.D. Flexible Suction Tube 10272

3 Spray Nozzle Assembly 19065

4 3/8" Copper Tubing 11000

5 Electrical Box N/A

6 Cycle and Spray Timer Relay (Behind Panel) 19073

7 Pressure Gauge 10276

8 Needle Valve 19070

9 Air Compressor 19072

10 Heater 19075

11 5 Gallon (18.9 Liter) Container of GS-710 19097

12 Level Sensor for Spray Odor Chemical (In Tank) 19071

13 1/4" Foot Valve (In Tank) 10269

Spray Odor Cabinet Assembly (25"x25")

Gaylord Part No.

19119

APPENDIX A: RECEIVING AND INSTALLATION

APPENDIX B: START UP INSTRUCTIONS

RECEIVING & INSTALLATION

RECEIVING

Most ClearAirTM units are shipped in one piece. However, some units, because of size or special jobsite conditions, may be shipped in multiple sections. Follow the instructions provided with the unit to join sections back together. If the unit includes media bed odor control, the odor control media is packaged separately. Verify against the shipping documents that you have received all items and note any shipping damage, obvious or hidden, to your carrier and on your Bill of Lading. If damage is found, immediately le a claim with the transport company. All units are thoroughly inspected and fully operation tested at the factory prior to shipment.

Verify that the electrical and air ow ratings on the unit name plate agrees with jobsite requirements. If a contradiction arises notify the factory prior to proceeding with installation.

SAFETY CONSIDERATIONS

Installing and servicing the ClearAirTM unit can be hazardous due to the presence of electrical components. Only trained and qualied service personnel should install or service this equipment.

Untrained personnel can perform basic maintenance, such as cleaning and replacing lters. All other operations should be performed by trained service personnel. When installing or servicing, observe precautions in literature and on tags and labels attached to unit.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have re extinguisher available. Read these instructions thoroughly.

WARNING

Before installing or servicing system, always turn off main power to system. There may be more than one disconnect

switch. Electrical shock can cause personal injury or death.

RIGGING

All units are provided with a minimum of four (4) lifting points for rigging attachment. WARNING: Use all lifting points provided. (Refer to Page B-2.) Spreader bars are mandatory to prevent contact and damage to the unit by lifting hooks, straps, cables, or chains. Consult the mechanical or structural engineer before moving the unit across the roof deck.

INSTALLATION CODES

This unit requires external plumbing and electrical connections to be made in the eld. It is recommended that the Authority Having Jurisdiction (AHJ) be consulted regarding local codes and installation procedures. Gaylord Industries is not responsible for obtaining necessary approvals and permits which may be required for installation, nor is it responsible for verifying that the unit has been installed in accordance with national, state, and local codes. In the absence of locally adopted codes use the latest editions of the National Electrical Code (NEC) and the International Mechanical Code (IMC). Connections of the exhaust duct to the inlet and outlet of the ClearAirTM unit must be fully welded to comply with NFPA-96.

INSTALLATION PRECAUTIONS

1. The services of qualied contractors are essential for safe and proper installation of this equipment.

2. The air volumes and external static pressures that are listed on the unit are for the middle of the operating range of the lters. The initial air volume should be at least 10% higher than the listed CFM. As the lters load up the air volume will drop. This is inherent to this type of unit. If the unit is set up at or below the design CFM, as the lters load up, the kitchen hood may experience smoke loss problems. Please consult the factory if you have questions.

3. The unit is designed for installation on a level surface.

4. When installed in an enclosed space a re rated enclosure may be required for the unit and associated duct work. Consult the Authority Having Jurisdiction.

5. Consult the Authority Having Jurisdiction regarding requirements covering the point of termination of the exhaust outlet of this unit. Minimum distances must usually be maintained between the exhaust outlet and any outside air intakes and/or adjacent structures or property lines.

6. Do not apply power to the unit until all electrical connections have been made and a pre-start-up preliminary inspection has been completed.

7. Allow a minimum of 36 inches clearance in front of the lter access door and electrical compartment door for service and routine maintenance.

SHORT TERM STORAGE

Units that include media bed odor control are provided with media which is shipped separate from the unit. Media must be stored in a dry place with less than 95% relative humidity.

LONG TERM STORAGE (OVER ONE MONTH)

If the unit is equipped with an exhaust fan it must be relubricated as soon as it arrives. To prevent corrosion all bearings should receive grease and be rotated the rst of every month. Turn the wheel by hand while greasing bearings. A clean 1/16" bead of grease must appear on each side of each bearing. Refer to specic bearing lubricating instructions on the fan. Also, refer to bearing lubricating instructions found in the exhaust fan section of this manual.

Bearings which are to be stored or idle for an extended period of time should be wrapped in a neutral grease-proof paper, foil, or plastic lm. Compounds can be recommended by the bearing manufacturer to provide protection for several months to several years.

After long-term storage, grease should be purged from the bearings and fresh grease injected prior to start-up.

A-1

EQUIPMENT LIFTING PROCEDURE

SPREADER BAR

LIFTING LUGS

FIGURE A-2-1

1. All units are provided with a minimum of four lifting points for rigging attachment. All lifting points must be used.

2. Spreader bars are mandatory to prevent contact and damage to the unit by lifting hooks, straps, cables or chains.

A-2

HOUSING ASSEMBLY INSTRUCTIONS

1. Attach “TPF Section” to “Media Bed Odor Control Section”:

Bolt “TPF Section” and “Media Bed Odor Control Section” bases together on outside of unit, using 3/4" holes. Tek screw walls and roofs together, using 3/16" holes. Continuously weld: oor, wall, and roof seams from inside of unit.

2. Attach “Media Bed Odor Control Section” to “Plenum Section” (if applicable):

Bolt “Media Bed Odor Control Section” and “Plenum Section” bases together on outside, using 3/4" holes. From inside plenum, tek screw walls and roofs together, using

/16" holes. Continuously weld: oor, wall, and roof seams

from inside of unit.

3.Attach Fan Inlet to “Plenum Section” outlet:

Push “Exhaust Fan Section” about 7" from “Plenum Section”. Tek screw & caulk fan duradyne to plenum interconnect ring, at 5" intervals (minimum). Duradyne is pre-attached to fan inlet side.

4. Attach “Plenum Section” to “Exhaust Fan Section”:

Bolt “Plenum Section” and “Exhaust Fan Section” bases together on outside, using 3/4" holes. From inside of plenum, tek screw walls and roofs together, using 3/16" holes. Continuously weld oor seam from inside plenum. “Exhaust Fan Section” walls and roof to remain removable for exhaust fan replacement, tek screw and bolt only.

5. Assemble “Media Bed Odor Control Section” (if applicable):

Refer to “Media Bed Odor Control Section assembly instructions” drawing”.

6. Attach “TPF Chase”

Bolt “TPF Chase” to rest of assembled unit. Connect Pressure tubing from sensors 1-4 to Pressure Switches 1-4 in the “Electrical Panel”, refer to Pressure Switch Tubing Diagram on page 38. Connect Thermostat wires from Thermostat to Electrical Panel, refer to Wiring Diagram on page 34 & 35.

FIGURE A-3-1

A-3

MEDIA BED ODOR CONTROL SECTION ASSEMBLY INSTRUCTIONS

NOTE: Assemble this section, only after the rest of the unit has been assembled.

1. Slide Odor Rack into unit through door opening. Tek screw rack to oor rails, using 3/16" holes.

2. Tek screw upper rack to both sides of roof rails.

3. Tek screw rst 3 sides to mounting rails from outside of the unit.

4. Attach fourth side by entering odor rack to reach screw holes.

5. Attach Odor Section Inner Door, ip latches to secure.

FIGURE A-4-1

A-4

EQUIPMENT FOOT OR ISOLATOR MOUNTING BRACKET

LEVELING NUT

ISOLATOR TOP CAP OR STEEL LOAD PLATE

COLOR CODED COIL SPRING

NEOPRENE BOTTOM SPRING CAP OR STEEL LOAD PLATE

EXHAUST FAN - INITIAL SETUP

INITIAL SET-UP

To prevent fan movement during shipping two metal straps have been placed over the fan and attached to the oor of the unit and four red shipping hold down brackets have been installed at each corner of the fan base. To remove the shipping straps and brackets proceed as follows:

1. Cut the two metal straps and remove.

2. Locate the red shipping hold down brackets and remove the tech screws that hold them to the ﬂoor of the unit and remove.

3. Check the fan for free movement, making sure the springs are seated within the top and bottom spring cap.

4. Check the fan for level and level if necessary with the leveling nuts.

PRE-OPERATIONAL MAINTENANCE

Before starting the exhaust fan perform the following preoperational maintenance:

1. Set screws & Belts:

a. Rotate fan impeller to check for shifting that may

have occured during shipment. If necessary, shift

wheel position and re-tighten. b. Check belt and pulley alignment. c. Check tightness of setscrews in blower wheel hub. d. Check tightness of set screws in bearing locking collar. e. Check tightness of set screws in motor and fan pulleys. f. Check tightness of all frame bolts and base bolts. g. Check tightness of bearing mounting bolts.

2. Belt tension. Take up or relieve tension in belts so that there is approximately 3/4" to 1" deection under 3 pounds pressure based on 2 1/2 to 3 foot centers on drive. Adjustment of belt tension is accomplished by use of adjustable motor base.

INITIAL OPERATION

After pre-operational checks, unit is ready for operation:

1. Start up blower. Check rotation.

2. If blower impeller is turning in the wrong direction, reverse rotation per instructions furnished by motor manufacturer.

INITIAL FAN LUBRICATION

To prevent corrosion bearings should receive grease and be rotated. Turn the wheel by hand while greasing bearings. A clean 1/16" bead of grease must appear on each side of each bearing. Refer to specic bearing lubricating instructions on the fan.

Bearings which are to be stored or idle for an extended period of time should be wrapped in a neutral grease-proof paper, foil, or plastic lm.

After long-term storage, grease should be purged from the bearings and fresh grease injected prior to start-up.

A-5

FIGURE A-5-1

ClearAir

UNIT STARTUP INSTRUCTIONS

Start up Procedure for RSCP-TPF

Check duct work for proper connection to unit. All incoming duct work should be minimum 18 GA SS or 16 GA BI and fully welded or joined per NFPA 96 requirements

Check the fan section and remove shipping braces if supplied per the instructions on pages 30 and 31.

If the unit was shipped in sections, check for proper assembly of the unit on pages A-2, A-3 and A-4. All eld joints must be welded grease and water tight.

Check for proper and complete installation of all lters. If some are missing locate them and install per the instructions on page 26.

If a media bed odor control system was provided make sure that it was installed per the instructions on pages 27 and 28.

If a spray odor system was provided, locate the 5 gallon pail of GS-710 provided in the spray odor control cabinet. Remove the lid and install the pick up tube and level sensor. For eld adjustments refer to page 29.

Check for proper air ow at the kitchen hood. Make sure that all access panels have been installed in the duct work and all lters or cartridges are in place in the hood. Check for proper air volume per hood manufacturer's instructions. Minimum ow should be the design volume. However, ows of up to 15% high are acceptable. The air ow will drop as the lters become dirty. Starting high will assure smoke capture even with lter loading.

Air volumes of 30 to 50% of design or a strong vibration may indicate that the fan is rotating backwards. Verify Fan rotation. If air ow is still low or there is excessive vibration check fan for loose components, duct discharge blockage, or open access panels. Excessive vibration may be caused by shipping braces that are still in place.

Once the proper air ow is set, the missing lter pressure switch needs to be set per the instructions under “Pres-

sure Switch Adjustments” on page 37. Perform the Filter Removal Test to verify operation.



B-1

Date of Inspection: ___________________________

Inspection Witnessed By:

Name: _____________________________________

Title: ______________________________________

Signature: __________________________________

Inspection Performed By:

Name: _____________________________________

Company: __________________________________

___________________________________________

Comments

___________________________________________

Model No _________________________________________________

Serial No _________________________________________________

CFM _________________________________________________

NAMEPLATE DATA:

___________________________________________

Distribution: Gaylord Industries, Inc. / Customer / Sales Rep

One Report Must Be Completed For Each Unit

This start-up Report Used For RSPC-TPF Pollution Control Units

OPERATIONAL CHECKLIST

to the ClearAir electrical panel.

SMOKE CONTROLLER SECTION

1. Close and latch all access doors & panels.

2. Verify that all circuit breakers are on and power is supplied

3. Place the door disconnect switch in the “On” position.

4. Push F1 on the Command Center.

a. Display panel should read FAN ON, STAND BY

Yes No

b. After a one minute delay the exhaust fan should start and

the display panel should read FAN ON, NORMAL AIR

Yes No

5. Push F2 on the Command Center.

a. Display panel should read FAN OFF Yes No

6. Is the ventilator(s) equipped with a Autostart system?

Yes No

7. Is the Command Center interfaced with the make-up air

system? Yes No

8. Is the Command Center interfaced with a building manage

ment system? Yes No

9. Is the Command Center interfaced with a building re alarm

system? Yes No

10. Is the Command Center equipped with the Remote Monitor

ing option? Yes No

11. Has the Missing Filter Pressure Switch, PS4, been ad

justed in accordance with instructions of page 37 of the

Technical Manual? Yes No

FAN SECTION

ClearAir RSPC-TPF Start-Up Inspection Report

PRELIMINARY CHECKLIST

disconnect panel.

ping, handling or installation damages and, if any, note

under comments.

File Number _________________________________________________

Job Name _________________________________________________

Address _________________________________________________

_________________________________________________

Facility Contact Name _________________________________________________________________ CSA Contact ______________________________________________________

UNIT EQUIPPED WITH EXHAUST FAN? Yes No

UNIT EQUIPPED WITH ODOR CONTROL? Yes No

ALL UNITS:

1. Open all removable access panels including electrical

2. Complete a thorough inspection of the unit for any ship-

3. Verify all Pre Filters are in place.

4. Verify all Bag Filers are in place.

5. Verify all Final Filters are in place.

IF UNIT EQUIPPED WITH EXHAUST FAN:

not loosened in shipment if a housed fan.

been removed from exhaust fan spring isolators.

and the fan wheel turns freely by rotating the pulleys.

rected toward any structure.

fan housing.

6. Verify that the spare fuses are provided inside the

Command Center.

7. Verify that the optional wall insulation is secure and has

8. Verify that all shipping tiedowns, bolts and braces have

9. Verify that the fan oats freely on the spring isolators

10. Verify that all bearing set collars are tight.

11. Verify the exhaust discharge is not obstructed or di-

12. Verify that the spare fan belts are provided inside the

design or as much as 15% high. If not have:

2. Check air ow at kitchen hood and verify air volume is at

a. Balancer adjust sheaves on 5 HP and smaller motors

b. Balancer change sheaves on 7.5 HP and larger

SPRAY ODOR (If equipped)

1. Locate container of GS-710

IF UNIT IS EQUIPPED WITH MEDIA BED ODOR CONTROL:

14. Verify that the Media Panels are in place.

IF THE UNIT IS EQUIPPED WITH A FIRE PROTECTION SYSTEM:

15. Type of re system: Wet Chemical Sprinkler

to be adjusted to maximize the spray odor effectiveness

decreasing the delay or increasing the spraying time will

improve the effecti veness of the spray odor. Increasing the

delay or decreasing the spray time will reduce the effective-

ness of the spray odor system.

2. Place GS-710 container in the spray odor cabinet

3. Remove cap and install pickup tube and level switch

4. Verify that both timers are set to 15 seconds. This may need

GAYLORD INDUSTRIES 10900 SW Avery Street Tualatin, OR 97062 • 1-800-547-9696 • FAX: 503-692-6048 • email: info@gaylordusa.com

B-2

LIMITED WARRANTY

THE GAYLORD ClearAirTM POLLUTION CONTROL UNIT

LIMITED WARRANTY

The Gaylord ClearAirTM Pollution Control Unit is warranted by GAYLORD INDUSTRIES to be free from defects of material and workmanship under normal use when installed, operated and serviced in accordance with factory recommendations.

GAYLORD INDUSTRIES’ obligation under this warranty shall be limited to repairing or replacing at its option any part of said equipment which GAYLORD INDUSTRIES’ examination shall disclose to its satisfaction to be thus defective, for a period of one (1) year from the date of installation provided proper and acceptable evidence of such installation is recorded at the factory, or 18 months from date of shipment whichever occurs rst.

GAYLORD INDUSTRIES SHALL NOT BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM A BREACH OF THIS WARRANTY.

All replacement parts furnished under this warranty shall be F.O.B. Gaylord Industries Tualatin, Oregon. The owner shall pay the necessary freight delivery charges, and necessary labor for removal and installation of parts, and any federal, state or local taxes.

SPECIFIC ITEMS NOT COVERED BY THIS WARRANTY:

1. Fan belts if equipped with an exhaust fan.

2. Pre lters, bag lters, nal lters, and Green Matrix LP media if equipped with odor control.

3. Routine maintenance and cleaning as spelled out in The Gaylord ClearAirTM Model RSPC-TPF Series Unit Technical Manual.

4. Malfunction or improper operation caused by uctuating electrical or power surges or improper installation.

This is the sole warranty with respect to the aforesaid items. NEITHER GAYLORD INDUSTRIES OR ANY OTHER PARTY MAKES ANY OTHER WARRANTY OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE AFORESAID OBLIGATIONS ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS AGREEMENT.

WORLDWIDE SALES, MANUFACTURING AND SERVICE

FOR THE NAME AND LOCATION OF THE NEAREST

CERTIFIED SERVICE AGENCY, VISIT OUR WEB SITE:

WWW.GAYLORDUSA.COM

OR CONTACT US AT:

GAYLORD INDUSTRIES

10900 S.W. AVERY STREET

TUALATIN, OREGON 97062 U.S.A Phone: 503-691-2010 1-800-547-9696 Fax: 503-692-6048 email: info@gaylordusa.com

www.gaylordusa.com

LOCAL SERVICE AGENCY

Gaylord RSPC-TPF-SO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual