8
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For More Information:
Phone: (503) 691-2010
Fax: (503) 692-6048
Toll Free: (800) 547-9696
email: info@gaylordusa.com
GAYLORD CLEARAIRTMFEATURES
• Constructed specifically to meet kitchen exhaust
duct standards
• 16 Gauge all welded exterior housing
• 99% Efficient three phase filter system
• State-of-the-Art optional spray odor control
system
• AMCA certified and listed to UL 762
• Heavy duty exhaust fan with motor, drives, and
bearings located outside the air system
• Stainless steel monitoring panel to monitor all
major components
• Suitable for indoor or outdoor installation
• Unit may be shipped in one piece or in sections to
facilitate entry and installation
GAYLORD CLEARAIRTMBENEFITS
• Single source responsibility when Gaylord
Ventilators are used guaranteeing compatibility
between the two systems
• Pre-engineered for the most efficient and cost-
effective systems
• Listed by ETL Testing Laboratories, assuring
acceptance by local building officials
• Service network of over 100 factory trained
agencies
responding to your service needs
• 30 years of experience in the engineering,
design and manufacturing of pollution control
equipment specifically for commercial kitchen
exhaust systems
• One year parts warranty
Over 55 years of experience in kitchen ventilation has made us acutely aware of the special
engineering and operational considerations necessary for the proper design of pollution control
equipment in kitchen exhaust systems. Each ClearAir unit is designed for the specific application,
guaranteeing the most efficient and cost effective system.
Web site: www.gaylordusa.com
Write: Gaylord Industries
10900 SW Avery St.
Tualatin, Oregon 97062 U.S.A.
GAYLORD® is a registered trademark of Gaylord Industries
ClearAireTM is a trademark of Gaylord Industries
“Expand-O-Cell”TM is a trademark of Gaylord Industries
TYPICAL CLEARAIRTM UNIT
TPF SERIES
Phase One – Pre Filter
16 Gauge Steel Housing
AMCA Certified Heavy Duty Exhaust Fan
Phase Three – Final Filter
Phase Two – Bag Filter
Fan Access
Formed
Galvanized
Steel Base
Spray Odor Control
Final Filter Access
Bag Filter Access
Pre Filter Access
Lifting Lugs
Unit illustrated with
optiona l Spray Odor
Control and Housed
Exhaust Fan
Fan Electrical Box
All Welded Construction
7
SPECIFICATIONS
by the IMC (International Mechanical Code) and NFPA-96. The
fan shall be AMCA certified and bear the AMCA seal for performance. The fan shall be listed to UL 762. The fan housing
shall be constructed of heavy gauge steel. The fan bearings
shall be heavy duty rigidly mounted on heavy structural steel
supports. The motor shall be ODP three phase mounted on a
common base with the fan and shall be pre-wired to the electrical cabinet located on the unit. The electrical cabinet shall include a disconnect switch, motor starter, overloads and fuses.
The factory provided drive assembly shall be adjustable pitch
on 5 HP and smaller and fixed pitch on 7.5 HP and larger. It
shall also be sized for a minimum 1.5 service factor. After final
system balancing, fixed pitch sheaves shall be provided and
installed by the air balancing contractor to provide proper flow at
actual installed conditions.
Exhaust Fan Housing
The exhaust fan section of the unit shall be enclosed with the
same material as the smoke control section. There shall be a
removable panel for access to the fan.
Unit Construction
The unit housing shall be constructed of a minimum of 16
gauge G90 bright galvanized steel. The perimeter base shall
be 12 gauge formed channel with lifting lugs at each corner
and along the length as required. The 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
Specifier Note: NFPA-96 requires a fire extinguishing system
for protection of the smoke and odor control sections and protection of the duct down stream of any filters 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 fire
extinguishing system, including nozzles piping and detection
runs. Pipe penetrating the unit cabinet shall use a UL listed fitting.
System shall be installed in accordance with the systems listing
and NFPA-96. The Ansul Automan cabinet shall be mounted on
the side of the unit for easy access, certification and service. If the
unit is exposed to freezing conditions, the Ansul Automan cabinet shall be mounted in an insulated thermostatically controlled
heated cabinet.
Water spray sprinkler fire system
Specifier Note: Units that are located indoors may be factory
pre-piped for a wet pipe building sprinkler system .
Provide a pre-piped water spray fire 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 fitting. Nozzles
shall be the bulb type rated at
325
o
F.
Check Out and Demonstration
Upon completion of installation, the entire pollution control system, including the kitchen exhaust hoods, shall be commissioned by a factory certified service technician. Start-up shall
include checking all filters, filter monitoring station, odor control and exhaust fan. The appropriate maintenance personnel
shall be given a technical manual and a complete demonstration of the system, including operation and maintenance procedures. Upon completion of the commissioning, a detailed
start-up report shall be made available to the architect and
owner certifying proper system ope
ration. Changes required in
fan drive components shall be performed by the air balancing
contractor per instruction of the Gaylord start-up representative.
2
Introduction
Air quality is a major concern in many large cities world wide,
particularly in America. 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 other reasons such as kitchens in high-rise buildings to allow the exhaust to discharge out the side of the structure saving
the cost of running the duct up many floors to the roof.
Smoke 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 (ESP). Incinerators 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 done properly can
be quite effective on both smoke and grease.
Gaylord Industries has manufactured Pollution Contr
ol
Equipment specifically designed for commercial kitchen exhaust systems since the early 1970’s, longer than any other
manufacturer. This experience has made us acutely aware of
the special engineering operational and maintenance considerations to ensure the most efficient and cost effective design.
Gaylord Industries manufactures two types of pollution control
equipment, the TPF Series (triple pass filter) detailed in this
brochure and the ESP Series (electrostatic precipitator) detailed in the ESP Series brochure. The TPF Series removes
smoke particulates by mechanical filtration, using a series of
high efficency filters, and the ESP Series removes smoke particulate by high-voltage ionization using electrostatic cells. Both
units are available with odor control and built-in exhaust fan.
ESP units have a higher first cost than TPF units however, filtration units require frequent replacement of filters thereby generating additional costs in materials, labor and filter disposal.
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.
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 discharging
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 equipment such as charbroiling, creates an opacity level of 60% to 70%. Opacity readings are taken by the human eye by viewing the smoke being
discharged and then assigning a percentage of opacity to what
is seen. Though this method is quite subjective, it is the method
practiced by control agency inspectors who are trained and
certified in determining opacity percentages.
Other more technical methods of determining opacity or particulate density are achieved through the use of opacity meters and
cascade impactors. This level of analysis is usually referred to as
source testing. Control agencies occasionally require this type of
analysis and if so, the testing is conducted by state certified contractors, which can be quite costly and time-consuming. The efficiency of a pollution control unit is based on how well it reduces the
opacity level of a given airstream. The Gaylord ClearAir ESP Series
unit will reduce the opacity level below 20%, thereby meeting the
requirements of environmental control a
gencies.
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 exists 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. The three common methods of abating odor are 1) the use of activated charcoal, which
absorbs and retains th
e odor molecules, 2) the use of an odoroxidant (potassium permanganate) which oxidizes the molecules
to solids and then retains them and 3) a spray odor neutralizer
system. Activated charcoal media, while less expensive than odoroxidant media, is not a popular choice, as charcoal is highly flammable and when it becomes fully saturated, begins to desorb
and release odors. Odor-oxidant media is very effective, is not
flammable and will not release odors. In either case, once the
abatement media is saturated the media must be replaced. The
life of the
media is dependent upon several factors such as how
much media is used, type of odor, amount of odor molecules,
grease loading and air temperature. Spray odor control neutralizes the odor by adsorption and is typically non-toxic and biodegradable and is the least expensive initially and operationally.
Typically, either of the above mentioned types of odor control
can remove 85% – 90% of the molecules depending upon the
type of cooking. Determining the efficiency of odor control can
be very subjective, as testing is usually condu
cted by the human nose. More scientific testing is available through ROG
analysis, but this involves considerable costs.
Gaylord Industries offers spray odor control as the standard
method and a media bed of 50/50 potassium permanganate
and carbon blend.
Grease Removal – The Important First Step
Grease particles are also measured in terms of microns and
grease generated by commercial cooking equipment varies in
particulate size from sub-micron to 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 if media type is used. It is highly recommended that a Gaylord GX2 or
CG3 UV Ultima
TM
Series Ventilator be used with the ClearAir unit
as it has a grease extraction efficiency of 99%. Other high efficiency exhaust hoods may be used with the ClearAir unit. Contact Gaylord Industries for details.
5
TYPICAL CONFIGURATIONS
KEY
RSPC = Remo te Smoke Pollu tion Control
PF = 30% Pre Filter
BF = 95% Bag Filter
FF = 99% Final Filter
SPO = Spray Odor
EF = Exhaust Fan – Un-housed
EFH = Exhaust Fan – Housed
C = Centrifugal Exhaust Fan
T = Tubular Exhaust Fan
DIMENSIONAL DATA
NOTES
1.“D” dimension is either
3
/4” or
12” depending if an Ansul fire
system is used. If a water spray
fire system is used or if no fire
system is installed, “D”
dimension =
3
/4”
2. SO = Single Pass Media Bed
Odor Control
DO = Double Pass Media
Bed Odor Control
3. A Plenum Section is required
for exhaust fan and spray odor
options.
4. Varies with Size of Exhaust
Fan
4
ILLUSTRATION 1
ILLUSTRATION 2
6
General
Furnish one (1) Gaylord ClearAir Pollution Control Unit model
RSPC-TPF series as manufactured by Gaylord Industries Inc.
of Tualatin, Oregon in accordance with the following:
The pollution control unit shall consist of a smoke control section, odor control section (optional) and an exhaust fan section
(optional) all built on a common base as an integral unit. Smoke
control shall be accomplished by a three stage high efficiency
filter section (TPF). The unit shall be ETL listed and labeled.
Smoke Control Section
The smoke control section shall have three phases of filters
The filters shall consist of replaceable 30% pre-filter, 95% bag
filter and a replaceable 95% DOP final filter. Replaceable filters
shall be mounted in filter slide tracks to prevent air bypass
around the ends of the installed filter bank. Filters shall be
accessed through removable side access panels with lift and
turn latches.
Phase one filters shall have an average efficiency of 25 to 40%
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, UL class I.
Phase two filters shall have an average efficiency of 90 to 95%
in accordance with ASHRAE test standard 52.1-1992. Sealing
surface and pocket retainers shall be configured to provide
84% open area. Seams in bag filters shall be sealed with
foamseal adhesive to completely eliminate air leakage through
stitch holes.
Phase three filters shall be 95% efficient on .03 micron particles (DOP smoke test), 97% efficient on nebulized staphylococcus aerosols, 99+% efficient on atmospheric test dust
(ASHRAE standard 52.1-92). The casing shall be 16 gauge
steel with corrugated a
luminum separators to insure media
stability. Media shall be fine-fiber, high strength microfiberglass
paper. Media end cuts shall be encapsulated in urethane potting adhesive. A thermostat, set at 250
o
F, shall also be located
in the filter section to shut down the exhaust fan in the event of
a fire.
Optional Fire Damper for use in Canada
The unit shall include a UL listed fire damper, with a 280
o
F
fusible link, located downstream of the filters to prevent passage of fire to the duct downstream of the unit
Filter Monitoring Panel
A monitor panel, for remote location, shall be supplied for the
operation and monitoring of the unit. The panel shall be constructed of 18 gauge stainless steel, number 4 finish, and be
suitable for surface or recessed mounting. The panel face
shall be a gasketed hinged door with a lift and turn flush latch.
The pane
l shall include an air proving time delay, relays and
indicator lights to continuously monitor the unit. Indicator lights
shall be “Fan On”, “Normal Air”, “Low Air”, “Replace Pre-Filters”, “Replace Bag Filters”, “Replace Final Filter”, “Missing
Filter”, and “Fire In Unit”. An audible alarm, with an alarm
cancel button, shall be included and shall activate whenever
the unit status is low air, replace filters, missing filters or fire
in the unit. Status other than “Fire In The Unit” shall not shut
down the exhaust fan.
Specifier Note: If the ClearAir unit is used in conjunction with a
water wash ventilator, the
monitor panel is built into the main
water wash control cabinet model GPC-6000 series.
Odor Control Options
Media bed of 50/50 Blend Potassium Permanganate and
Carbon Blend
The unit shall be provided with odor control utilizing a media
bed of 50% potassium permanganate 50% carbon blend that
is UL class I rated. The odor removal media shall be housed in
slide out reusable steel modules. There shall be a 30% pleated
media after filter located immediately downstream of the odor
control media. Replaceable filters shall be mounted in filter
slide tracks to prevent air bypass around the ends of the installed filter bank. The odor control media and after filters shall
be removabl
e through side access doors with lift and turn
latches.
Spray Odor Control
The unit shall be provided with a spray odor control system
utilizing an odor neutralizer chemical. The odor spray control
cabinet shall be mounted on the side of the unit and shall
contain an air compressor piped to the atomizing 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 GS710 Odor Neutralizer. The cabinet shall contain a heater to
prevent freezing of the odor neutralizer,
Exhaust Fan Options
Exhaust Fan (Standard Centrifugal Fan)
The unit shall include a centrifugal exhaust fan. The exhaust
fan shall be an SWSI upblast arrangement #9 or #10 with a
non-overloading BI, AF or FB 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 certified and bear the AMCA
seal for performance. The fan shall be listed to UL 762. The fan
housing shall be constructed of heavy gauge steel. The fan bearings shall be heavy duty self-aligning p
illow block type rigidly
mounted on heavy structural steel supports. The motor shall be
ODP three phase mounted on a common base with the fan and
shall be pre-wired to the electrical cabinet located on the unit. The
electrical cabinet shall include a disconnect switch, motor starter,
overloads and fuses. The factory provided drive assembly shall
be adjustable pitch on 5 HP and smaller, fixed pitch on 7.5 HP and
larger. It shall also be sized for a minimum 1.5 service factor. After
final system balancing, fixed pitch sheaves shall be provided and
installed by
the air balancing contractor to provide proper flow at
actual installed conditions.
Exhaust Fan (Optional Tubular Fan)
The unit shall include a tubular centrifugal exhaust fan. The
exhaust fan shall be an arrangement #10 with a non-overloading BI, AF wheel. The motor, drives, bearings and fan mounting
base shall be located out of the exhaust air stream as required
SPECIFICATIONS
3
ClearAir Unit Description
The Gaylord “ClearAir” TM Pollution Control unit, TPF Series, is
designed specifically for the removal of smoke particles from
the air stream of commercial kitchen exhaust systems and to
eliminate or reduce odor to an acceptable level if equipped with
the optional odor control section. The ClearAir Unit is designed
for use with a Gaylord high efficiency water-wash or cartridge
Ultima ventilator but may be used with other high efficiency
exhaust hoods. In general, with UV technology, use of any pollution control equipment with baffle filter
style hoods is not rec-
ommended.
The typical ClearAir Unit includes a smoke control, odor control
and exhaust fan section and is available in sizes ranging in
capacity from 2000 CFM to 32,000 CFM. The ClearAir Unit is of
heavy duty construction and is suitable for indoor or outdoor
installations.
Smoke Control Section
Smoke control consists of a three phase, (triple pass) filter
system. Phase one filters are a 4" deep pleated filter with an
average efficiency of 25% to 30%. Phase two filters are a deep
bag type with an average efficiency of 90% to 95%. Phase three
filters are a 12"
deep high efficiency filter rated at 95% on 0.3
Micron particles (DOP smoke test).
Odor Control Options
The standard odor control offered is a spray odor control system
using Gaylord Formula GS-710 that neutralizes odors by adsorption. GS-710 is specifically formulated to chemically neutralize organic compounds and bacteria found in kitchen exhaust. It
is non-toxic, non-caustic, biodegradable, and people safe.
The spray system is mounted in a cabinet on the side of the unit
and includes a control system, a high pressure pump to atomize the solution and a
5 gallon container. The spray control is
adjustable for continuous or intermittent operation as determined by the amount of odor control required.
The second option is a media bead of 50/50 potassium permanganate and carbon blend. When heavy and extra heavy
duty cooking equipment is involved, a double pass media bed
is required. The life of the media is dependent upon several
factors such as the type of odor, amount of odor molecules,
grease loading and air temperature. The media bed has a
better performance than spray odor control. Refer to the specifications on page 6 for further details.
Exhaust Fan Options
An exhaust fan may be provided as an integral part of the ClearAir
unit as illustrated on the following pages. The fan may be a
utility set with upblast discharge or a tubular centrifugal type for
discharge out the end of the unit. Refer to the specifications on
page 7 for further details.
Controls and Monitoring
A filter monitoring panel, Model FM-100, is supplied for the
operation and monitoring of the unit. The panel is constructed
of 18 gauge stainless steel and may be
surface or recessed mounted. The
panel would ty
pically be located in
the kitchen area and if a Gaylord
Water Wash Ventilator is included
as part of the ventilation system, that
panel is incorporated with the Water Wash Control Panel. The panel
contains the following indicator
lights:
• Fan On
• Normal Air
• Low Air
• Replace Pre Filters
• Replace Bag Filters
• Replace Final Filters
• Missing Filter
• Fire in Unit
FILTER MONITORING
STATION FM-100
TYPICAL CLEARAIRTM UNIT
TPF SERIES
Phase One – Pre Filter
16 Gauge Steel Housing
AMCA Certified, UL 762 listed, Heavy Duty Exhaust Fan
Phase Three – Final Filter
Phase Two – Bag Filter
Fan Access
Formed
Galvanized
Steel Base
Spray Odor Control
Final Filter Access
Bag Filter Access
Pre Filter Access
Lifting Lugs
Unit illustrated with optional
Spray Odor Control and
Housed Exhaust Fan
Fan Electrical Box
34”
10”
7”
All welded construction
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