Gaylord TPF User Manual

8

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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.