Greenheck Energy Recovery Filter Hood System User Manual

Page 1

Document 479288

Energy Recovery Filter System

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage!

Energy Recovery Filter System

General Description

Description and Purpose

The energy recovery ﬁlter system is an arrangement of high efﬁciency grease ﬁlters with heat recovery coils to be mounted in a commercial kitchen hood and piped back to an existing water heater. While the smoke and efﬂuent generated off the commercial cooking appliances will naturally be ﬁltered, the heat generated by the cooking process will be used to preheat water being supplied to the water heater, thus reducing operating expenses and the need for larger and more expensive hot water heaters.

WARNING

Electrical shock hazard. Product contains electrically activated components. This can cause equipment damage, personal injury, or death. Service must only be performed by personnel that are knowledgeable in the operation of the equipment being controlled. Read the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment.

DANGER

Always disconnect power before working on or near the control panel provided. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

All field installation of electrical equipment must be done to meet all NEC and electrical codes.

Energy Recovery Filter System 1

Page 2

Table of Contents

Installation

Receiving, Unpacking, Handling, Storage .........2

Installation

Components and Installing Control Cabinet ......2

System Installation ..........................3

Plumbing and Electrical Requirements ..........4

Control Cabinet Layout ......................4

Operation ...................................5

Maintenance ................................5

Balancing and Testing Methods .................6

Troubleshooting ..............................7

Replacement Parts ...........................7

Codes and Standards .........................7

Our Commitment .............................8

Receiving - Upon receiving the product, check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all of the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report must be ﬁlled out by the carrier upon arrival and reported to the Trafﬁc Department. If damaged upon arrival, ﬁle a claim with the carrier. Any physical damage to the unit after acceptance is not the responsibility of the manufacturer.

Unpacking - Verify that all of the required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited only to items on the bill of lading.

Handling - Make sure the equipment does not suffer any heavy vibration or knocks. Handle in such a manner as to keep from scratching or chipping any coating. Damaged ﬁnish may reduce the ability of unit to resist corrosion.

Storage - Products are protected against damage during shipment. If the product must be stored prior to installation, it must be protected from dirt and moisture. Indoor storage is highly recommended. For outdoor storage, cover the control package with a tarp to keep it clean, dry. The user assumes responsibility of the equipment and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

NOTE

All installation must follow local plumbing and electrical codes.

Components

Components included with the energy recovery ﬁltration system.

Quantity Description

Two size options:

• 20 inch high x 20 inch wide (50.8 x 50.8 cm) or

Varies

• 16 inch high x 20 inch wide (40.64 x 50.8 cm) Special energy recovery ﬁlters with quick couplers and hoses attached

2 3/8 inch (0.95 cm) UL Listed hood penetration seal

1 18 inch (45.72 cm) stainless steel hose

1 24 inch (60.96 cm) stainless steel hose

24 inch high x 36 inch wide x 14 inch deep

(60.96 x 91.44 x 35.56 cm) control cabinet

1 Male disconnect

1 Female disconnect

1 Filter spacer

Installing Control Cabinet

The cabinet should be mounted to a secure surface through the holes around the back perimeter of the cabinet. Use at least six (6) mounting holes evenly spaced around the back perimeter of the cabinet. If the pre-drilled holes do not work, drill additional holes around the perimeter for mounting. The cabinet will weigh approximately 85 pounds (38.56 kg).

NOTE

It is the responsibility of the installer to ensure studs or other structural members should be the point of fastening when attaching this cabinet to a wall.

NOTE

Improper storage which results in damage to the unit will void the warranty.

Energy Recovery Filter System2

Page 3

System Installation

FLOW

*HOOD PENETRATION

Quantity of ﬁlters varies based on hood size

*HOOD PENETRATION

TO FILTERS

1 INCH FNPT CONNECTION

WATER

HEATER

TO WATER HEATER

3/4 INCH FNPT CONNECTION

TO DRAIN 3/4 INCH FNPT CONNECTION

PIPING PROVIDED BY OTHERS

ELECTRICAL PROVIDED BY OTHERS

ELECT. 120 VAC 15 AMP FROM BREAKER

3/4 INCH FNPT CONNECTION

1. Remove the existing ﬁlter(s) from commercial kitchen hood for retroﬁt or from the shipping container for a new installation.

2. Drill two 1

⁄8-inch holes in the hood top, side or back above the ﬁlter rack, one close to the left and one close to the right side of the

Hood Surface

1-1/8 inch

(2.86 cm)

diameter hole

hood.

3. Install a hood penetration seal (item 6) in the hood top above the ﬁlter rack. To do this, disassemble the compression seal and insert the seal into the hole from the inside of the hood making sure the gasket is placed on the ﬁtting before inserting it into the hole. Install the lock washer and nut and tighten

INTERIOR OF HOOD

3/8 inch UL Listed Hood Penetration Seal PN 451167

Gasket

Hood

Lock Washer

Nut

securely as shown.

EXTERIOR OF HOOD

FROM FILTERS

FROM WATER SUPPLY LINE 1 INCH FNPT CONNECTION

MUST BE IN ACCESSIBLE LOCATION FOR TESTING

ITEM QTY DESCRIPTION

1 1 Control Cabinet

2 1 No Flow Status Light

3 1 Pushbutton Switch, System ON/OFF

4 1 Pushbutton Switch, Pressure Release

5 Varies Filter Assembly (quantity varies based on hood size)

*6 2 3/8-inch FNPT Hood Penetration Seal, (1

7 1 18 inch Stainless Steel Hose

8 1 3/8-inch Quick Disconnect

9 1 24-inch Stainless Steel Hose

10 1 Thermal Expansion Tank (provided by others)

11 1 Water Hammer Arrestor (provided by others)

12 1 1/4 Turn Ball Valve to Test Flow Rate (provided by others)

*TOP, SIDE, OR BACK OF HOOD. TO BE COMPLETED IN FIELD BY OTHERS. DO NOT OBSTRUCT FIRE SYSTEM PIPING.

FLOW

/8 inch hole)

4. Attach the 18 inch stainless steel hose (item 7) to the left-most hood penetration seal, and the 24 inch stainless steel hose (item 9) to the right-most hood penetration seal.

5. Attach the extra female coupler to the 18 inch hose (item 7) on left end of the hood, and the male coupler to the 24 inch hose (item 9) on the right end of the hood.

6. Install new ﬁlters in hood from left to right. Hook up the quick-connect couplers between the ﬁlter assemblies.

7. If applicable, install adjustable ﬁlter spacers to ﬁll in the gap(s) on the hood ends.

8. Install all other plumbing, as shown on this drawing. Please refer to plumbing requirements section on page 4 for more information.

9. Make all of the electrical connections. Please refer to electrical requirements section on page 4 for more information.

Energy Recovery Filter System 3

Page 4

Plumbing Requirements

1. Connect the main water supply connection to the 1-inch FNPT connection labeled “FROM WATER SUPPLY”.

NOTE

The water supply line must be pressurized to 40 PSI minimum.

Control Cabinet Layout

Pressure

Relief

Connection

(to a drain)

System

Pressure

Release

Electrical

Controls

Flow Switch

Circulation

Pump

2. Provide the piping from the water heater to the 1-inch FNPT connection labeled “TO WATER HEATER”.

3. Provide the piping from the left-most hood penetration seal on hood to the 3/4-inch FNPT connection labeled “TO FILTERS”.

4. Provide piping from the right-most hood penetration seal on the hood to the 3/4-inch FNPT connection labeled “FROM FILTERS”. In line within this pipe run, provide a water hammer arrestor (provided by others), a thermal expansion tank (provided by others), and a 3/4-inch turn ball valve to test the ﬂow rate (provided by others). This ball valve needs to be in an accessible location for testing.

5. Provide piping to an external drain from the 3/4-inch FNPT connection labeled “TO DRAIN”.

Electrical Requirements

Located in a NEMA-3R box in the center of the control cabinet is the electrical connection cabinet. Both the pump and pressure release solenoid valve will be wired to the electrical connections cabinet from the factory.

CONTROL INPUT: 120 VAC, 15 AMPS FROM BREAKER

No Flow

Light

Pump

ON/OFF

WATER HEATER

TO DRAIN

SHUT OFF

VALVE

Throttle Valve

TO FILTERS

FROM FILTERS

Shut Off Valve

SHUT OFF VALVE

WARNING

Leave the pump running during cold weather conditions to prevent freezing during cold temperatures.

Pump Switch

FI-A

BK 21

Pressure Release

PR-A

FI-B

1411

2421

Flow Switch

PR-B

P1H

NCC

A1R1A2

Pump

BK WH

P1N

LT1

No Flow - Red Light

LT2

A1R2A2

Pressure Release Solenoid Valve

BK WH

R2 - On

Delay

SL2SL1

SVNSVH

Connect 120 VAC power from a 15 amp breaker to terminals H1 and N1.

CONTROL INPUT: 120 VAC, 15 AMPS FROM BREAKER

Energy Recovery Filter System4

Page 5

Operation

Start-Up Procedure

1. Turn on the fan for the kitchen hood.

2. Turn on the cooking equipment.

3. When the equipment reaches operating temperature, push the green ON/OFF button on the control cabinet to turn the system on.

4. Adjust the “Throttle Valve” to maximize overall energy savings.

• Start with the valve half open.

• Monitor the “Inlet” temperature gauge on control

cabinet and adjust the “Throttle Valve” to maximize the “Outlet” temperature.

• Do not completely close “Throttle Valve”, make

sure valve is at least one-quarter open.

• To maximize savings, the “Throttle Valve” must be

set during peak cooking conditions.

5. Turn the cooking equipment off.

6. Push the green ON/OFF button on the control cabinet to turn the system off.

7. Turn the fan off for the kitchen hood.

NOTE

Do not completely close the “Throttle Valve” when the system is operational.

Sequence of Operation

1. During cooking operations, turn on the fan for the kitchen hood.

2. Push the green ON/OFF button on the control cabinet to turn on the energy recovery ﬁlter system.

NOTE: If ﬂow is not detected, the red light will

illuminate and the circulation pump will shut down. If this occurs, stop the system and verify ﬁlters are properly connected and all valves are open.

3. After cooking operations, push the green ON/OFF button on the control cabinet to turn off the energy recovery ﬁlter system.

4. Turn off the fan for kitchen hood.

Maintenance

Cleaning ﬁlters

Filters should be cleaned a minimum of once a week depending on the cooking equipment, cooking frequency, food type and quantity. When servicing or cleaning the ﬁlters, turn the pump power off (green button on control cabinet should not be lit). Close the ball valve in the cabinet that supplies the water to the ﬁlters. Then press the ‘Pressure Release’ button on the control cabinet for about 5-10 seconds.

NOTE

Do not wash coil with a high pressure washer, as it will damage the ﬁns.

Do not take ﬁlter apart and clean it unless you are a trained service technician. This is to prevent the coated aluminum ﬁns from being damaged.

When washing assembled ﬁlters in a dishwasher, it is recommended to use Ecolab® Solid Metal Pro®

When serviced by untrained personnel:

1. Remove ﬁlter spacer from the hood.

2. Disconnect the quick connect couplers between the ﬁlter assemblies.

3. Remove the ﬁlters from hood.

4. Place the ﬁlters, assembled, into a deep sink or dishwasher and wash thoroughly.

5. Place the ﬁlters back into hood.

6. Hookup the quick couplers between the ﬁlters and to the connections on the hood.

7. Insert the ﬁlter spacer.

If normal cleaning techniques are not adequately cleaning the ﬁlters, then a trained service technician should be requested to service as follows:

1. Remove the ﬁlter spacer from the hood.

2. Disconnect the quick connect couplers between ﬁlter assemblies.

3. Remove the ﬁlters from hood.

4. Position the ﬁlter on its back, face up, and unscrew the four truss head machine screws from ﬁlter face.

5. Turn the ﬁlter over so it lies on its face.

6. Remove the ﬁlter back from assembly.

7. Remove the coil section from assembly.

8. Wash all three parts (front, back, and coil) in a sink with mild detergent.

9. After all the parts are clean, lay the ﬁlter front face down, and place the coil into the ﬁlter front. Make sure the hose connection is on the bottom of the ﬁlter.

10. Place the ﬁlter back over the top of the coil.

11. Turn the ﬁlter over so the face is now visible and replace the four machine screws.

12. Place the ﬁlter assembly back into the hood.

13. Hookup quick couplers between the ﬁlters and to the connections in the hood.

14. Insert ﬁlter spacer.

Truss Head

Machine

Screws

Filter Front

Coil

WARNING

Make sure the “Pressure Release” button is pressed before disconnecting anything. If system is not purged properly, water spillage can occur, which can cause hot water burns.

Connection

Bottom of Filter

Hose

Quick

Connect

Energy Recovery Filter System 5

Filter Back

Page 6

Balancing and Testing Methods

Shortridge Method

With all the ﬁlters in place, determine the total hood exhaust volume with a Shortridge meter as follows:

1. All of the cooking equipment should be on. If the hood has internal short circuit make-up air, it should be turned off.

2. Measure velocities

• Set up the Shortridge meter.

• For 20 in. (500 mm) wide ﬁlters, position the

grid as shown in Fig. A and B. Average the two measurements.

• Take velocity readings for each ﬁlter.

3. Calculate each ﬁlter’s volumetric ﬂow rate as follows:

Calculate each ﬁlter’s average velocity by summing

the velocity readings and dividing by the number of readings for each ﬁlter.

Multiply the average velocity by the conversion

factor to obtain the volumetric ﬂow rate for each ﬁlter.

4. Calculate the hood’s total volumetric ﬂow rate by summing the volumetric ﬂow rate of each individual ﬁlter in the hood as calculated in Step 3.

Place standoff spacers against face of outlet or inlet grill, ﬁlter, coil, etc.

Maintain 1½ inch (38.1 mm) margin

Swivel bracket

Tubing connectors

Extension rods

Pushbutton handle and plug

Handle bracket

Captive knob screws

Edge of outlet/inlet active face area

Maintain 1½ inch (38.1 mm) margin

Tubing harness

Pressure input ports

External read jack

Neckstrap

NOTE

For best accuracy, multiply the velocity of each filter by its conversion factor and sum the flow rates. Averaging the velocity measured for all filters may cause error.

Nominal Filter Size (H x L) Imperial

Inches Millimeters

20 x 20 500 x 500 3.0 .279

16 x 20 400 x 500 2.0 .185

Example: Measured velocities for a 20 x 20 ﬁlter = 185 and 189 ft/min.

Average Velocity =

(Imperial)

(Metric)

Flow rate for one ﬁlter =

(Imperial)

(Metric)

Sum of Velocity Readings

Number of Readings

185 + 189

3383 + 3456

Conversion

Factor

= 187.0 ft/min.

= 3420 m/hr

Average

Velocity

= 3.0 x 187.0 ft/min. = 561.0 cfm

= .279 x 3420 m/hr = 954 m3/hr

Fig. A

Fig. B

Conversion

Factor

17.25 in.

(2978.15 mm)

Metric

Conversion

Factor

14 in.

(355.6 mm)

2.75 in.

(69.85 mm)

6 in.

(152.4 mm)

10 in.

(254 mm)

10 in.

(254 mm)

Total hood ﬂow rate = (Filter 1 Flow Rate) + … + (Filter x Flow Rate)

(Imperial)

(Metric)

Energy Recovery Filter System6

= 561.0 + 555.2 + 534.6 + 539.9 = 2190.7 cfm

= 954 + 944 + 909 + 918 = 3725 m3/hr

Page 7

Troubleshooting

Replacement Parts

Pump does not run.

• Conﬁrm the fans are running and the pump switch has been pressed to activate the pump.

• Check voltage on terminals H1 and N1 in the electrical panel to conﬁrm that there is 120 VAC.

• Check voltage on terminals P1H and P1N and conﬁrm that there is 120 VAC.

• Inspect motor for disconnected wires.

• Motor may be faulty or failing, service motor.

Hot water heater inlet temperature is not hot enough.

• Conﬁrm that the panel is running during cooking operations/fan operation.

• Conﬁrm appliances are running.

• Close off the throttle valve to help force more water through the ﬁlters.

WARNING

Do not close the throttle valve completely, as there may not be enough water supplied to the water heater.

Pressure release button will not purge water to drain.

• Conﬁrm the ball valve that supplies water to the ﬁlters is closed.

• While holding the button, check the voltage between SVH and SVN to conﬁrm 120 VAC.

• The pressure release solenoid valve may be faulty or failing, service solenoid valve.

Part Number Description

Filter Part Numbers

475863 Core Heat Exchanger

476407 18 inch (45.72 cm) Stainless Steel Hose

476411 Relief Valve

476409 Female Coupler

476410 Male Coupler

Cabinet Part Numbers

459010 Temperature/Pressure Gauge

381050 Solenoid Valve

381049 Coil for Solenoid Valve

476329 Pump

System Parts

476408 24 inch (60.96 cm) Stainless Steel Hose

451167

476409 Female Coupler

476410 Male Coupler

(shipped loose)

3/8 inch (0.95 cm) UL Listed Hood Penetration Seal

Codes and Standards Compliance

• UL 1046

• NSF/ANSI Standard 2 – Food Equipment

No ﬂow light is on.

• Conﬁrm ball valves are open.

• Check quick connect ﬁttings to ensure they are properly installed and connected to allow ﬂow.

• Check for frozen or broken water lines.

Energy Recovery Filter System 7

Page 8

Our Commitment

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Speciﬁc Greenheck product warranties are located on greenheck.com within the product area tabs and in the Library under Warranties.

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at www.amca.org.

Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com