Greenheck Fan 474754 User Manual

Part Number 474754

Grease Grabber™ Power Play

Kitchen Exhaust Pollution Control System

Installation, Operation and Maintenance Manual

Please read and save these instructions. 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! Retain instructions for future reference.

Grease Grabber™ Power Play

The Greenheck Grease Grabber™ Power Play is a pre-engineered electrostatic precipitator type ﬁltration pollution control unit with integral exhaust fan (available without exhaust fan as an option). The unit is designed to remove grease and smoke particles as well as odor molecules from the kitchen exhaust airstream. This installation manual covers procedures for receiving, installing, and maintaining the ﬁltered section of the unit.

For additional instructions and maintenance information on the integral exhaust fan, when applicable, refer to the fan nameplate to determine model type and visit www.greenheck.com to download the corresponding manual.

General Safety Information

Only qualiﬁed personnel should install this system. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

DANGER

Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the fan, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.

CAUTION

Do not install this equipment in explosive atmospheres.

• Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

• The rotation of the fan wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.

• Fan motor must be securely and adequately grounded.

• Do not spin fan wheel faster than maximum cataloged fan rpm. Adjustments to fan speed signiﬁcantly effects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

• Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.

• Verify that the power source is compatible with the equipment.

• Never open access doors to a duct while the fan is running.

• The precipitator contains safety electrical interlock switches at all maintenance access doors. Do not attempt to defeat these interlocks.

Grease Grabber™ Power Play Kitchen Exhaust Pollution Control System

Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the packing list ensuring 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 the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and ﬁled with the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all 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 to only items on the packing list. Filters and carbon panels are shipped on separate skids in their original packaging. Do not remove factory packaging or install ﬁlters until just prior to commissioning. Remove all other shipping/packing materials including fan tie down straps.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit 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.

INDOOR

The ideal environment for the storage of units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To

Grease Grabber™ Power Play Kitchen Exhaust Pollution Control System

avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

OUTDOOR

Units designed for outdoor applications may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The unit should be placed on a level surface to prevent water from leaking into it. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic ﬁlm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

Inspection and Maintenance during Storage

While in storage, inspect equipment once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lintfree cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

Removing from Storage

As units are removed from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation. Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.

2. Rotate the fan wheel(s), where applicable, by hand and assure no parts are rubbing.

Table of Contents

Installation .................................4

Rigging/Placing Equipment .................4

Duct Connections .........................5

Plumbing ..................................5

Detergent Dispenser .......................5

Cabinet Assembly .........................5

Electrical ..................................6

Electrostatic Cell Wiring ....................6

Exhaust Fan Motor Wiring ..................7

System Control Panel Wiring ................7

Initial System Start-Up .......................7

Manual vs. Auto Operation ..................8

Operation ..................................8

Washing ..................................9

Reset Mode ...............................9

Detergent Dispenser .......................10

Adjustments ..............................10

Flow Control Valve Adjustment ...............10

Maintenance ..............................10

Maintenance Log ...........................12

Warranty ..................................12

An aluminum mesh pre-ﬁlter removes large airborne particles from the incoming airstream prior to reaching the ionizer cell. The permanent electrostatic collector section removes grease and smoke particles from the airstream using a high voltage ionizer cell(s). The ionizer imparts a positive charge on the grease and smoke particles as they pass. These particles are then repelled by positively charged plates and collected on negatively charged plates. Upon completion of each cooking day, a wash sequence is initiated for the self-cleaning function of the electrostatic cell via the remote mounted control panel. The aluminum mesh mist eliminator prevents wash water from entering the safety ﬁlter and carbon panel sections of the unit. The safety bag ﬁlter is intended to protect the carbon panel section if power is lost to the ionizer collector cell.

NOTE

Power Play is designed to remove sub-micron, airborne particulate generated from cooking processes. This system is NOT INTENDED to eliminate regular hood and ductwork cleaning and service. Improper care and maintenance of this system and associated hoods and ductwork may present a ﬁre hazard.

Grease Grabber™ Power Play System Function

Grease Grabber Power Play is an electrostatic precipitator style air ﬁltration unit, with an additional carbon ﬁlter module, designed for two speciﬁc functions:

• Remove smoke/grease particles from kitchen exhaust.

• Remove odor molecules from kitchen exhaust.

NOTE

Grease Grabber Power Play must be connected to a listed exhaust hood assembly and must be installed in accordance with local building codes, NFPA 96 and NEC.

NOTE

The unit must be installed with a minimum 18 inch clearance to combustible materials and must be installed as part of a listed duct assembly.

System Components

NOTE

The installation criteria for each of the system components shown below should be considered when selecting a site for install. For further detail on installing the components, refer to the INSTALLATION section on page 4.

Cabinet Assembly

The unit body is shipped on a common mounting rail ready for installation. If the unit was ordered with an exhaust fan, the fan will also be mounted as part of the cabinet assembly. Unless speciﬁed at time of order, the cabinet assembly must be mounted indoors and be protected from weather as well as be easily accessible for service personnel. (1) 1½ or 2 inch (depending on unit size) water supply line and (1) 3inch waste water drain line is required at the unit for the system’s wash function.

Safety Filters & Carbon Panels

Filter and ionizer cell quantities for each stage are based on unit size (see table on page 4). A consistent quantity of ﬁlters/ionizer cells are provided for each stage of the unit (pre-ﬁlter, ionizer cells, mist eliminator, and safety bag ﬁlter). Quantity of carbon panels will vary based upon unit exhaust rate. Install ﬁlters and carbon panels only when system is ready for start-up.

Grease Grabber™ Power Play Kitchen Exhaust Pollution Control System

Filter Quantities

Unit Size

02-03 1 1 02-04 2 0 02-05 2 1 02-06 3 0 04-03 2 2 04-04 4 0 04-05 4 2 04-06 6 0 04-07 6 2 04-08 8 0 04-09 8 2 06-03 3 3 06-04 6 0 06-05 6 3 06-06 9 0 06-07 9 3 06-08 12 0 06-09 12 3

Remote Mounted Detergent Dispenser

A 55 gallon remote mounted detergent dispenser is included as part of the electrostatic collector self-wash system. Included as part of the 55 gallon dispenser assembly is a solenoid valve, pressure gauge, ball valve, y strainer, and backﬂow preventer. The detergent dispenser must be mounted indoors on a solid, level foundation, as close to the cabinet assembly as possible, and in a freeze protected location accessible to maintenance personnel. The 1/2 inch line from the detergent dispenser must be connected to the water supply line within 5 feet of the precipitator. Refer to the PLUMBING section for details on plumbing connections.

Remote Mounted System Control Panel and Power Pack (2 pieces)

The system control panel allows the user to interface with the unit and controls operation as well as monitors wash and other functions. The Power Pack contains a power transformer and works in conjunction with the System Control Panel and the unit’s high voltage ionizer cells. The System Control Panel should be mounted in an area easily accessible to daily operational staff. The Power Pack should be mounted as close as possible to the System Control Panel and both should be mounted as close to the cabinet assembly as possible. Allow adequate room from the face of the panels for door swing clearance and servicing.

Safety Filter

Quantity

(2 ft. tall x 2 ft. wide)

Safety Filter

Quantity

(2 ft. tall x 1 ft. wide)

High Voltage Cable

High voltage cable is supplied to connect the ionizer/ collector sections of the precipitator to the ionizer and collector terminals in the Power Pack. The red cable (50 ft supplied) is used for the ionizer and the blue cable (50 ft supplied) is used for the collector. Refer to the ELECTRICAL section for details on wiring.

Installation

Rigging/Placing Equipment

1. The unit is furnished with lifting lugs at the four corners and along the length as necessary.

2. Lift into place using all the lifting lugs.

3. Field weight will vary depending upon ﬁnal selections such as fan type, accessories, etc. Approximate weights are shown in the table below.

Unit Size

02-03 3100 1409 02-04 3620 1645 02-05 4025 1830 02-06 4280 1945 04-03 4000 1818 04-04 4580 2082 04-05 5200 2364 04-06 5700 2591 04-07 6420 2918 04-08 7080 3218 04-09 7560 3436 06-03 5200 2364 06-04 6140 2791 06-05 6800 3091 06-06 7325 3330 06-07 8275 3761 06-08 8800 4000 06-09 9510 4350

4. The unit can be positioned on a base or curb suitable for this purpose.

5. The unit must be anchored to its base/curb.

6. Alternatively, the unit may be suspended from an adequate overhead structure, using suitable undercarriage or hanging rods (by others). If the unit is suspended by hanging rods, minimum 1/2inch (12.7 mm) diameter threaded rod is to be used. All hanger brackets/lifting lugs must be used to ensure proper support of the unit. The unit must also be hung level to ensure proper operation.

7. A service clearance of 42 inches must be provided on the access door side of the unit.

8. A minimum 18 inch clearance must be maintained between this unit and any combustible material.

Approximate

Weight (lbs)

Approximate

Weight (kg)

Grease Grabber™ Power Play Kitchen Exhaust Pollution Control System

9. The remote mounted detergent dispenser frame mounts to a foundation using the four mounting holes located at the base of the unit. For details on wiring this item, refer to the ELECTRICAL section. For details on plumbing connections, refer to the PLUMBING section.

Duct Connections

Ductwork must conform to the IMC and SMACNA guidelines.

As speciﬁed in NFPA 96, Ch. 7.5 (latest edition), exhaust duct systems must be constructed in the following manner; unless otherwise speciﬁed by the local authority having jurisdiction (AHJ).

Materials

Ducts shall be constructed of and supported by carbon steel not less than 1.37 mm (0.054 in.) (No. 16 MSG) in thickness or stainless steel not less than 1.09 mm (0.043 in.) (No. 18 MSG) in thickness.

Installation

All seams, joints, penetrations, and duct to hood collar connections shall have a liquid-tight external weld.

An inlet transition is furnished to match the inlet duct size. The inlet transition is furnished with a listed duct access door for inspection and cleaning.

Units intended for indoor mounting are provided with an outlet mounting ﬂange, either at the unit discharge or as part of a factory supplied UL 762 listed exhaust fan. Outlet ductwork from the exhaust fan is required to be per the above mentioned methods unless otherwise speciﬁed by the local authority having jurisdiction (AHJ).

NOTE

All water piping exposed to freezing temperatures must to be trace heated and insulated to prevent damage to the unit.

NOTE

For unit sizes 06-08 and 06-09, a minimum 2 inch incoming water service is required.

Wash Cycle

Unit Size

02-03 7.2 .36 02-04 9.6 .48 02-05 12.0 .60 02-06 14.4 .72 04-03 14.4 .72 04-04 19.2 .96 04-05 24.0 1.20 04-06 28.8 1.44 04-07 33.6 1.68 04-08 38.4 1.92 04-09 43.2 2.16 06-03 21.6 1.08 06-04 28.8 1.44 06-05 36.0 1.80 06-06 43.2 2.16 06-07 50.4 2.52 06-08 57.6 2.88 06-09 64.8 3.24

Detergent Dispenser

From the pump located on the base of the detergent dispenser, connect a ½-inch piping connection for the detergent supply to the 1½-inch water supply line. A quarter turn ball valve (by others) can be installed on this line if necessary for servicing. The connection of the ½-inch detergent supply line to the 1½-inch water supply line should be made within 5 feet of the cabinet assembly.

Water Flow

Rate (gpm)

Wash Cycle

Detergent Flow

Rate (gpm)

Plumbing

Once all system components are installed, plumbing connections for the system can be made. It is recommended that plumbing connections be done prior to making electrical connections.

From the building, a 1½- or 2-inch (refer to drawings) hot water line is required for connecting the wash system. Recommended water temperature is 140˚F at 45 psi pressure. Refer to the chart on this page for information on water and detergent quantity requirements. Install the quarter turn ball valve (provided) at the incoming water source to allow the water to be turned off for servicing. Next, install the strainer (provided), backﬂow preventer (provided), pressure gauge (provided), and solenoid valve (provided) respectively. Locate these items along the incoming water line in a location convenient for inspection/servicing.

Grease Grabber™ Power Play Kitchen Exhaust Pollution Control System

Cabinet Assembly

The unit is supplied with two (2) 1¼- or (2) 1½-inch wash headers located at the top of the cabinet assembly. Connect the water supply line to both of the wash headers at the top of the cabinet. Bring a 3-inch waste water drain piping connection with P trap to the drain pipe on the side of the cabinet assembly. The trap drain line water column for the drain should be sized for the total system resistance plus 1 in. wg.

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