GAYLORD RSPC-ESP-OW Series Technical Manual Download Page 9

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___________________________________________________________Chapter 1 – Introduction, Page 1-1

About this Manual

The purpose of this manual is to provide the Operator, Maintenance and Service personnel instructions for

operating, maintaining and troubleshooting the Gaylord ClearAir™ Pollution Control Unit, Model RSPC-ESP-

OW.

This manual also includes information and guidance to contractors for the initial installation of the

Unit.

The manual is divided into chapters for easy reference to a particular subject. The pages in the chapters

are numbered with the Chapter number, then a dash, and then the Page number. So for example pages in

Chapter 2 are numbered 2-1, 2-2, 2-3 etc. Figures and Tables are numbered in a similar manner. For

example Figure 5-3-2 is on Page 5-3 and is the second figure. Please keep your manual in a convenient

location for so it can be accessed easily.

If you have any questions regarding the Gaylord ClearAir Unit please contact Gaylord Industries.

Web:

www.gaylordventilation.com

E-Mail:

[email protected]

Main Phone: 503-691-2010

Toll Free: 800-547-9696

This manual and other Gaylord product manuals may be downloaded from the Gaylord website:

www.gaylordventilation.com

or be purchased by calling Gaylord Industries.

Summary of Contents for RSPC-ESP-OW Series

Page 1: ...d Maintenance Of The Gaylord ClearAir Model RSPC ESP OW Series Pollution Control Unit GAYLORD INDUSTRIES 10900 SW Avery Street Tualatin Oregon 97062 USA Email info gaylordventilation com Toll Free 800 547 9696 Fax 5023 692 6048 www gaylordventilation com ...

Page 2: ...n electronic mechanical photocopying recording means or otherwise without prior written permission of Gaylord Industries Copyright 2016 Gaylord Industries 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 ...

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Page 5: ...r Steam Cleaning 3 5 Chapter 4 Smoke Control Section Principle of Operation 4 1 Smoke Control Wash Cycle 4 2 Smoke Control Wash Cycle Water Consumption 4 7 Smoke Control Wash Cycle Recommend Detergent 4 8 Smoke Control Maintenance 4 10 Smoke Control Troubleshooting 4 20 Smoke Control Troubleshooting Charts 4 20 Smoke Control Trouble Shooting Green ESP Light Off Condition 4 22 Testing Voltages at t...

Page 6: ...intenance Loose Fill Media 5 4 Spray Odor Control Overview 5 6 Spray Odor Control Setting Timers 5 7 Spray Odor Control Maintenance 5 7 Spray Odor Control Chemical 5 8 Chapter 6 Exhaust Fan Section Overview 6 1 Initial Set Up 6 1 Pre Operational Maintenance 6 2 Initial Fan Lubrication 6 2 Idle Fan Requirements 6 3 Initial Operation 6 3 Preventive Maintenance 6 3 Troubleshooting 6 4 Chapter 7 Parts...

Page 7: ...rage A 1 Rigging A 2 Appendix B Assembly Overview B 1 Assembly Instructions B 1 Appendix C Installation Installation Codes C 1 Installation Precautions C 1 Appendix D Nameplate Sample Nameplate D 1 Appendix E Cell Rotation and Filter Cleaning Log Sheet Sample Log Sheet E 1 Appendix F Startup Inspection and Tests Overview F 1 Pre Startup Requirements F 1 Pre Startup Check List F 1 Startup Inspectio...

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Page 9: ...the chapters are numbered with the Chapter number then a dash and then the Page number So for example pages in Chapter 2 are numbered 2 1 2 2 2 3 etc Figures and Tables are numbered in a similar manner For example Figure 5 3 2 is on Page 5 3 and is the second figure Please keep your manual in a convenient location for so it can be accessed easily If you have any questions regarding the Gaylord Cle...

Page 10: ...gned 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 ClearAir ESP unit is available in several configurations 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 exhaust fan and odor abatement...

Page 11: ...m 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 finely atomized spray This spray performs a similar function to potassium permanganate in that it adsorbs or chemically neutralizes odors This process has the benefit of the end user being able to adjust the amount of spray and thus the eff...

Page 12: ...e power pack s and ground them to drain the residual electrical charge from both the power pack s and ESP Cells The ESP Cell access door shall interface with the electrical panel access door so that it cannot be opened without first opening the electrical panel access door The high volt age power pack s shall be self limiting type and shall be self contained The electrical panel shall include indi...

Page 13: ...he IMC International Mechanical Code and NFPA 96 The fan shall be AMCA certified 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 P E rated ODP three phase mounted on a common base with the fan and shall be pre wi...

Page 14: ...ng and NFPA 96 The Ansul Automan cabinet shall be mounted on the side of the unit for easy access certification and service ___Water spray sprinkler fire system Specifier Note Units that are located indoors or in locations that do not freeze 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 sh...

Page 15: ...Smoke Pollution Control 1 ESP Single Pass Electrostatic Cells 2 ESP Double Pass Electrostatic Cells ESP Cell Configuration WxH 1x1 2x1 3x1 2x2 3x2 4x2 3x3 4x3 3x4 4x4 Nominal FPM ESP Cell Velocity 250 FPM Heavy and Extra Heavy Duty Cooking 500 FPM Light and Medium Duty Cooking Type of Wash OW Oscillating Wash Odor Control Option SO Single Pass Odor DO Double Pass Odor SPO Spray Odor BLANK No Odor ...

Page 16: ...Air Flow Right Hand Unit Right Hand Access Access Side R or L Determined by Facing the Unit with the Inlet Airflow to back of head ESP Cells Single Pass 1ESP Figure 2 2 1 Typical ClearAir Unit Without Fan Enclosure Debris Screens or Impactor Filters Exhaust Fan Section EFN Plenum Section Optional Spray Odor SPO Moisture Separator Odor Media DO Shown Fan Type Centrifugal shown or Tubular ...

Page 17: ..._________________Chapter 2 Models and Configuration Page 2 3 Typical Installation Figure 2 3 1 Typical Arrangement with Water Wash Ventilator with the Main Control Cabinet Serving Both the Water Wash Ventilator and the ClearAir Unit ...

Page 18: ...4________________________________________________ Typical Installation Cont Figure 2 4 1 Typical Arrangement with Water Wash Ventilator with the Main Wash Control Cabinet Serving the Water Wash Ventilator and Sub Panel Serving the ClearAir Unit ...

Page 19: ...nd an Ansul fire extinguishing system as an option The following illustrations are examples of the most common configurations 1ESP Single Pass Electrostatic Cells 2ESP Double Pass Electrostatic Cells AF 30 After Filter Optional DO Double Pass Odor Control DS Debris Screen EFS Exhaust Fan unhoused spring isolated EFN Exhaust Fan unhoused not spring l d EFHS Exhaust Fan housed spring isolated EFHN E...

Page 20: ... Electrostatic Cells AF 30 After Filter Optional DO Double Pass Odor Control DS Debris Screen 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 FD Optional Curtain Fire Damper MS Moisture Separator SO Single Pass Odor Control SPO Double Spray Odor Control Cabinet ...

Page 21: ... turning on the cooking equipment Caution The chemical fire extinguishing system may discharge if the exhaust fan is not on while the cooking equipment is on or still hot To start the Exhaust Fan and ClearAir Unit push the START FAN button on the Gaylord Command Center Refer to Figure 3 1 1 If the Command Center is programmed to start the fan automatically then the START Fan button does not need t...

Page 22: ...Light This is a normal condition indicating that the ESP Cells are operating properly Fluctuating Green Light Normally a fluctuating green light is a temporary condition lasting until the Cells are dry immediately following a wash cycle This is caused by moisture left between the Cell plates which will evaporate Green Light Off A green light off indicates one of the following conditions exists 1 E...

Page 23: ...until the temperature in the Ventilator drops below the set point for 60 minutes Upon pushing the STOP FAN button the following will occur 1 The Exhaust Fan will shut off 2 The Makeup Air system will shut off 3 The ESP sells will shut off 4 The system Status Light will turn off 5 If equipped with spray odor control it will shut off 6 The ClearAir wash cycle will begin Important Note If the ClearAi...

Page 24: ...xhaust fan After the thermostat has cooled below 250 F the exhaust fan may be restarted by pushing the START FAN button As an option the ClearAir Unit may be wired so in addition to the exhaust fan shutting off the water sprays within the ClearAir Unit come on The water will run continually until the thermostat cools below 250 F then run for another 2 minutes At the conclusion of this cool down cy...

Page 25: ...ed light mounted on the face of the Control Cabinet or Command Center will illuminate when the chemical tank is empty We recommend the use of Gaylord Formula GS 710 odor control chemical Refer to page 5 8 for details and ordering information Other Required Maintenance 1 Smoke Control Section Odor control media require scheduled maintenance Refer to Odor Control Maintenance beginning on Page 5 2 2 ...

Page 26: ...Chapter 3 Daily Operation Page 3 6_________________________________________________________ This Page Intentionally Left Blank ...

Page 27: ...g equipment involved Every other plate is energized with 5000 volts of D C power and the alternating plates are grounded At the entry point of the Cell is a series of thin wires spaced approximately 4 101 60mm apart These wires referred to as ionizing wires are energized with 10 000 volts D C and as the smoke particles enter the Cell and pass over the wires they receive a positive charge As the ch...

Page 28: ...erfaced with a Sub Panel that serves the ClearAir Unit The hot water solenoid valves and detergent pump for the ClearAir Unit are housed in the Sub Panel and the detergent container is typically located below or next to the panel The detergent pump and container for the Ventilator are both housed in the main Control Cabinet located in the kitchen In both arrangements the Exhaust Fan ClearAir Unit ...

Page 29: ...________________________________________Chapter 4 Smoke Control Section Page 4 3 Smoke Control Wash Cycle Cont Wash Manifolds Figure 4 3 1 Manifold Linkage Linkage Figure 4 3 2 Oscillating Motor Oscillating Motor ...

Page 30: ... Inlet Hand Valve Figure 4 4 1 Typical Main Control Cabinet Sub Panel is the Same Except Without Command Center Control Compartment Appearance may vary depending upon Model Number of Command Center There is not a Command Center in the Control Compartment of Sub Panels Figure 4 4 2 Typical Command Center Only Note Sub Panels would typically not have a detergent container within the Panel but would ...

Page 31: ...N button or automatically as programmed If the ClearAir Unit is serving a water wash Ventilator the Ventilator wash cycle always occurs first followed by the ClearAir wash cycle Upon initiation of the ClearAir wash cycle the unit is washed in the following sequence The 3 minute wash and rinse times are the standard recommend times to be programmed in the Command Center If the Cells are not adequat...

Page 32: ...r different times as needed to adequately clean the ESP Cells The Command Center illustrated in this manual may not represent the model of Command Center you have Refer to the Technical Manual for your specific model of Command Center for complete instructions on programming wash delay and rinse cycle times If you do not have a Technical Manual for your Command Center obtain the model number from ...

Page 33: ...1 4 110 4 110 4 No Wash No Wash 110 4 No Rinse 331 2 3 x 3 18 2 1 1 4 62 1 62 1 62 1 62 1 62 1 62 1 310 0 3 x 4 24 2 1 1 4 82 8 82 8 82 8 82 8 82 8 82 8 414 0 4 x 2 16 2 1 1 4 110 4 110 4 No Wash No Wash 110 4 No Rinse 331 2 4 x 3 24 2 1 1 4 82 8 82 8 82 8 82 8 82 8 82 8 414 0 4 x 4 32 2 1 1 4 110 4 110 4 110 4 110 4 110 4 110 4 662 4 Note Water consumptions are 2 3 GPM per Cell based on a set flo...

Page 34: ...mula G 510EF for Cleaning the Ventilator Exterior Mix one part Formula G 510EF to twenty parts water in hand spray bottle Spray on let stand for a few minutes and wipe off Formula G 510EF for Other Cleaning Jobs The colloidal action of Formula G 510EF makes it a cleaner especially well suited for use in kitchens The colloids break up dirt and grease into millions of tiny particles that constantly ...

Page 35: ... and delivery charges also removal and installation costs Any federal state or local taxes are also extra Requests for repairs or replacement part should be made to 2010 Products Inc P O Box 7609 Salem Oregon 97303 This is the sole warranty with respect to FORMULA G 510EF 2010 Products Inc MAKES NO OTHER WARRANTY OF ANY KIND WHATSOEVER EXPRESSED OR IMPLIED AND ALL IMPLIED WARRANTIES OF MERCHANTABI...

Page 36: ...s 30 365 Medium Duty Braising pans Tilting skillets fryers griddles grooved griddles open burner ranges hot top ranges and conveyor ovens 21 126 Heavy Duty Gas and electric charbroilers upright broilers woks and conveyor broilers 14 84 Extra Heavy Duty Solid fuel broilers 7 NA Ventilators with UV Ultra Violet systems are not used when covering Extra Heavy Duty equipment The number of ESP Cells a u...

Page 37: ...ucted as described in steps 1 through 2 b below This test is necessary to insure that the power to the Transformer has shut off and the Grounding Disc made proper contact with the brass grounding screws to drain all the residual power from the Transformer 1 Open the Electrical Compartment door first the smaller door and then the Cell Plumbing Compartment door Opening the Electrical Compartment doo...

Page 38: ...he left side into the holding channel to keep out of the way while removing the Cells Refer to Figure 4 18 1 4 Pull all the Cells straight out slowly CAUTION Each Cell weighs 53 lbs and may be awkward to handle particularly Cells in the upper racks rows 3 and 4 It is highly recommended that a heavy duty steel wheeled ladder be used in removing the upper Cells Extreme care must be taken to avoid da...

Page 39: ...wires to the terminals on the Outer Cell Close the Cell and Electrical Compartment doors 7 Place the dirty Cells in the soak tanks Fill with hot water and add Formula G 510EF at a ratio of one part detergent to ten parts water Leave the Cell in the tank until the next rotation Figure 4 13 1 Outer Cell End View Figure 4 13 2 Inner Cell End View Cell Terminals Spring Terminals ...

Page 40: ... Cell Unit 3 Cell Unit 4 Cell Unit 6 Cell Unit 8 Cell Unit 9 Cell Unit 12 Cell Unit 16 Cell Unit 1 1 1 1 1 1 1 1 1 0 1 2 3 2 3 2 3 3 Note Some units are equipped with a second row of ESP Cells referred to as double pass Additional spare cells are not recommended for double pass units as the second pass does not get as dirty as the first pass Figure 4 13 3 Typical Outer Cell Inner Cell with Springs...

Page 41: ...3 O l O l l O l l l 2 O l O l l O l l l 1 O l O l l O l l l 2x3 3x3 4x3 4 O l O l l O l l l 3 O l O l l O l l l 2 O l O l l O l l l 1 O l O l l O l l l 2x4 3x4 4x4 Figure 4 15 1 Cell Configuration O Outer Cell l Inner Cell WxH The following illustrations show the standard Cell configurations The 1 row is always the bottom row The Outer Cell O is always the first Cell next to the Cell access door R...

Page 42: ... Control Section Page 4 16__________________________________________________ Smoke Control Maintenance Cont Figure 4 16 1 Outer Cell Nameplate Cell Identification Cell Identification Figure 4 16 2 Outer Cell Nameplate ...

Page 43: ...l Maintenance Cont Electrical Compartment Transformer Transformer Cooling Fan Figure 4 17 1 Electrical Cells Plumbing Compartments with Doors Opened Pressure Gauge Oscillating Manifold Motor Plumbing Compartment Plunger Safety Switch ESP Cells Slide Into These Two Racks Not Installed For This Photo Drain ...

Page 44: ...e that will not harm aluminum Some Control Cabinets are equipped with a low detergent indicator If so equipped a green light mounted on the face of the Control Cabinet will flash if the detergent tank is empty or if the detergent pump is malfunctioning and detergent is not pumping If the detergent tank is filled with water the detergent switch will activate as if there is no detergent Depending up...

Page 45: ...ge insulators white porcelain material Clean the insulators to avoid possible high voltage tracking to the ground d Check for any material which has lodged or built up between adjacent plates Periodic Pressure Wash or Steam Cleaning The National Fire Protection Association Standard 96 NFPA 96 requires all hood ducts and fans be inspected and cleaned if needed at periodic intervals based on the typ...

Page 46: ...harts are designed to easily find common problems the probable cause and guidance on corrective action In some cases the Corrective Action column will reference specific pages for additional guidance and corrective action Troubleshooting Smoke Control ESP Cells Symptom Probable Cause Corrective Action Fluctuating green monitor light 1 Normally this is a temporary condition lasting until the Cells ...

Page 47: ...off cont 1 Faulty Cell Possible causes are a Grease build up on plates or porcelain insulators b Foreign material lodged between plates c Broken Ionizer wire For all three possible causes first perform the tests following the test flow chart on page 4 22 1 Remove any foreign material between Cell plates 2 Remove grease buildup by cleaning or replace the Cell Replace missing or broken ionizing wire...

Page 48: ...l Connection Points instructions Voltage Good Green Light on No Voltage No Green Light Possible Plunger Safety Switch failure Proceed to Testing Plunger Safety Switch instructions ESP Cell failure Proceed to Testing ESP Cells Repair Plunger Safety Switch Plunger Safety Switch OK Possible Transformer Failure Proceed to Testing Transformer Voltage instructions No Voltage Replace Transformer Voltage ...

Page 49: ...4 23 2 4 Connect the ground wire of the meter to the ground lead wire 5 By hand push in and hold the Plunger Safety Switch The green light should be on Now measure voltage from ground to the 5KV volt lead wire and then from ground to the 10KV volt lead wire If proper voltage is obtained it indicates an ESP Cell failure Proceed to Testing ESP Cells instructions If there is no voltage it indicates a...

Page 50: ...s follows Testing for Mechanical Failure 1 Turn off the power to the ESP Cells by turning the Disconnect Switch on the ClearAir Main Electrical Panel to the off position Refer to Figure 4 23 1 2 Open the Electrical Compartment access doors 3 Push in the Plunger Safety Switch and verify that the Grounding Disc is pushing the micro switch down until you can hear the click of the switch engaging Refe...

Page 51: ...ompartment door first the smaller door and then the Cell Plumbing Compartment door Opening the Electrical Compartment door releases the Plunger Safety Switch shutting off power to the transformer by releasing the micro switch and draining residual power from the transformer s the by Grounding Disc making contact with the brass grounding screws Refer to Figure 4 17 1 and 4 24 1 2 To test proceed as...

Page 52: ...hestDCVscale 3 Tape the Door Safety Switch closed 4 Push in and hold the Plunger Safety Switch 5 Place probe or clip labeled common against ground connection on the power supply Place high voltage probe against the COLL connection point Voltage should be 4 700 to 5 500 DC If voltage is below 4 700 it indicates that the power supply module is defective and must be replaced Refer to the Parts Chapte...

Page 53: ...r 2 Leaving all the Cell lead wires connected pull all the first Cells Outer Cells out about 4 3 Push in and tape the Door Safety Switch in the closed position 4 By hand push in Plunger Safety Switch and hold Refer to Figure 4 24 2 Now measure voltage from ground on the Cell to the 5KV volt connection point Voltage should be between 4 700 and 5 500 volts DC If proper voltage is not obtained it ind...

Page 54: ...ell Do not grip or push on the Cell plates or the ionizer wires 3 Remove all the Outer Cells and place off to the side 4 Slide all the first set of Inner Cells to the Cell opening Attach one end of an alligator clip wire to the Grounding spring connection point on the Cell and the other end to the end of the Ground lead wire Refer to Figure 4 29 1 5 Attached one end of an alligator clip wire to th...

Page 55: ...eign material lodged between Cell plates If found remove 2 Grease build up between Cell plates If found clean thoroughly 3 Cell plates warped or damaged reducing the distance between Warped or damaged plates cannot be repaired The Cell must be replaced 4 Broken ionizing wire Refer to Replacing Ionizing Wires on page 4 30 5KV Spring Connection Point Ground Spring Connection Point 10KV Spring Connec...

Page 56: ...he Cell on a work bench and proceed as follows 1 Remove all of the broken wiresfrom the Cell mountingbrackets Refer to Figure 4 30 1 2 Install the new wire as follows a Insert hook of one spring into the hole b Use long nose pliers and carefully pull second spring until hook can be secured in mounting bracket hole Figure 4 30 1 Replacing Ionizing Wires Ionizing Wires Cell Mounting Brackets ...

Page 57: ...Unit Refer to Figure 4 39 1 The flow pressure should be 30 psi minimum to 50 psi maximum 1 With the wash cycle on try adjusting the water pressure regulator located at the inlet of the unit to achieve the desired pressure 2 Check the hand valves inside the Main or Sub Wash Control Cabinet to make sure they are fully opened Refer to Figure 4 41 1 3 Check any valves upstream of the Wash Control Cabi...

Page 58: ...and follow the instructions for a clogged spray nozzle L Ratio of Detergent to water is too low 1 Change adjustment on Detergent Pump Refer to Page 4 46 for instructions M Wash manifold is not oscillating properly 1 Refer to Page 4 38 for corrective action 2 Water spray nozzles do not come on when in a wash cycle A Malfunctioning water solenoid valve 1 Refer to Page 4 50 for instructions B Malfunc...

Page 59: ... 3 psi and when the water solenoid valve closes to shut off the Wash Cycle 1 No action necessary 2 Continuous discharge of water when the Ventilator is not in a Wash Cycle A Foreign material in the check valve of the Backflow Preventer 1 Refer to page 4 49 Leave the inlet hand valve open and close the outlet hand valve If there is still continuous discharge it indicates that foreign material is pr...

Page 60: ... are not adequately cleaned it may be necessary to increase the length of the wash cycle The wash cycle may be programmed for between 3 9 minutes Refer to your specific Command Center Technical Manual for instructions on programming the wash time 3 Length of Delay Between Wash Cycles The delay time between the washes and rinses are programmed in the Command Center for a length of time to allow the...

Page 61: ...er Safety Switch shutting off power to the transformer by releasing the micro switch and draining residual power from the transformer s by the Grounding Disc making contact with the brass grounding screws Refer to Figure 4 17 1 and 4 24 1 Extreme Caution Before removing the lead wires from Cells a Standard Safety Voltage Test must be conducted as described on page 4 11 This test is necessary to in...

Page 62: ...folds are connected to the water inlet pipe with a quick disconnect fitting Slide the outer couple towards the water inlet and push the manifold away and off to one side Refer to Figure 4 36 2 2 Slide the manifold out through the Cell Plumbing Compartment access door Figure 4 36 1 Motor Manifold Figure 4 36 2 Standard Manifold Square Manifold Manifold Extension Pipe Linkage Quick Disconnect Linkag...

Page 63: ...o Figure 4 37 1 Remove the screw and gently pry out the nozzle with a utility knife or a flat blade screwdriver The nozzle has a small amount of silicone sealing it to the manifold 2 Apply a very small amount of silicone to the shoulder and gasket area of the nozzle and slide into the hole Refer to Figure 4 37 2 3 Insert the hex screw and gently tighten to 7 inch lbs max Caution over tightening ma...

Page 64: ... position Referring to the wiring diagrams electrically check the end switch and relay for proper operation d If it is determined that the motor is defective remove and replace as follows 1 Shut off the electrical power using the Disconnect Switch on the Main Electrical Panel Refer to Figure 4 23 1 2 Shut off the water to the unit 3 It may be necessary to remove the side panel on the Plumbing Comp...

Page 65: ... 6 Reconnect the electrical Extreme Caution Before removing the lead wires from Cells a Standard Safety Voltage Test must be conducted as described on page 4 11 This test is necessary to insure that the Grounding Disc made proper contact with the brass grounding screws to drain all the residual power from the transformer 7 Remove the first ESP Cell that is nearest the motor so you can see the posi...

Page 66: ... supply pipe at the union Refer to Figure 4 39 1 c Remove the C retainer ring from the brass swivel elbow Refer to Figure 4 38 1 d Slide the body of the swivel elbow along with the connected water supply pipe straight out e Remove the two O rings Refer to Figure 4 38 2 f Apply O ring lubricant on the O ring and around the receiver of the brass swivel elbow g Slide on the new O rings h Slide the br...

Page 67: ...Initial Operation To prime and operate the pump for the first time it is recommended that water be used instead of detergent to prevent detergent from spilling in case of leaks at the system s fittings The pump is operating properly when both upper and lower poppet checks in the pump head can be seen moving up and down slightly Detergent Pump Detergent Flow Switch Brass Check Valve Temperature Pre...

Page 68: ...up and down slightly Note Be careful not to tighten to much as it will cut the O ring 3 Check all fittings to ensure an airtight system If the pump still does not work properly check and rebuild or replace the Foot Valve Pump Head and or Brass Check Valve in the following order 1 Foot Valve Refer to Figure 4 43 1 and Figure 4 43 2 a The Foot Valve should be clean and immersed in the detergent b To...

Page 69: ...eaning replace with a new one 2 Pump Head Refer to Figure 4 41 1 and Figure 4 42 1 a Remove check and the clean the Pump Head as follows 1 Disconnect the vinyl tubing coming into the bottom of the head 2 Disconnect the copper tubing coming out the right top of the head 3 Remove the four mounting screws Figure 4 45 1 Pc 5 and remove the head from the Pump Head Base Figure 4 43 1 Foot Valve Figure 4...

Page 70: ...Pump Head does not operate properly after cleaning replace with a Pump Head Kit Refer to page 7 8 for parts 3 Brass Check Valve Refer to Figure 4 41 1 and Figure 4 45 1 Pc 15 a Remove check and clean Brass Check Valve as follows 1 Turn off water at the Outlet Hand Valve that is part of the Backflow Preventer Refer to Figure 4 41 1 2 Disconnect the copper tubing coming from the Detergent Flow Switc...

Page 71: ...abinet pump junction box 2 Disconnect the electrical conduit and wiring from the pump junction box 3 Disconnect the vinyl tubing coming up from the Detergent Tank 4 Disconnect the copper tubing coming out the right top of the pump head 5 Remove the two nuts at the pump mounting bracket and remove the pump 6 Mount new pump 7 Reconnect the vinyl and copper tubing line 8 Reconnect the wiring and cond...

Page 72: ...ithin the hours of fan operation 2 Type of food product being cooked 3 Water pressure Required minimum pressure is 30 psi at the ClearAir Unit pressure gauge 4 Water temperature Required temperature is 140 F Min to 180 F Max 5 Length of Wash Cycle 6 Frequency of Wash Cycle 7 Delay between wash and rinse 8 Type of detergent Refer to page 4 8 for recommended detergent 9 Ratio of detergent to water I...

Page 73: ...w Switch The Detergent Flow Switch Refer to Figure 4 47 1 is a sealed unit and cannot be repaired If determined that the Flow Switch is faulty replace as follows 1 Turn off power to the Command Center 2 Disconnect the wiring from the pump junction box 3 Disconnect the copper tubing on both sides of the switch 4 Install a new Flow Switch Detergent Consumption Chart Cam Setting Oz Per Minute at 40 P...

Page 74: ...reen 4 Using a wire brush and hot detergent water clean the screen 5 Replace the Screen Screen Plug and tighten thoroughly 6 Test for leaks Backflow Preventer Reduced Pressure Principle Device Overview A Backflow Preventer is mounted within the Wash Control Cabinet and is required by code to prevent contaminated water water with detergent from back flowing upstream to potable water Refer to Figure...

Page 75: ...mon and usually occurs if there are inlet pressure fluctuations of more than 3 psi and when a solenoid valve closes after a Wash Cycle Continuous Discharge If there is continuous discharge or rapid spitting of water out the relief valve when the Ventilator is not in a Wash Cycle contact the Watts Regulator Company for service Caution In no case should the relief valve outlet port be plugged closed...

Page 76: ...n material trapped in the valve and the water should stop 2 If tapping does not release the foreign material the valve must be disassembled and checked To disassemble the valve proceed as follows Refer to Figure 4 51 1 Danger Always shut off electrical power when repairing electrical controls Contact with unsecured power will result in immediate injury or death to personnel a Shut off electric pow...

Page 77: ...for your Command Center the Troubleshooting Section 2 If there is power it indicates that the Solenoid is burned out To replace the Solenoid proceed as follows Danger Always shut off electrical power when repairing electrical controls Contact with unsecured power will result in immediate injury or death to personnel a Shut off electric power to the Wash Control Cabinet b Open the junction box next...

Page 78: ...Chapter 4 Smoke Control Section Page 4 52_________________________________________________ RSPC ESP Drain ...

Page 79: ...r a sample Nameplate 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 potassium permanganate media has a flat efficiency curve meaning that the efficiency or effectiveness stays constant until the media has expended and then the efficiency drops off rapidly The carbon portion of...

Page 80: ...of the last inspection and Media Panel installation can be filled 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 ...

Page 81: ...st 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 3 Carefully slide out the Modules 4 Place the Module on edge with the open side up V side down refer to Figure 5 3 1 5 Flip the Locking Clip up refer to Figure 5 3 1 6 Pull out both Media Panels refer to Figure 5 3 2 7 Slid...

Page 82: ...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 thedepletedModulesand replace with the new Modules 3 Empty the media from the depleted Modules into containers for disposal 4 Pack the empty used Modules into the boxes the new ones came in a...

Page 83: ... 5 1 6 Empty the old media into a container for disposal 7 Place the filling jig over opening 8 Pour the media into the Module 9 To eliminate voids shake or vibrate the Module to ensure that the media settles 10 Continue adding media until Module is full 11 Caution Do not overfill as it may cause the sides to bulge 12 Replace cover plate and install securing screw 13 Optional some dusting may occu...

Page 84: ... off the length of time on dependent upon the amount of odor created by the cooking process There are 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 Refer to Figures 5 7 1 and 5 7 2 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 Legend 1 S...

Page 85: ...actory odor control as follows 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 Spray Odor Control Maintenance 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 t...

Page 86: ...ing a Remove the cleanout plug from the nozzle body and using a very thin pin or wire clean the hole in the fluid cap orifice and replace the cleanout plug b 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...

Page 87: ...here are up to a total of six spring isolators one on each of the four corners and possibly two more in the mid section of the fan The four on each corner are factory screwed down to help secure the fan during shipment The two isolators at the motor end can be easily reached for adjustment The two on the wheel end of the fan are accessed through the fan inlet plenum chamber by removing the two acc...

Page 88: ...nd base bolts g Check tightness of bearing mounting bolts 2 Belt tension a The deflection of the belt is approximately 1 4 inch per foot of center distance when firmly pressing the belt in the center b If the belt does not have the proper deflection adjustment is accomplished by use of adjustable motor base Initial Fan Lubrication To prevent corrosion bearings should receive grease and be rotated ...

Page 89: ...witch located on the ClearAir unit Main Electrical Panel Refer to Figure 4 23 1 Place a sign on the Command Center or any other control that starts the exhaust fan stating Do Not Start Fan Fan Maintenance In Process 1 Inspect bolts and setscrews for tightness Tighten as necessary Worn setscrews should be replaced immediately 2 Inspect belt wear and alignment Replace worn belts with new belts and a...

Page 90: ...elt 3 Magnetic starter overload cut out 1 Push starter reset button If overloads continue to cut out search for cause Noise in exhaust fan 1 Bad fan bearings 1 Replace bearings 2 Loose tie rods or blades 1 Replace fan wheel 3 Fan wheel loose on shaft 1 Tighten wheel 4 Foreign objects located in fan wheel or fan housing 1 Clean the fan wheel Chart C 6 4 1 Exhaust Fan Troubleshooting Warning Running...

Page 91: ...aylord Certified Service Agency CSA For the location of your nearest CSA please go to www galordventilation com and click on Service Agency Locator PC Description Gaylord Part Photo Illustration 1 Spray Nozzle 19717 2 Wash Manifold Oscillating Motor 19700 3 Brass Swivel Elbow O Rings Special Order 4 Shaft Collar 19859 5 Rubber Oil Seal 18797 Table T 7 1 1 Parts List Miscellaneous ...

Page 92: ...uick Disconnect 10324 20323 2 1 4 Turn Door Latch Key for Latch 19547 19548 3 Lift and Turn Latch 16547 4 T Handle Latch 19771 5 Fire Thermostat 15 Length 250 F Normally Open 18782 6 Water Solenoid Valve Slow Close 1 1 4 10144 7 Water Solenoid Valve Repair Kit 1 1 4 8221G9 14390 8 Coil for Water Solenoid Valve 120V 10156 Table T 7 2 1 Parts List Miscellaneous Cont ...

Page 93: ... Cont PC Description Gaylord Part Photo Illustration Soak Tank 24 Cells 12801 1 Debris Screen 30167 Not Illustrated 2 Impactor Filter 20006 3 Moisture Separator 30080 4 Vermiculite Gasket 10879 5 Orange Silicone Gasket 18993 6 Bulb Seal Gasket for Access Doors 20123 Table T 7 3 1 Parts List Miscellaneous Cont ...

Page 94: ...9833 2 Wire Terminal Stud 14753 3A Instruction Label Outer Cell 16846 3B Instruction Label Inner Cell 16844 4 Plate Insulator same as Ionizer Insulator 19883 5 Ionizer Wire 10338 6 5 KV Label 16999 7 10 KV Label 17000 8 Ground Label 16998 9 Inner Cell Coil Spring 11301 10 Outer Cell Complete 76131 11 Inner Cell Complete 76132 Figure 7 4 1 ESP Cells Table T 7 4 1 Cell Parts List ...

Page 95: ...for 1 4 Cells 16514 3 Electrical Compartment Plunger Safety Switch 12798 4 Cooling Fan 30424 5 Cell Status Light Green Not Illustrated 12512 6 Cell High Voltage Cable 6 ft Lengths 15228 7 Cell Terminal Connector Cover 90 Degree Rubber Boot 10332 8 Spark Plug Cell Terminal Connectors 10355 Table T 7 5 1 Electrical Compartment Parts List Figure 7 5 3 Electrical Compartment Figure 7 5 2 Cell High Vol...

Page 96: ...l drawings for part Varies 2 Fuse Block Refer to Gaylord submittal drawings for part Varies 3 Fuses Refer to Gaylord submittal drawings for part Varies 4 Motor Starter Refer to Gaylord submittal drawings for part Varies 5 Disconnect Switch Refer to Gaylord submittal drawings for part Varies Figure 7 6 1 Main Electrical Compartment Table T 7 6 1 Main Electrical Compartment Parts List 5 4 1 2 3 ...

Page 97: ...ir Gap Assembly for Backflow Preventer for 1 25 50287 3 Reduced Pressure Principle Backflow Preventer 1 25 11319 4 Detergent Container 19793 5 Pressure Temperature Gage 10175 6 Detergent Flow Switch 16892 7 Detergent Check Valve Brass 25 10246 8 Detergent Pump 10222 9 Command Center Guard not shown package of 2 75587 10 Door Latch not shown 19351 9 3 1 6 4 8 7 5 2 Table T 7 7 1 Figure 7 7 1 Typica...

Page 98: ...1 10272 9 Tube Nut not sold with Kit Part No 10275 1 na 10 Bottom Adaptor with O Ring sold with Kit Part No 10275 1 na 11 Spring sold with Kit Part No 10275 1 na 12 Poppet Check sold with Kit Part No 10257 2 na 13 Brass Outlet sold with Kit Part No 10275 1 na 14 Tube Nut Brass sold with Kit Part No 10275 1 na 15 Check Valve Brass 1 10265 16 Adjustable Cam Assembly 1 20466 17 Bracket Motor Mounting...

Page 99: ... 10272 3 Spray Nozzle Assembly 19065 4 3 8 Copper Tubing 11000 5 Electrical Box N A 6 Cycle and Spray Timer Relay 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 750 19097 12 Spray Chemical Level Sensor In Tank 19071 13 1 4 Foot Valve In Tank 10269 Figure 7 9 1 Spray Odor Control Cabinet Table T 7 9 1 Pieces 5 and 6 no...

Page 100: ...Chapter 7 Parts Page 7 10________________________________________________________________ This Page Intentionally Left Blank ...

Page 101: ...m Page 8 1 Wiring Diagrams The Wiring Diagrams on the following pages are typical for Typical ClearAir Units and may not represent your installation Always refer to the Gaylord submittal drawings for the actual Wiring Diagrams for your installation Figure 8 1 1 Wiring For 2x2 1ESP ...

Page 102: ...Chapter 8 Wiring Diagram Page 8 2_________________________________________________________ Wiring Diagrams Cont Figure 8 2 1 Wiring For 3x1 1ESP ...

Page 103: ..._________________________________________________________Chapter 8 Wiring Diagram Page 8 3 Wiring Diagrams Cont Figure 8 3 1 Wiring For 3x3 1ESP ...

Page 104: ...Chapter 8 Wiring Diagram Page 8 4_________________________________________________________ Wiring Diagrams Cont Figure 8 4 1 Wiring For 4x4 1ESP ...

Page 105: ..._________________________________________________________Chapter 8 Wiring Diagram Page 8 5 Wiring Diagrams Cont Figure 8 5 1 Wiring For 2x2 2ESP ...

Page 106: ...Chapter 8 Wiring Diagram Page 8 6_________________________________________________________ Wiring Diagrams Cont Figure 8 6 1 Wiring For 3x1 2ESP ...

Page 107: ..._________________________________________________________Chapter 8 Wiring Diagram Page 8 7 Wiring Diagrams Cont Figure 8 7 1 Wiring For 3x3 2ESP ...

Page 108: ...Chapter 8 Wiring Diagram Page 8 8_________________________________________________________ Wiring Diagrams Cont Figure 8 8 1 Wiring For 4x4 2ESP ...

Page 109: ...r 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 fire extinguisher available Read these instructions thoroughly Odor Control Media Short Term Storage Units that include media b...

Page 110: ...4 lifting points for rigging attachment WARNING Use all lifting points provided Refer to Figure A 2 1 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 Spreader Bar Lifting Point 4 Figure A 2 1 Typical Rigging ...

Page 111: ...ides using the provided 3 4 holes Tech screw the walls and roofs together using the provided 3 16 holes From inside the unit continuously weld the floor wall and roof seams water tight From outside the unit stitch weld and fire seal along the seams 2 AttachOdorControlSection 2 to Plenum Section 3 Bolt Section 2 and Section 3 bases together on the outer sides using the provided 3 4 holes From insid...

Page 112: ...Appendix B Assembly Page B 2____________________________________________________________ This Page Intentionally Left Blank ...

Page 113: ...t to the inlet and outlet of the ClearAirunit must be fully welded to comply with NFPA 96 Installation Precautions 1 The services of qualified contractors are essential for safe and proper installation of this equipment 2 The unit is designed for installation on a level surface 3 When installed in an enclosed space a fire rated enclosure may be required for the unit and associated duct work Consul...

Page 114: ...Appendix C Installation Page C 2___________________________________________________________ This Page Intentionally Left Blank ...

Page 115: ...__________________________________________________________Appendix D Nameplate Page D 1 Nameplate Figure D 1 1 Nameplate ...

Page 116: ...Appendix D Nameplate Page D 2__________________________________________________________ This Page Intentionally Left Blank ...

Page 117: ..._Appendix E Cell Rotation and Filter Cleaning Log Sheets Page E 1 Cell Rotation and Filter Cleaning Log Sheet Date ESP Cell Row Number Changed Out Debris Screen or Impactor Filter and Moisture Separator Cleaned Comments Chart E 1 1 ...

Page 118: ...Appendix E Cell Rotation and Filter Cleaning Log Sheets Page E 2________________________________ This Page Intentionally Left Blank ...

Page 119: ... Up Check List ____ ClearAir Unit is installed as per Gaylord Submittal Drawings ____ Check to ensure that duct work is a minimum 16 GA steel or 18 GA stainless steel all welded and continuously welded to the connection at the ClearAir Unit ____ If the unit was shipped in sections check for proper assembly of the unit as shown on pages B 1 and B 2 ____ Check the fan section to ensure that the ship...

Page 120: ...illed with media 9 ___ Verify that the Odor Control Media Monitoring Tube is in place If Equipped with Spray Odor Control 10 ___ Verify that the container of spray odor chemical Gaylord Formula GS 710 is in the spray odor cabinet and that the pickup tube is inserted into the container If Equipped with an Exhaust Fan 11 ___ Verify that the wall insulation in secure and has not loosened in shipment ...

Page 121: ...aximize the spray odor effectiveness Decreasing the delay or increasing the spraying time will improve the effectiveness of the spray odor Increasing the delay of decreasing the spray time will reduce the effectiveness Wash System 1 Push the Stop Fan button on the Command Center and check the following a Exhaust Fan shut off ___ Yes ___ No b Water turned on ___ Yes ___ No c Oscillating motor opera...

Page 122: ...pany Name ___________________________________________________________ Title ______________________________________________________ Date __________ Comments _______________________________________________________________________________________ _______________________________________________________________________________________ ____________________________________________________________________...

Page 123: ...ufactured by Gaylord Industries such as electrical switches relays solenoid coils etc shall be warranted under the terms and conditions of the warranty that is published by the manufacturer of said component parts This warranty does not cover routine maintenance and inspection of the cleaning system as spelled out in The Gaylord Ventilator Technical Manual This warranty also does not cover malfunc...

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