WARNING. Effective Date: 1-03

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1 Effective Date: 1-03 TECHNICAL MANUAL FOR INSTALLATION, OPERATION AND MAINTENANCE OF THE GAYLORD "ClearAir"TM MODEL "TPF" SERIES POLLUTION CONTROL UNITS WITH FM-100 SERIES MONITOR STATION WARNING Improper installation, adjustment, alteration service or maintenance can cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment. Only trained and qualified service personnel should install or service this equipment S.W. AVERY STREET P.O. BOX 1149 TUALATIN, OR USA PHONE: TOLL FREE: FAX:

2 Undisputed World Leader in Engineered Systems for Commercial Kitchens tm GAYLORD INDUSTRIES, INC. World Headquarters: P.O. Box 1149 Tualatin, Oregon U.S.A. To Our Customers... Congratulations on your recent purchase of a Gaylord ClearAir Pollution Control Unit. We are proud to be able to provide you with a quality product that exemplifies our long-standing dedication to quality engineering. Your unit is assembled from some of the very finest components available and is designed for years of efficient, effective, and troublefree operation. In addition, this unit has undergone rigorous quality control inspections and was fully operationally tested prior to shipment. If you have further questions, please call us toll free at We are more than happy to help. Sincerely, Gaylord Industries, Inc. STREET ADDRESS: S.W. Avery Street, Tualatin, Oregon U.S.A. PHONE: FAX: gaylord@gaylordusa.com COMMERCIAL KITCHEN EXHAUST SYSTEMS FIRE PROTECTION HEAT RECLAIM UTILITY DISTRIBUTION ROOF TOP UNITS POLLUTION CONTROL AIR HANDLING UNITS

3 TECHNICAL MANUAL FOR INSTALLATION, OPERATION AND MAINTENANCE OF THE GAYLORD ClearAir MODEL TPF SERIES POLLUTION CONTROL UNITS WITH FM-100 SERIES MONITOR STATION Published by: GAYLORD INDUSTRIES, INC. Tualatin, Oregon U.S.A. First Printing: January, 2003 Copyright 2003, Gaylord Industries, Inc. ALL RIGHT RESERVED. NO PART OF THIS BOOK MAY BE REPRO- DUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY AN ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORD- ING MEANS OR OTHERWISE WITHOUT THE WRITTEN PERMISSION OF GAYLORD INDUSTRIES, INC. COPYRIGHT 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. Additional Copies $15.00 The Gaylord ClearAir Unit is designed and engineered by GAYLORD INDUSTRIES, INC. P.O. Box 1149, Tualatin, Oregon

4 TABLE OF CONTENTS INTRODUCTION... 1 PRINCIPLE OF OPERATION... 2 TYPICAL TPF MODELS... 3 GENERAL INFORMATION... 5 TYPICAL INSTALLATION... 7 SAMPLE ClearAir CONFIGURATIONS... 8 NAMEPLATE DATA RECEIVING & INSTALLATION EQUIPMENT LIFTING PROCEDURE ODOR CONTROL SECTION GENERAL DESCRIPTION ODOR CONTROL MEDIA SERVICE AND MAINTENANCE REPLACING THE MEDIA FILTERS EXHAUST FAN SECTION MAINTENANCE PARTS LISTS WIRING DIAGRAM TERMINAL VOLTAGES WARRANTY... Inside back cover

5 INTRODUCTION 1

6 GAYLORD CLEARAIR TM AND / OR FIRE SYSTEM DISCHARGE The ClearAir Unit Model RSPC-TPF Series is ETL Listed under the category Air Filtering Device, Report # U.S DO NOT OPERATE UNIT WITH MISSING FILTERS OR WITH FILTERS THAT SHOULD BE REPLACED AS INDICATED BY MONITOR- ING LIGHTS. THIS IS A SMOKE POLLUTION CONTROL DEVICE AND WILL NOT OPER- ATE PROPERLY WITH MISSING OR DIRTY FILTERS. G AYLORD INDUSTRIES, INC. TUALATIN, OREGON U.S.A. Phone: Fax: info@gaylordusa.com Form No. TPF FP/19038 PRINCIPLE OF OPERATION Construction FILTER MONITORING STATION FM-100 POLLUTION CONTROL UNIT CONTROL PANEL MODEL FM-100 FAN ON NORMAL AIR LOW AIR REPLACE PRE FILTERS REPLACE BAG FILTERS REPLACE FINAL FILTERS MISSING FILTER FIRE IN UNIT THERMOSTAT ACTIVATION 6(1625Ã/,*+7 CANCEL ALARM BUTTON - CAUTION - 2

7 CLEARAIR TPF TYPICAL MODELS OUTLET TO FAN PF BF QM FF PF BF QM FF FD EF FAN DISCHARGE PF BF QM FF SO AF FD OUTLET TO FAN PF BF QM FF SO FD EF FAN DISCHARGE 3

8 GAYLORD CLEARAIR TM AND / OR FIRE SYSTEM DISCHARGE The ClearAir Unit Model RSPC-TPF Series is ETL Listed under the category Air Filtering Device, Report # U.S DO NOT OPERATE UNIT WITH MISSING FILTERS OR WITH FILTERS THAT SHOULD BE REPLACED AS INDICATED BY MONITOR- ING LIGHTS. THIS IS A SMOKE POLLUTION CONTROL DEVICE AND WILL NOT OPER- ATE PROPERLY WITH MISSING OR DIRTY FILTERS. G AYLORD INDUSTRIES, INC. TUALATIN, OREGON U.S.A. Phone: Fax: info@gaylordusa.com Form No. TPF FP/19038 CLEARAIR TPF TYPICAL MODELS PF BF QM FF DO AF FD EF FAN DISCHARGE POLLUTION CONTROL UNIT CONTROL PANEL MODEL FM-100 FAN ON NORMAL AIR LOW AIR REPLACE PRE FILTERS REPLACE BAG FILTERS REPLACE FINAL FILTERS MISSING FILTER FIRE IN UNIT THERMOSTAT ACTIVATION 6(1625Ã/,*+7 CANCEL ALARM BUTTON - CAUTION - 4

9 GENERAL INFORMATION 5

10 GENERAL INFORMATION 6

11 TYPICAL INSTALLATION 7

12 SAMPLE ClearAir TPF CONFIGURATIONS The ClearAir unit is available in sizes ranging in capacity from 1000 to 32,000 CFM (472 to 15,102 L/s). Each unit is equipped with Three Phase Filters and may include an exhaust fan, odor abatement equipment and Quencher System, or Ansul System as an option. The following illustrations are examples of the most common configurations. KEY AF = 30% After Filter BF = Bag Filter DO = Double Pass Odor Kor48/Carbon blend EF = Exhaust Fan FD FF PF SO SP = Curtain Fire Damper = 95% Final Filter = 30% Pre-Filter = Single Pass Odor Kor48/Carbon blend = Spray Odor Manifold SMOKE CONTROL ONLY (Remote Fan) SMOKE CONTROL WITH SINGLE PASS ODOR CONTROL (Remote Fan) SMOKE CONTROL WITH PLENUM (Remote Fan) SMOKE CONTROL WITH DOUBLE PASS ODOR CONTROL (Remote Fan) SMOKE CONTROL WITH SPRAY ODOR CONTROL AND OPTIONAL FIRE DAMPER (Remote Fan) 8

13 SAMPLE ClearAir TPF CONFIGURATIONS KEY AF = 30% After Filter BF = 95% Bag Filter CL = Chlorine Odor Control DO = Double Pass Odor Kor48/Carbon blend EF = Exhaust Fan FD FF PF SO SP QM = Curtain Fire Damper = 99% Final Filter = 3-% Pre-Filter = Single Pass Odor Kor48/Carbon blend = Spray Odor Manifold = Quencher Manifold SMOKE CONTROL WITH EXHAUST FAN AND OPTIONAL FIRE DAMPER SMOKE CONTROL WITH SINGLE PASS ODOR CONTROL, EXHAUST FAN AND OPTIONAL FIRE DAMPER SMOKE CONTROL WITH DOUBLE PASS ODOR CONTROL, EXHAUST FAN AND OPTIONAL FIRE DAMPER SMOKE CONTROL WITH SPRAY ODOR CONTROL, EXHAUST FAN AND OPTIONAL FIRE DAMPER 9

14 NAMEPLATE DATA The ClearAir nameplate is located on the electrical compartment access door of the unit. If inquiring on service or ordering parts, please have model number and serial number available. SMOKE POLLUTION CONTROL UNIT MODEL NUMBER RSPC -TPF - ENGINEERING DATA FILTER SECTION CFM INT. STATIC PRESSURE "W.G. VOLTS PHASE HERTZ AMPS WATTS 1 SERIAL NUMBER MAX. FUSE SIZE MAX. BREAKER SIZE AMPS AMPS SUITABLE FOR USE WITH CONTROL MODEL NO. FOR EITHER INDOOR OR OUTDOOR INSTALLATION GAYLORD INDUSTRIES, INC. P.O. BOX S.W. AVERY STREET TUALATIN, OREGON FOR NAME OF THE NEAREST SERVICE AGENCY CALL: Or Visit OPTIONAL FAN SECTION CFM TOTAL STATIC PRESSURE "W.G. EXHAUST FAN POWER CIRCUIT: VOLTS PHASE HERTZ AMPS FLA MIN. CIRCUIT AMPACITY MAX. FUSE SIZE AMPS MAX. BREAKER SIZE AMPS The ClearAir unit Model RSPC-TPF Series is ETL Listed under the category Air Filtering Device, Report # FORM NO. CATPFNP 902/ CAUTION- THE FILTER INDICATOR LIGHTS SHOULD BE INSPECTED FREQUENTLY TO ENSURE THAT COLLECTED GREASE IS BEING REMOVED BY THE FILTER. REFER TO THE TECHNICAL MANUAL FOR SPECIFIC INSTRUCTIONS. ClearAir NAMEPLATE 10

15 NAMEPLATE DATA The assigned model number of a ClearAir unit will indicate the number of Filter Banks and if it has odor control or double pass odor control, if it has an exhaust fan plus other data. The following example shows the make-up of a model number. The model number of your ClearAir unit along with other data can be found on the nameplate which is attached to the electrical control panel on the ClearAir unit. - (Optional) 11

16 RECEIVING & INSTALLATION RECEIVING Most ClearAir units are shipped in one piece. However, some units, because of size or special jobsite conditions, may be shipped in multiple sections. Follow the instructions provided with the unit to join sections back together. If the unit includes odor control, the KOR48/carbon odor control media is packaged separately. Verify against the shipping documents that you have received all items and note any shipping damage, obvious or hidden, to your carrier and on your Bill of Lading. If damage is found, immediately file a claim with the transport company. All units are thoroughly inspected and fully operation tested at the factory prior to shipment. Verify that the electrical and air flow ratings on the unit name plate agrees with jobsite requirements. If a contradiction arises notify the factory prior to proceeding with installation. SAFETY CONSIDERATIONS Installing and servicing the ClearAir unit can be hazardous due to the presence of electrical components. Only trained and qualified service personnel should install or service this equipment. Untrained personnel can perform basic maintenance, such as cleaning and replacing filters. All other 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. WARNING Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Electrical shock can cause personal injury or death. RIGGING All units are provided with a minimum of four (4) lifting points for rigging attachment. WARNING: Use all lifting points provided. (Refer to Page 13) 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. INSTALLATION CODES This unit requires external plumbing and electrical connections to be made in the field. It is recommended that the authority having jurisdiction (AHJ) be consulted regarding local codes and installation procedures. Gaylord Industries is not responsible for obtaining necessary approvals and permits which may be required for installation, nor is it responsible for verifying that the unit has been installed in accordance with national, state, and local codes. In the absence of locally adopted codes use the latest editions of the national electrical code and the uniform mechanical code. Connections of the exhaust duct to the inlet and outlet of the ClearAir unit must be fully welded to comply with NFPA-96. NSTALLATION PRECAUTIONS 1. The services of qualified contractors are essential for safe and proper installation of this equipment. 2. The air volumes and external static pressures that are listed on the unit are for the middle of the operating range of the filters. The initial air volume should be at least 10% higher than the listed CFM. As the filters load up the air volume will drop. This is inherent to this type of unit. If the unit is set up at or below the design CFM, as the filters load up, the kitchen hood may experience smoke loss problems. Please consult the factory if you have questions. 3. The unit is designed for installation on a level surface. 4. When installed in an enclosed space a fire rated enclosure may be required for the unit and associated duct work. Consult the authority having jurisdiction. 5. Consult the authority having jurisdiction regarding requirements covering the point of termination of the exhaust outlet of this unit. Minimum distances must usually be maintained between the exhaust outlet and any outside air intakes and/or adjacent structures or property lines. 6. Do not apply power to the unit until all electrical connections have been made and a pre-start-up preliminary inspection has been completed. 7. Allow a minimum of 36 inches clearance in front of the filter access door and electrical compartment door for service and routine maintenance. SHORT TERM STORAGE Units that include odor control are provided with KOR48/ carbon media which is shipped separate from the unit. KOR48/carbon media must be stored in a dry place with less than 95% relative humidity. LONG TERM STORAGE (OVER ONE MONTH) If the unit is equipped with an exhaust fan it must be re-lubricated as soon as it arrives. To prevent corrosion all bearings should receive grease and be rotated the first of every month. Turn the wheel by hand while greasing bearings. A clean 1/16" bead of grease must appear on each side of each bearing. Refer to specific bearing lubricating instructions on the fan. Also, refer to bearing lubricating instructions found in the exhaust fan section of this manual. Bearings which are to be stored or idle for an extended period of time should be wrapped in a neutral grease-proof paper, foil, or plastic film. Compounds can be recommended by the bearing manufacturer to provide protection for several months to several years. After long-term storage, grease should be purged from the bearings and fresh grease injected prior to start-up. 12

17 EQUIPMENT LIFTING PROCEDURE SPREADER BAR LIFTING LUGS 1. All units are provided with a minimum of four lifting points for rigging attachment. All lifting points must be used. 2. Spreader bars are mandatory to prevent contact and damage to the unit by lifting hooks, straps, cables or chains. 13

18 ODOR CONTROL SECTION ODOR CONTROL MEDIA INSPECTION FREQUENCY CHART TYPE OF COOKING FREQUENCY EQUIPMENT IN DAYS LIGHT DUTY Ovens, steamers, and kettles MEDIUM DUTY Braising pans/tilting skillets, fryers, griddles, grooved griddles, open burner ranges, hot top ranges, and conveyor ovens HEAVY DUTY Gas and electric char broilers, upright broilers, woks and conveyor broilers EXTRA HEAVY DUTY Solid fuel broilers 14 ODOR CONTROL MEDIA MONITORING TUBE FORM NO. OCMM 797 (USE GREASE PENCIL) LAST REFILL DATE INITIAL LAST INSPECTION DATE INITIAL

19 ODOR CONTROL SECTION MEDIA MONITORING TUBE 15

20 ODOR CONTROL SECTION CYCLE AND SPRAY TIMERS Odor Spray System Control Cabinet Assembly Illustration No. Description Part # s 1 TPF Interior Wall Section NA 2 Cabinet 23" x 23" x 11" Deep NA 3 Time Delay Relays Level sensor /8" Copper Tubing NA 6 1/4" Flexible Suction Line Air Compressor Spray Nozzle Assembly Pressure Gauge Needle Valve Gallon (18.9 Liter) Container /4" Foot Valve Heater (optional)

21 ODOR CONTROL SECTION 17

22 EXHAUST FAN SECTION FIGURE 3 OPERATING POSITION (SIDE VIEW) FIGURE 1 SHIPPING POSITION (SIDE VIEW) FIGURE 2 EXPANDED ASSEMBLY FIGURE 4 ISOLATOR ADJUSTING 18

23 EXHAUST FAN SECTION (Continued) FAN SIZE "A" DIMENSION (IN INCHES) /8 5/16 11/ /8 7/16 9/ /8 5/8 3/ /8 1-1/16 1-1/ /8 1-1/4 1-3/8 TABLE 1 19

24 MAINTENANCE Approximate number of filter changes per year Light Duty Medium Heavy Extra Heavy 30/30 Filter Bag Filter Final Filter Odor Control Media type Total Filters changed per year

25 DESCRIPTION PARTS - MISCELLANEOUS PART NUMBER ILLUSTRATION Lift And Turn Latch Thermostat 12" Length 250 F N.O % After Filter % Pre Filter % Bag Filter % Final Filter C-150 Switch Relay CR1,2,6,7 Time Delay Relay Relay CR3 Relay CR4,5, Alarm Cancel Button Lights Red Green Clear Pressure Switch Fuse FU2,FU

26 WIRING DIAGRAM 22

27 FM-100 TERMINAL VOLTAGES TERMINAL DESCRIPTION FAN OFF FAN ON INT. FIRE L1 Main Power Connection : Hot 120 VAC 120 VAC 120 VAC L2 Main Power Connection : Neutral Common 31 Output to Supply Fan Motor Starter 0 VAC 120 VAC 0 VAC 33 Thermostat Return 0 VAC 0 VAC 120 VAC 34 Fused Supply to Press. Sw. & T-Stat. 120 VAC 120 VAC 120 VAC VAC Neutral Leg High Voltage Common 36 Spray Odor Power 0 VAC 120 VAC 0 VAC 38 Output to Exhaust Fan Motor Starter 0 VAC 120 VAC 0 VAC P1 Pressure Switch #1 - Pre-Filters 0 VAC See Note 1 0 VAC P2 Pressure Switch #2 - Bag Filters 0 VAC See Note 2 0 VAC P3 Pressure Switch #3 - Final Filters 0 VAC See Note 3 0 VAC P4 Pressure Switch #1 - Missing Filter 0 VAC See Note 4 0 VAC RF1 Remote On/Off Switch Terminals for RF2 RSPC-TPF N/A N/A N/A SF3 N.O. Dry Contacts for Supply Fan SF4 Remote Control Center Open Closed Open EF3 N.O. Dry Contacts for Exhaust Fan EF4 Remote Control Center Open Closed Open A11 N.O. Dry Contacts for Interface to A12 Building Fire Alarm / Monitor System Open Open Closed Q11 N.C. Dry Contacts for Interface to Q12 Fire System Fuel Shutoff Control Closed Closed Open LC Low Chemical (if unit has Spray Odor) See Note 5 See Note 5 See Note 5 Notes (1) Measures HIGH Pressure, when Filters are Dirty VAC when Pressure is HIGH & Fan is On (2) Measures HIGH Pressure, when Filters are Dirty VAC when Pressure is HIGH & Fan is On (3) Measures HIGH Pressure, when Filters are Dirty VAC when Pressure is HIGH & Fan is On (4) Measures LOW Pressure, when a Filter is Missing VAC when Pressure is LOW & Fan is On (5) Measures LOW Chemical VAC when Chemical is LOW (anytime) 23

28 LIMITED WARRANTY

29 WORLDWIDE SALES, MANUFACTURING AND SERVICE FOR THE NAME AND LOCATION OF THE NEAREST CERTIFIED SERVICE AGENCY, CALL,WRITE, OR TO: GAYLORD INDUSTRIES, INC. P.O. BOX S.W. AVERY STREET TUALATIN, OREGON U.S.A. Call: FAX: LOCAL SERVICE AGENCY FORM NO. TM CATPF 902 COPYRIGHT 2002, GAYLORD INDUSTRIES, INC. LITHO USA