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GAYLORD RSPC-ESP-OW Series Technical Manual

Pollution control unit
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Rev 09
Technical Manual
For
Installation, Operation
And 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

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Summary of Contents for GAYLORD RSPC-ESP-OW Series

  • Page 1 Rev 09 Technical Manual Installation, Operation And Maintenance 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 All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form by an electronic, mechanical, photocopying, recording means or otherwise without prior written permission of Gaylord Industries. ©Copyright 2016, Gaylord Industries...
  • Page 3 Page iii...
  • Page 4 Page iv This Page Intentionally Left Blank...

  • Page 5: Table Of Contents

    Page v Table of Contents Chapter 1 – Introduction About the Manual …………………………………….………………………………………………………………………………….. 1-1 Introduction…………………………………………….…………………………………………………………………………………….. 1-2 Basic Facts About Smoke …………………………..…………………………………………………………………………………. 1-2 Basic Facts About Odor …….……………………………………….…………………………………………………………………. 1-3 Grease Removal - The Important First Step ………………………………………………………………………………….. 1-3 Specifications ……………………………………………………………………………………………………………………………….. 1-4 Chapter 2 –...
  • Page 6 Page vi Table of Contents – Cont. Clogged Spray Nozzle ………………………………………………………………………………………………….………….. 4-35 Oscillating Wash …………………………………………………………………………………………………………………….. 4-38 Wash Control Cabinet ……………………………………………………………………………………………………….……. 4-41 Detergent Pump …………………………………………………………………………………………………………………….. 4-41 Detergent Flow Ratio ……………………………………………………………………………………………………………... 4-46 Detergent Consumption ……………………………………………………………………………………………………….… 4-47 Detergent Flow Switch ………………………………………………………………………………………………………….… 4-47 Line Strainer …………………………………………………………………………………………………………………………... 4-48 Backflow Preventer …………………………………………………………………………………………………………………...
  • Page 7 Page vii Table of Contents – Cont. Chapter 8 – Wiring Diagrams Eight Diagrams Beginning on Page ………………………………………………………………………………………………... 8-1 Appendix “A” – Receiving, Rigging and Storage Overview ………………………………………………………………………………………………………………………………………. A-1 Receiving ………………………………………………………………………………………………………………………………………. A-1 Safety Considerations ……………………..……………………………………………………………………………………………. A-1 Odor Control Media Short Term Storage ………………………………………………………………………………………. A-1 Exhaust Fan Receiving and Storage …………………………………………………………………………………………….…...
  • Page 8 Page viii This Page Intentionally Left Blank...
  • Page 9 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...

  • Page 10: Chapter 1 - Introduction

    The Gaylord pollution control unit, trademarked ClearAir, can be manufactured with either electrostatic precipitation (ESP) or Filtration (TPF). Gaylord Industries has been manufacturing ESP’s specifically designed for commercial kitchen exhaust systems since the early 1970’s, longer than any other manufacturer.

  • Page 11: Basic Facts About Odor

    The efficiency of a pollution control unit is based on how well it reduces the opacity level of a given airstream. The Gaylord ClearAir unit will reduce the opacity level below 20%, thereby meeting the requirements of environmental control agencies.

  • Page 12: Specifications

    Specifications General Furnish one (1) Gaylord ClearAir Pollution Control Unit model RSPC-ESP series as manufactured by Gaylord Industries of Tualatin, Oregon in accordance with the following: The pollution control unit shall consist of a smoke control section, odor control section (optional) and an exhaust fan section (optional) all built on a common base as an integral unit.
  • Page 13 The cabinet shall include one 5 gallon container of Gaylord Formula GS-710 Odor Neutralizer. The cabinet shall contain a heater to prevent freezing of the odor neutralizer, if mounted outdoors.
  • Page 14 Chapter 1 – Introduction, Page 1-6___________________________________________________________ Specifications (Cont.) Exhaust Fan Housing The exhaust fan section of the unit shall be enclosed with the same material as the smoke control section. There shall be a removable panel for access to the fan. Unit Construction The unit housing shall be constructed of a minimum of 16 gauge G90 bright galvanized steel.

  • Page 15: Model Number Chart

    ________________________________________________Chapter 2 – Models and Configuration, Page 2-1 Model Numbers The assigned model number of a ClearAir RSPC-ESP unit will indicate the number of Cell banks and if equipped with spray odor control, single or double pass odor control, if it has an exhaust fan plus other data.
  • Page 16 Chapter 2 – Models and Configuration, Page 2-2________________________________________________ Model Numbers (Cont.) Fan Type Centrifugal (shown) or Tubular Exhaust Fan Section (EFN) Plenum Section Optional Spray Odor (SPO) Odor Control (optional) Section (SO, DO) ESP Section ESP Cell Configuration (3 x 2) Debris Screens Odor Media or Impactor...

  • Page 17: Typical Installation

    ________________________________________________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 Chapter 2 – Models and Configuration, Page 2-4________________________________________________ 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: Sample Clearair Configurations

    ________________________________________________Chapter 2 – Models and Configuration, Page 2-5 Sample ClearAir Configurations The ClearAir unit is available in sizes ranging in capacity from 100 to 32,000 CFM (472 to 15,102 L/s). Each unit is equipped with Electrostatic Precipitators for smoke control, and may include and exhaust fan, odor abatement equipment and an Ansul fire extinguishing system as an option.
  • Page 20 Chapter 2 – Models and Configuration, Page 2-6________________________________________________ Sample ClearAir Configurations (Cont.) 1ESP = Single Pass Electrostatic Cells EFHS = Exhaust Fan, housed, spring isolated 2ESP = Double Pass Electrostatic Cells EFHN = Exhaust Fan, housed, not spring isolated = 30% After Filter - Optional = Optional Curtain Fire Damper DO = Double Pass Odor Control = Moisture Separator...

  • Page 21: Chapter 3 - Daily Operation

    Daily Operation Overview All functions of the Gaylord Ventilator and ClearAir Unit, such as starting the Exhaust Fan, starting the wash cycle, etc., are controlled by the Command Center located on the Main Control Cabinet (Refer to Figure 3-1-1). The ClearAir Unit contains an internal wash system that is activated each time the Exhaust Fan is turned off.
  • Page 22 Chapter 3 – Daily Operation, Page 3-2_________________________________________________________ Daily Operation (Cont.) Status Lights There are one or more Status Lights located on the face of the Main Command Center Cabinet to monitor the status of the ESP Cells (Refer to Figure 3-2-1) or it may be displayed on the Command Center Screen. There is a duplicate set of Status Lights mounted on the ClearAir unit.
  • Page 23 To stop the Exhaust Fan and begin the ClearAir Unit Wash Cycle push the STOP FAN button on the Gaylord Command Center (Refer to Figure 3-3-1). If the Command Center is programmed to stop the fan automatically then the STOP FAN button does not need to be pushed.

  • Page 24: Fire Cycle

    The National Fire Protection Association Standard 96, (NFPA-96) requires a fire extinguishing within the ClearAir unit. Typically this is wet chemical type furnished and installed at the Gaylord factory in a cabinet mounted on the ClearAir unit (Refer to Figure 3-4-1). If this system discharges, it must be recharged by a fire extinguishing system company before the Exhaust Fan can be restarted.

  • Page 25: Periodic Pressure Wash Or Steam Cleaning

    Operator Maintenance Detergent The detergent tank should be checked at least weekly and filled with the recommended detergent Gaylord Formula G-510EF. Refer to page 4-8 for details and ordering information. Formula G-510EF is non-corrosive and will not damage the aluminum plates of the ESP Cells. Caution; If a detergent other than Formula G- 510EF is used it must be of the type that will not harm aluminum.
  • Page 26 Chapter 3 – Daily Operation, Page 3-6_________________________________________________________ This Page Intentionally Left Blank...

  • Page 27: Principle Of Operation

    ___________________________________________________Chapter 4 – Smoke Control Section, Page 4-1 Smoke Control – Principle of Operation Principle of Operation The ClearAir Pollution Control Unit removes smoke particles by electrostatic precipitation. The principle of operation of electrostatic precipitation is actually quite basic. The electrostatic Cell is made up of a series of aluminum plates spaced approximately 1/4”...

  • Page 28: Smoke Control - Wash Cycle

    ESP Cells with hot detergent injected water to remove the daily accumulation of smoke and grease particles. If the ClearAir unit is connected to a Gaylord water wash Ventilator, the wash down systems and controls of the two are interfaced. There are two possible arrangements of controls for the operation of the Ventilator and the ClearAir Unit as illustrated on pages 2-4.
  • Page 29 ___________________________________________________Chapter 4 – Smoke Control Section, Page 4-3 Smoke Control – Wash Cycle (Cont.) Wash Manifolds Linkage Figure 4-3-1 Manifold Linkage Oscillating Motor Figure 4-3-2 Oscillating Motor...
  • Page 30 Chapter 4 – Smoke Control Section, Page 4-4___________________________________________________ Smoke Control – Wash Cycle (Cont.) Detergent Pump Detergent Flow Switch Control Compartment. Appearance may vary Brass Check depending upon Valve Model Number of Command Center. There is not a Temperature Command Center in Pressure Gauge the Control Compartment of Sub...
  • Page 31 From either the Main Control Cabinet or a Sub Panel there is a 1-1/4” hot water line to a pressure regulator, furnished by Gaylord, located at the water inlet of the ClearAir Unit. The pressure regulator must be set for a flow pressure of 30 psi min. – 50 psi max. There is a pressure gauge inside the plumbing compartment that houses the oscillating motor to assist in adjusting the flow pressure.
  • Page 32 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 the nameplate on the Command Center and contact Gaylord Industries. Refer to page 1-1 for contact information.
  • Page 33 ___________________________________________________Chapter 4 – Smoke Control Section, Page 4-7 Smoke Control – Wash Cycle (Cont.) Table 4-7-1 Model RSPC-ESP-OW Series Water Consumption Chart Single Pass ESP Base on a Minimum Flow Pressure of 30 PSI * Cell # of Total Total...

  • Page 34: Smoke Control - Wash Cycle - Recommend Detergent

    Chapter 4 – Smoke Control Section, Page 4-8___________________________________________________ Smoke Control – Wash Cycle – Recommend Detergent Overview Formula G-510EF is the only detergent recommended by Gaylord Industries for use in the wash down system of The Gaylord ClearAir Unit. Formula G-510EF is a concentrated colloid cleaner specially...
  • Page 35 CONSEQUENTIAL DAMAGES RESULTING FROM A BREACH OF THIS WARRANTY. IMPORTANT If a cleansing agent other than FORMULA G-510EF is used with The Gaylord Ventilator injection pump and solenoid valves, it is recommended that a warranty similar to the above be obtained from the manufacturer of said product, that the detergent has foaming properties similar to FORMULA G-510EF and that the above-referenced Warranty shall become null and void.

  • Page 36: Smoke Control - Maintenance

    C- 4-14-4. Note; Spare Cells are optional and must be ordered with the ClearAir Unit or may be ordered from the Gaylord Parts Department. NOTE: Some units are equipped with a second row of ESP Cells, referred to as double pass and denoted in the...
  • Page 37 second pass does not get as dirty as the first pass. __________________________________________________Chapter 4 – Smoke Control Section, Page 4-11 Smoke Control – Maintenance (Cont.) ESP Cell Rotation – Cont. It is recommended that the Cells be rotated out by row (Refer to Figure 4-15-1). So, for example, if the ClearAir unit is 3 rows high, in the first rotation all the Cells in row #1 would be removed and replaced with clean spare Cells.
  • Page 38 removed from the ESP Cells and the Cells removed. Chapter 4 – Smoke Control Section, Page 4-12__________________________________________________ Smoke Control – Maintenance (Cont.) Standard Safety Voltage Test – Cont. Figure 4-12-1 Figure 4-12-2 Ionizer Voltage Test Collector Voltage Test Cell Rotation Procedure 1.
  • Page 39 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-13 Smoke Control – Maintenance (Cont.) Cell Rotation Procedure – Cont. Re-connect the 3 lead wires to the terminals on the Outer Cell. Close the Cell and Electrical Compartment doors. 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.
  • Page 40 Chapter 4 – Smoke Control Section, Page 4-14__________________________________________________ Smoke Control – Maintenance (Cont. Figure 4-13-3 Typical Outer Cell Inner Cell with Springs Not Shown Spare Cell Chart Table T-4-14-1 (Recommended Quantities) Spare Cells Size of Unit Outer Cell Inner Cell 1 Cell Unit 2 Cell Unit 3 Cell Unit...
  • Page 41 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-15 Smoke Control – Maintenance (Cont.) Figure 4-15-1 Cell Configuration The following illustrations show the standard Cell configurations. O = Outer Cell The # 1 row is always the bottom row. The Outer Cell, (O) is always l = Inner Cell the first Cell next to the Cell access door.
  • Page 42 Chapter 4 – Smoke Control Section, Page 4-16__________________________________________________ Smoke Control – Maintenance (Cont.) Cell Identification Figure 4-16-1 Outer Cell Nameplate Cell Identification Figure 4-16-2 Outer Cell Nameplate...
  • Page 43 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-17 Smoke Control – Maintenance (Cont.) ESP Cells Slide Into These Two Racks – Not Installed For This Photo Plumbing Compartment Electrical Compartment Oscillating Manifold Motor Transformer Pressure Gauge Plunger Safety Switch Transformer Drain Cooling Fan Figure 4-17-1...
  • Page 44 Detergent The detergent tank should be checked at least weekly and filled with the recommended detergent Gaylord Formula G-510EF. Refer to page 4-8 for details and ordering information. Formula G- 510EF is non-corrosive and will not damage the aluminum plates of the ESP Cells. Caution; If a detergent other than Formula G-510EF is used it must be of the type that will not harm aluminum.
  • Page 45 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-19 Smoke Control – Maintenance (Cont.) Six Month Maintenance Every 6 months remove and inspect the ESP Cells and check the following: Extreme Caution: Before removing the lead wires from Cells, a Standard Safety Voltage Test must be conducted as described on page 4-11.

  • Page 46: Smoke Control - Troubleshooting

    Chapter 4 – Smoke Control Section, Page 4-20__________________________________________________ Smoke Control – Troubleshooting Overview Proper voltage through the ESP Cells is essential for maximum smoke removal. There is one or more power supply Transformers located in the electrical compartment of the ClearAir unit (Refer to Figure 4-17-1). The quantity is dictated by the number of Cells, but typically there is one transformer(s) for every row of Cells.
  • Page 47 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-21 Smoke Control – Troubleshooting (Cont.) Chart C-4-21-1 Troubleshooting Smoke Control – ESP Cells (Cont.) Symptom Probable Cause Corrective Action Green light off (cont.) 1. Faulty Cell. Possible causes For all three possible causes first are: perform the tests following the a.

  • Page 48: Smoke Control - Troubleshooting (Charts)

    Chapter 4 – Smoke Control Section, Page 4-22__________________________________________________ Smoke Control – Troubleshooting Green ESP Light Off Condition Use the following flow chart as a guide to troubleshoot a green light off condition. Then refer to the specific test procedures. Check Voltages at the Wire to Cell Connection Points.

  • Page 49: Testing Voltages At The Cell Connection Points

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-23 Smoke Control – Troubleshooting (Cont.) Testing Voltages at the Cell Connection Points To check for proper voltages, proceed as follows: 1. Open the Electrical Compartment door first (the smaller door) and then the Cell/Plumbing Compartment door.

  • Page 50: Testing Plunger Safety Switch

    Chapter 4 – Smoke Control Section, Page 4-24__________________________________________________ Smoke Control – Troubleshooting (Cont.) Testing Plunger Safety Switch 1. There is one or more Plunger Safety Switch located in the Electrical Compartment (Refer to Figure 17-1 and 4-24-1). The Plunger Safety Switch, when released by opening the Electrical Compartment door, shuts off the power to the power supply transformer and bleeds power from the transformer, by the Grounding Disc making contact with the brass grounding screws (Refer to Figure 4-17-1, 4-24-...

  • Page 51: Transformer Voltage Test

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-25 Smoke Control – Troubleshooting (Cont.) Transformer Voltage Test Extreme Caution: Before removing the lead wires from the Transformer a Pre-Transformer Voltage Test must be conducted as described in steps 1 and 2 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.
  • Page 52 Chapter 4 – Smoke Control Section, Page 4-26__________________________________________________ Smoke Control – Troubleshooting (Cont.) Transformer Voltage Test – (Cont.) Collector Voltage Test Disconnect the high voltage wires from the power supply points “COLL” and “ION” (Refer to Figure 4-26-1 and 4-26-2). Set selector switch on volt meter to the highest DCV scale.

  • Page 53: Testing Esp Cells

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-27 Smoke Control – Troubleshooting (Cont.) Testing ESP Cells To check for proper operation of each Cell, proceed as follows: Note: The lack of a Green light may be caused by more the one Cell failing. It is recommended that the following tests be conducted on all Cells.
  • Page 54 Chapter 4 – Smoke Control Section, Page 4-28__________________________________________________ Smoke Control – Troubleshooting (Cont.) Testing Inner Cells Note: the next set of tests requires two test wires with an alligator clip on each end. Note: the next set of tests requires removal of all the Inner Cells. ClearAir units wider than 2 Cells wide the 3 and 4 Cells are difficult to remove without the use of a long handled tool.

  • Page 55: Shorting Cell Plates

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-29 Smoke Control – Troubleshooting (Cont.) Testing Inner Cells – (Cont.) 5KV Spring Connection Point Ground Spring Connection Point 10KV Spring Connection Point Figure 4-29-1 Inner Cell – End View Shorting Cell Plates There are three primary causes of an ESP Cell shorting.

  • Page 56: Replacing Ionizing Wires

    Chapter 4 – Smoke Control Section, Page 4-30__________________________________________________ Smoke Control – Troubleshooting (Cont.) Replacing the Ionizing Wires To replace an Ionizing Wire place the Cell on a work bench and proceed as follows: 1. Remove all of the broken wires from the Cell mounting brackets (Refer to Figure 4-30-1).

  • Page 57: Wash System - Troubleshooting

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-31 Wash System – Troubleshooting Using the Troubleshooting Charts The following Troubleshooting Charts are designed to easily find common problems with the wash system, 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.

  • Page 58: Wash System Troubleshooting Charts

    1 Refer to Page 4-50 for instructions. not come on when in a solenoid valve. wash cycle. Malfunction in the Gaylord Refer to the Technical Manual for Command Center or other the specific control for instructions Gaylord Stop and Start Controller.
  • Page 59 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-33 Wash System – Troubleshooting (Cont.) Chart C-4-33-1 Troubleshooting the Wash System – Backflow Preventer Symptom Probable Cause Corrective Action 1 Intermittent discharge of A. Intermittent discharge of 1 No action necessary. water. water through the relief valve is fairly common and usually occurs if there is inlet...

  • Page 60: Inadequate Washing Of The Esp Cells

    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 the nameplate on your Command Center and contact Gaylord Industries. Refer to page 1-1 for contact information.

  • Page 61: Clogged Spray Nozzle

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-35 Wash System – Troubleshooting (Cont.) 4. Clogged Spray Nozzle To check for a clogged spray nozzle proceed as follows: Extreme Caution: Before removing the lead wires from Cells, a Standard Safety Voltage Test must be conducted as described on page 4-11.
  • Page 62 Chapter 4 – Smoke Control Section, Page 4-36__________________________________________________ Wash System – Troubleshooting (Cont.) Clogged Spray Nozzle – Cont. Manifold Extension Pipe Square Manifold Linkage Figure 4-36-1 Motor Manifold Removing a Standard Manifold. 1. The Standard Manifolds 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).
  • Page 63 _________________________________________________Chapter 4 – Smoke Control Section, Page 4-37 Wash System – Troubleshooting (Cont.) Removing and Replacing Nozzles Procedure Clogged nozzles may be cleaned by soaking in vinegar but it is recommended that they be replaced with a new one. Also, the gasket on the back side of the nozzle is not replaceable so if damaged the nozzle must be replaced.

  • Page 64: Oscillating Wash

    Chapter 4 – Smoke Control Section, Page 4-38__________________________________________________ Wash System – Troubleshooting (Cont.) 5. Oscillating Wash To check to see if the wash manifolds are oscillating proceed as follows: a) Open the Electrical and Cell/Plumbing Compartment access doors. b) Initiate a wash cycle and check to see if the motor drive is moving and that the clamp is holding the manifold so the manifold is moving back and forth (Refer to Figure 4-39-1).
  • Page 65 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-39 Wash System – Troubleshooting (Cont.) Oscillating Wash - Cont. Brass Swivel Elbow Shaft Clamp Water Supply Pipe Union Conduits Figure 4-39-1 Plumbing Compartment Upper Section e) To replace the motor proceed as follows: 1) Slide the new motor over the manifold.
  • Page 66 Chapter 4 – Smoke Control Section, Page 4-40__________________________________________________ Wash System – Troubleshooting (Cont.) Oscillating Wash - Cont. 9) To check, initiate the wash cycle and observe the motor drive moving back and forth. Shaft Clamp “C” Ring Position Indicator Ring Position Indicator “0”...

  • Page 67: Wash Control Cabinet

    __________________________________________________Chapter 4 – Smoke Control Section, Page 4-41 Wash System – Troubleshooting (Cont.) Wash Control Cabinet Detergent Pump Detergent Flow Switch Control Compartment. Appearance may vary Brass Check depending upon Valve Model Number of Control. There is not a Control Compartment Temperature on Sub Panels.
  • Page 68 Chapter 4 – Smoke Control Section, Page 4-42__________________________________________________ Wash System – Troubleshooting (Cont.) Detergent Pump – Initial Operation (Cont.) If the pump does not self-prime, an air lock may have developed within the pump head and the following action should be taken: 1.
  • Page 69 __________________________________________________Chapter 4 – Smoke Control Section, Page 4-43 Wash System – Troubleshooting (Cont.) Detergent Pump – Cont 7) Replace Foot Valve and test. 8) If the Foot Valve does not operate properly after cleaning replace with a new one. Figure 4-43-1 Foot Valve Figure 4-43-2 Foot Valve...
  • Page 70 Chapter 4 – Smoke Control Section, Page 4-44_________________________________________________ Wash System – Troubleshooting (Cont.) Detergent Pump – Cont. 4) Remove the Top Cap (Figure 4-45-1, Pc. 21) and then remove the Spring (Figure 4-45-1, Pc 11) and the Poppet Check (Figure 4-45-1, Pc. 12). Repeat this procedure for the Bottom Adaptor (Figure 4-45-1, Pc.10) 5) Inspect the Pump Head for cracks and replace with a complete new Pump Head if necessary.
  • Page 71 _________________________________________________Chapter 4 – Smoke Control Section, Page 4-45 Wash System – Troubleshooting (Cont.) Figure 4-45-1 Figure 4-45-2 Detergent Pump Pump Head Exploded View Exploded View Detergent Pump Motor If is determined that the pump motor is burned out the entire Detergent Pump must be replaced. To remove the pump, proceed as follows: 1.
  • Page 72 Chapter 4 – Smoke Control Section, Page 4-46_________________________________________________ Wash System – Troubleshooting (Cont.) Detergent Pump – Cont. Detergent Flow Ratio The Detergent to water ratio is determined by the setting on the Adjustable Cam located on the end of the motor shaft (Refer to Figure 4-46-1).
  • Page 73 _________________________________________________Chapter 4 – Smoke Control Section, Page 4-47 Wash System – Troubleshooting (Cont.) Detergent Pump – Cont. The following Detergent Consumption Chart shows the approximate amount of detergent used with different Cam Settings with the pump pumping against a water pressure of 30 psi. Chart C-4-47-1 Detergent Consumption Chart Length of Wash Cycle...

  • Page 74: Line Strainer

    Chapter 4 – Smoke Control Section, Page 4-48_________________________________________________ Wash System – Troubleshooting (Cont.) Line Strainer The Line Strainer (Refer to Figure 4-48-1 and 4-48-2) prevents foreign material from going downstream and causing the Reduced Pressure Principle Device, Solenoid Valves and the ClearAir water spray nozzles to malfunction.
  • Page 75 _________________________________________________Chapter 4 – Smoke Control Section, Page 4-49 Wash System – Troubleshooting (Cont.) Backflow Preventer – Cont. Initial Start-Up To avoid water hammer or shock damage, perform the following initial start-up procedures: 1. Close the Outlet Hand Valve. 2. Open the Inlet Hand Valve slowly, fill the valve and bleed the air through test cock number 2, 3, and 4. 3.

  • Page 76: Water Solenoid Valve

    Chapter 4 – Smoke Control Section, Page 4-50_________________________________________________ Wash System – Troubleshooting (Cont.) Water Solenoid Valve Overview Depending upon the number of ESP Cells, one or more water Solenoid Valves is located at the bottom of the Plumbing Compartment (Refer to Figure 4-50-1). The Solenoid Valve(s) is controlled by the Command Center.
  • Page 77 _________________________________________________Chapter 4 – Smoke Control Section, Page 4-51 Wash System – Troubleshooting (Cont.) Water Solenoid Valve (Cont.) If solenoid valve sticking is a recurring problem, it indicates that foreign material in the water supply line is escaping through the line strainer located in the Wash Control Cabinet. The screen in the line strainer should be removed, checked for holes, and cleaned.
  • Page 78 Chapter 4 – Smoke Control Section, Page 4-52_________________________________________________ RSPC-ESP Drain...

  • Page 79: Media Panel Type Odor Control

    ____________________________________________________Chapter 5 – Odor Control Section, Page 5-1 Odor Control Overview ClearAir Units are available with two types of odor control, a media bed type or a spray odor control. There are two types of media beds, one is called the Loose Fill type and the other is called the Media Panel type.
  • Page 80 Chapter 5 – Odor Control Section, Page 5-2____________________________________________________ Odor Control - Maintenance Maintenance – Media Panel Type Generally the life of the Odor Control Media is the number of days shown in Table T-5-2-1. However every cooking condition varies and therefore it is important to establish the frequency of inspection and replacement of the media.
  • Page 81 Refer to page 5-4 for contact information. Once the media in the Monitoring Tube has expended, and you wish to continue checking with the Media Monitoring Tube it must be replaced with a new one. To order new Media Monitor Tube contact Gaylord Industries. Replacing Media Panels Caution: Each Module weighs approximately 28 lbs.
  • Page 82 Chapter 5 – Odor Control Section, Page 5-4___________________________________________________ Odor Control – Maintenance (Cont.) Ordering New Media Panels The Media Panels slide into Modules, and there are two Media Panels per Module (Refer to Figure 5-3-2). To order new Medial Panels contact Green Ladder Technologies. Green Ladder Technologies, LLC 1502 Louis Bork Drive Batavia, IL 60510...
  • Page 83 ___________________________________________________Chapter 5 – Odor Control Section, Page 5-5 Odor Control – Maintenance (Cont.) Caution - Exhaust fan must be off before opening the odor control media access door. Refilling the Modules is a relatively simple task not requiring any special tools. Follow steps 1-15: Turn off exhaust fan.

  • Page 84: Spray Odor Control - Overview

    Chapter 5 – Odor Control Section, Page 5-6____________________________________________________ Spray Odor Control Overview The Spray Odor Control system is housed in a cabinet mounted on the ClearAir Unit (refer to Figure 5-6- 1). The major components are a spray nozzle, air compressor, timers and a 5 gallon tank to hold the Spray Odor solution.

  • Page 85: Spray Odor Control - Maintenance

    ____________________________________________________Chapter 5 – Odor Control Section, Page 5-7 Spray Odor Control Setting the Timers CAUTION: Always de-energize the ClearAir Unit before opening the Electrical and Timer Control Panel inside the Odor Spray Cabinet. The Spray Odor Control unit operates on spray-on and spray-off timed cycles while the ClearAir Unit is in the “Fan On”...
  • Page 86 We recommend the use of FORMULA GS-710. This material has been effective at removing between 80% and 90% of the odors from the kitchen exhaust in many applications. For the contact information of the nearest FORMULA GS-710 distributor, contact Gaylord Industries. Gaylord Industries...

  • Page 87: Overview

    _____________________________________________________Chapter 6 – Exhaust Fan Section, Page 6-1 Exhaust Fan – Initial Set-Up Overview The exhaust fan in the ClearAir Unit is a heavy duty type. The size of the fan, motor, and drives has been chosen for the most efficient operation. Initial Set-Up For shipping purposes the leveling bolt on the spring isolators under the fan have been screwed down and the entire fan assembly strapped down.

  • Page 88: Pre-Operational Maintenance

    Chapter 6 – Exhaust Fan Section, Page 6-2_____________________________________________________ Exhaust Fan – Initial Set-Up (Cont.) Access Panels to Spring Isolators Figure 6-2-1 Access to Spring Isolators Pre-Operational Maintenance Before starting the exhaust fan perform the following pre- operational maintenance: 1. Set screws & Belts: a) Rotate fan impeller to check for shifting that may have occurred during shipment.

  • Page 89: Idle Fan Requirements

    ___________________________________________________Chapter 6 – Exhaust Fan Section, Page 6-3 Exhaust Fan – Initial Set-Up (Cont.) Idle Fan Requirements 1. If the fan is going to sit idle for any length of time, rotate the wheel several revolutions every three to five days to keep a coating of grease on all internal bearing parts. Turn the wheel by hand while greasing bearings.

  • Page 90: Troubleshooting

    Chapter 6 – Exhaust Fan Section, Page 6-4_____________________________________________________ Exhaust Fan - Troubleshooting Chart C-6-4-1 Exhaust Fan Troubleshooting Troubleshooting – Exhaust Fan Symptom Probable Cause Corrective Action Reduced Airflow 1. Fan wheel turning in the 1. Re-wire fan motor. wrong direction. ** 2.

  • Page 91: Overview

    _________________________________________________________________Chapter 7 – Parts, Page 7-1 Parts – Miscellaneous Overview The parts shown on the following pages are available from a Gaylord Certified Service Agency (CSA). For the location of your nearest CSA please go to www.galordventilation.com and click on Service Agency Locator.
  • Page 92 Chapter 7 - Parts, Page 7-2_________________________________________________________________ Parts – Miscellaneous – Cont. Table T-7-2-1 Parts List Miscellaneous (Cont) Gaylord Description Photo/Illustration Part # 10324 Quick Disconnect 20323 1/4 Turn Door Latch 19547 Key for Latch 19548 Lift and Turn Latch 16547 “T”...
  • Page 93 _________________________________________________________________Chapter 7 – Parts, Page 7-3 Parts – Miscellaneous – Cont. Table T-7-3-1 Parts List Miscellaneous (Cont.) Gaylord Description Photo/Illustration Part # Soak Tank (24” Cells) 12801 Debris Screen 30167 Impactor Filter 20006 Moisture Separator 30080 Not Illustrated Vermiculite Gasket...

  • Page 94: Parts List - Esp Cells

    Chapter 7 – Parts, Page 7-4_________________________________________________________________ Parts – ESP Cells Figure 7-4-1 ESP Cells Table T-7-4-1 Cell Parts List Gaylord Description Part # Ionizer Insulator (same as Plate Insulator) 19833 Wire Terminal Stud 14753 Instruction Label – Outer Cell 16846 Instruction Label –...

  • Page 95: Parts List - Electrical Compartment

    _________________________________________________________________Chapter 7 - Parts, Page 7-5 Parts – Electrical Compartment Table T-7-5-1 Electrical Compartment Parts List Gaylord Description Part # Cell Access Door Safety Switch 30431 Not Illustrated High Voltage Transformer/Power 16514 Supply (for 1-4 Cells) Electrical Compartment Plunger 12798...

  • Page 96: Parts List - Main Electrical Compartment

    Gaylord Description Part # Terminal Block(Refer to Gaylord Varies submittal drawings for part #) Fuse Block ( Refer to Gaylord Varies submittal drawings for part #) Fuses ( Refer to Gaylord submittal Varies drawings for part #) Motor Starter ( Refer to Gaylord...

  • Page 97: Parts List - Wash Control Cabinet

    Parts – Wash Control Cabinet Figure 7-7-1 Typical Wash Control Cabinet Table T-7-7-1 Washdown Control Cabinet Plumbing Parts List Description Gaylord Part # 17140 Line Strainer – 1.25” 50287 Air Gap Assembly for Backflow Preventer for 1.25” 11319 Reduced Pressure Principle Backflow Preventer – 1.25”...
  • Page 98 Chapter 7 - Parts, Page 7-8_________________________________________________________________ Parts – Detergent Pump Figure 7-8-1 Detergent Pump Exploded View Table T-7-8-1 Detergent Pump Parts List GAYLORD DECRIPTION PART NO. Detergent Pump - Complete 10222 Electrical J-Box (not sold separately) Pump Motor (not sold separately) Detergent Pump Test Switch 10238 Pump Head Screws (sold with Kit Part No.

  • Page 99: Parts List - Spray Odor Control

    Pieces 5 and 6 not shown Pieces 12 and 13 not shown Figure 7-9-1 Spray Odor Control Cabinet Table T-7-9-1 Odor Control Parts List Gaylord PC # Description Part # Spray Odor Control Cabinet 19119 1/4” I.D. Flexible Suction Tube...
  • Page 100 Chapter 7 - Parts, Page 7-10________________________________________________________________ This Page Intentionally Left Blank...
  • Page 101 _________________________________________________________Chapter 8 –Wiring Diagram, 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...
  • 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: Overview

    __________________________________________Appendix A – Receiving, Rigging and Storage, Page A-1 Receiving Overview 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 the sections back together.

  • Page 110: Rigging

    Appendix A – Receiving, Rigging and Storage, Page A-2__________________________________________ Rigging Instructions All units are provided with a minimum of four (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.
  • Page 111 ____________________________________________________________Appendix B – Assembly, Page B-1 Assembly Overview Typically, ClearAir units are shipped as one piece and no unit assemble is required. Sometimes, for building accessibility reasons, the unit is shipped in multiple pieces. If this is the case, use the following instructions to assemble.

  • Page 112: Appendix B - Assembly

    Appendix B – Assembly, Page B-2____________________________________________________________ This Page Intentionally Left Blank...

  • Page 113: Appendix "C" - Installation

    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.
  • Page 114 Appendix C – Installation, Page C-2___________________________________________________________ This Page Intentionally Left Blank...

  • Page 115: Appendix "D" - Nameplate

    __________________________________________________________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 Sheet

    _______________________________Appendix E – Cell Rotation and Filter Cleaning Log Sheets, Page E-1 Chart E-1-1 Cell Rotation and Filter Cleaning Log Sheet ESP Cell Debris Screen or Impactor Date Number Filter, and Moisture Comments Changed Separator Cleaned...
  • Page 118 Appendix E – Cell Rotation and Filter Cleaning Log Sheets, Page E-2________________________________ This Page Intentionally Left Blank...

  • Page 119: Overview

    Pre Start-Up Check Overview As one of the benefits of purchasing a Gaylord ClearAir Unit is a complete Start-Up Inspection is performed by a Gaylord Authorized Representative or a Gaylord Certified Service Agency. These tests must be conducted prior to use by the operator. Typically at the time the Start-Up Inspection is performed, the operation and general maintenance of the Gaylord equipment is demonstrated and described to the operating personnel.
  • Page 120 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.
  • Page 121 Appendix F – Startup, Inspection and Tests, Page F-3____________________________________________ ClearAir Start-Up Inspection and Test Report – Page 2 Operational Check List ESP Section 1. ___ Close and latch all access doors and panels. 2. ___ Verify that all circuit breakers are on and power is supplied to the ClearAir Unit. 3.
  • Page 122 1. Explain Daily Operation beginning on page 3-1. _____ (CSA Initial) 2. Thoroughly review the required Operator Maintenance beginning on Page 3-5. ____ (CSA Initial) 3. Provide a copy of the Gaylord Technical Manual for Installation, Operation, and Maintenance. ____ (CSA Initial) 4.

  • Page 123: Limited Warranty

    The Manufacturer’s obligation under this warranty and any warranties implied by law shall be limited to repairing or replacing at its option any part of said equipment when either Gaylord Industries, or the Licensed Gaylord Manufacturer’s examination shall disclose to its satisfaction to be thus defective, for a period of one (1) year from the date of beneficial use, or eighteen months from date of shipment, whichever occurs first, provided proper and acceptable evidence of such is recorded at the factory.
  • Page 124 © Copyright 2016 Gaylord Industries Litho in U.S.A. Form Number TM-RSPC-ESP-OW Rev 09 082016/20927...

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