Document 477102 Thermo Recovery Filter™ System Installation, Operation and Maintenance Manual Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Thermo Recovery Filter™ System WARNING Electrical shock hazard. Product contains electrically activated components. This can cause equipment damage, personal injury, or death. Service must only be performed by personnel that are knowledgeable in the operation of the equipment being controlled. Read the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment. DANGER Always disconnect power before working on or near the control panel provided. Lock and tag the disconnect switch or breaker to prevent accidental power up. CAUTION All field installation of electrical equipment must be done to meet all NEC and electrical codes. General Description Description and Purpose The Thermo Recovery Filter™ system is an arrangement of high efficiency grease filters with heat recovery coils to be mounted in a commercial kitchen hood and piped back to an existing water heater. While the smoke and effluent generated off the commercial cooking appliances will naturally be filtered, the heat generated by the cooking process will be used to preheat water being supplied to the water heater, thus reducing operating expenses and the need for larger and more expensive hot water heaters. Product Application The product is designed for Type I hood systems to replace existing kitchen hood filters. It needs to be connected to the building’s existing water supply. Thermo Recovery Filter System 1 Table of Contents Receiving, Unpacking, Handling, Storage . . . . . . . . . 2 Installation Components and Installing Control Cabinet. . . . . . 2 System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 3 Plumbing and Electrical Requirements. . . . . . . . . . 4 Control Cabinet Layout. . . . . . . . . . . . . . . . . . . . . . 4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Balancing and Testing Methods. . . . . . . . . . . . . . . . 6-7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Codes and Standards. . . . . . . . . . . . . . . . . . . . . . . . . 8 Our Commitment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Receiving - Upon receiving the product, check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notification on the delivery receipt acknowledging any damage to the product. All damage should be noted on all of the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report must be filled out by the carrier upon arrival and reported to the Traffic Department. If damaged upon arrival, file a claim with the carrier. Any physical damage to the unit after acceptance is not the responsibility of the manufacturer. Unpacking - Verify that all of the required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Confirmation of shipment(s) must be limited only to items on the bill of lading. Handling - Make sure the equipment does not suffer any heavy vibration or knocks. Handle in such a manner as to keep from scratching or chipping any coating. Damaged finish may reduce the ability of unit to resist corrosion. Storage - Products are protected against damage during shipment. If the product must be stored prior to installation, it must be protected from dirt and moisture. Indoor storage is highly recommended. For outdoor storage, cover the control package with a tarp to keep it clean, dry. The user assumes responsibility of the equipment and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user. NOTE Improper storage which results in damage to the unit will void the warranty. 2 Thermo Recovery Filter System Installation NOTE All installation must follow local plumbing and electrical codes. Components Components included with the energy recovery filtration system. Quantity varies Description 20 inch wide x 20 inch high (50.80 x 50.80 cm) special energy recovery filters with quick couplers/hoses attached 2 3/8 inch (0.95 cm) UL Listed hood penetration seal 1 18 inch (45.72 cm) stainless steel hose 1 24 inch (60.96 cm) stainless steel hose 1 24 inch high x 36 inch wide x 14 inch deep (60.96 x 91.44 x 35.56 cm) control cabinet 1 Male disconnect 1 Female disconnect 1 Filter spacer Installing Control Cabinet The cabinet should be mounted to a secure surface through the holes around the back perimeter of the cabinet. Use at least six (6) mounting holes evenly spaced around the back perimeter of the cabinet. If the pre-drilled holes do not work, drill additional holes around the perimeter for mounting. The cabinet will weigh approximately 85 pounds (38.56 kg). NOTE It is the responsibility of the installer to ensure studs or other structural members should be the point of fastening when attaching this cabinet to a wall. Cabinet shoul a secure surf holes around perimeter of t Use at least holes evenly s back perimete If the pre-dri work, drill add around the pe mounting. System Installation 7 TO FILTERS 3/4 INCH FNPT CONNECTION FLOW 7 6 HOOD TOP HOOD TOP 8 10 9 FLOW FROM FILTERS 3/4 INCH FNPT CONNECTION 12 TO WATER HEATER FROM WATER SUPPLY LINE 1 INCH FNPT CONNECTION 1 INCH FNPT CONNECTION 2 13 MUST BE IN ACCESSIBLE LOCATION FOR TESTING 11 3 1 4 5 TO DRAIN 3/4 INCH FNPT CONNECTION WATER HEATER PIPING PROVIDED BY PLUMBER 0.75 to 0.875 inch (19.0 to 22.2 mm) diameter hole ITEM QTY 1 1 DESCRIPTION Control Cabinet 2 1 Temperature / Pressure Gauge Incoming Water 3 1 Temperature / Pressure Gauge Heated Water 4 1 Pushbutton Switch, Pressure Release 5 1 Pushbutton Switch, System ON/OFF 6 6 20 x 20-inch Filter Assembly 7 2 3/8-inch FNPT Hood Penetration Seal, (one 11/8 inch hole) 8 1 18 inch Stainless Steel Hose 9 1 3/8-inch Quick Disconnect 10 1 24-inch Stainless Steel Hose 11 1 Thermal Expansion Tank (provided by others) 12 1 Water Hammer Arrestor (provided by others) 13 1 3/4-inch Turn Ball Valve To Test Flow Rate (provided by others) 4. Attach the 18 inch stainless steel hose (item 8) to the left-most hood penetration seal, and the 24 inch stainless steel hose (item 10) to the right-most hood penetration seal. 5. Attach the extra female coupler to the 18 inch hose (item 8) on left end of the hood, and the male coupler to the 24 inch hose (item 10) on the right end of the hood. 6. Install new filters in hood from left to right. Hook up the quick-connect couplers between the filter 8 assemblies. 7 7. If applicable, install adjustable filter spacers to fill in Used 297309 CAD Drawing from Tyler Schilling. Emailed to Barbon onthe March 22, ends. 2011 the gap(s) hood 10 Updated the PN of the Resistive Temperature Detector to 384925 as provided in edits from Aaron Van Krey - October 18, 2 8. Install all other plumbing, as shown on this drawing. 9 Please refer to plumbing requirements section May 10, 2013 - used this drawing for the ThermoGreen Filter System. Use the quik-seal part found in theon Temperature Int page for more information. Installation Instruction drawing for the hood. Remove the4Octagon Extension and the J-Box Plate (cover). Deleted other portions of the drawing which are relevent theelectrical ThermoGreen Filter System 9.not Make all oftothe connections. Please refer to 3. Install a hood penetration seal (item 7) in the hood electrical requirements section on page 4 for more top above the filter rack. To do this, disassemble the information. compression seal and insert the seal into the hole from the inside of the hood making sure the gasket is placed on the 3/8 inch UL Listed Hood Penetration Seal fitting before PN 451167 Gasket inserting it into the hole. Hood Install the lock Lock Washer Nut washer and INTERIOR OF HOOD nut and tighten securely as shown. EXTERIOR OF HOOD 1. Remove the existing filter(s) from commercial kitchen Hood Surface hood. 2. Drill two 11⁄8-inch holes in the hood top above the filter rack, one Hood Surface close to the left and one close 1-1/8 inch to the right side (2.86 cm) diameter hole of the hood. Thermo Recovery Filter System 3 Plumbing Requirements 1. Connect the main water supply connection to the 1-inch FNPT connection labeled “FROM WATER SUPPLY”. NOTE The water supply line must be pressurized to 40 PSI minimum. 2. Provide the piping from the water heater to the 1-inch FNPT connection labeled “TO WATER HEATER”. 3. Provide the piping from the left-most hood penetration seal on hood to the 3/4-inch FNPT connection labeled “TO FILTERS”. 4. Provide piping from the right-most hood penetration seal on the hood to the 3/4-inch FNPT connection labeled “FROM FILTERS”. In line within this pipe run, provide a water hammer arrestor (provided by others), a thermal expansion tank (provided by others), and a 3/4-inch turn ball valve to test the flow rate (provided by others). This ball valve needs to be in an accessible location for testing. 5. Provide piping to an external drain from the 3/4-inch FNPT connection labeled “TO DRAIN”. Electrical Requirements WARNING In colder climates, leave this jumper installed so the pump operates in recirculation mode during frigid periods when fan is not running. If cold air enters through the exhaust fan(s) when the fan(s) are off and the pump isn’t running, the pipes and filters may potentially rupture and damage the energy recovery filter system. Control Cabinet Layout Pressure and Temperature Gauges Pressure Relief Connection Electrical Controls System Pressure Release Throttle Valve Shut Off Valve Pump ON/OFF N1 N1 Pump Switch RD BK Pump Switch INT-A RD BK INT-A R2 11R214 11 14 R3 INT-B RD INT-B RD BK R1 BK 11R114 11 14 Pump P1H P1H 11 14 L1 Pressure Release BKPressure Release P1 WT P1N WT P1N Pressure Release Solenoid Valve CONTROL INPUT: 120 VAC, Pressure Release Solenoid Valve WT 15 AMPS FROM BREAKER BK SVH BK SVH H1 SVN SV BK SV FROM FILTERS PS LT1 PS BK Pump WT P1 BK TO FILTERS TO WATER HEATER WT R1 A2 A1 R1 A2LT1A1 11R314 WT SVN SHUT OFF VALVE WT WT FROM WATER SUPPLY N WT WT N1 1. Connect 120 VAC power from a 15 amp breaker to terminals H1 and N1. CONTROL INPUT: 120 VAC, N L1 15 AMPS FROM BREAKER L1 CONTROL INPUT: 120VAC, 15AMPS FROM BREAKER N H1 L1 CONTROL INPUT: 120VAC, 15AMPS FROM BREAKER N N1 H1BK Pump Switch R2 RD RD WT N1 R1 11 14 H1 A2 A1 N1 LT1 2. We provide two different relays to PSinterlock with an 11 14 external fan run signal. Pump R1 WT BK WT BK P1 P1H • Connect112414 VAC from the hood fanP1Ninterlock to terminals F-24A and F-24B if 24 VAC is utilized in Pressure Release Solenoid Valve Pressure Release the fan control panel (provided by others). WT BK WT BK SVH SVN SV OR• Connect 120 VAC from the hood fan interlock to terminals F-120A and F-120B if 120 VAC is utilized in the fan control panel (provided by others). R3 24 VAC From Hood Fan Interlock F-24A 4 Circulation Pump N CONTROL INPUT: 120VAC, 15AMPS FROM BREAKER H1 H1 A factory-provided jumper will be installed between terminals INT-A and INT-B to bypass the fan interlock and ensure that the pump continues to recirculate water through the filter system. This is recommended in regions where outdoor temperatures fall near 40˚F (4.4˚C). Remove this jumper if either of the hood fan interlock relays are used as explained in item 2. (to a drain) Located in a NEMA-3R box in the center of the control cabinet is the electrical connection cabinet. Both the pump and pressure release solenoid valve will be wired to the electrical connections cabinet from the factory. CONTROL INPUT: 120VAC, 15AMPS FROM BREAKER N L1 L1 NOTE BL A1 R2 YW A2 F-24B 120 VAC From Hood Fan Interlock F-120A Thermo Recovery Filter System BK A1 R3 WT A2 F-120B TO DRAIN SHUT OFF VALVE Operation NOTE Start-Up Procedure 1. Turn on the fan for the kitchen hood. 2. Turn on the cooking equipment. 3. When the equipment reaches operating temperature, push the green ON/OFF button on the control cabinet to turn the system on. 4. Adjust the “Throttle Valve” to maximize overall energy savings. • Start with the valve half open. • Monitor the “Inlet” temperature gauge on control cabinet and adjust the “Throttle Valve” to maximize the “Outlet” temperature. • Do not completely close “Throttle Valve”, make sure valve is at least one-quarter open. • To maximize savings, the “Throttle Valve” must be set during peak cooking conditions. 5. Turn the cooking equipment off. 6. Push the green ON/OFF button on the control cabinet to turn the system off. 7. Turn the fan off for the kitchen hood. NOTE Do not completely close the “Throttle Valve” when the system is operational. Sequence of Operation 1. During cooking operations, turn on the fan for the kitchen hood. 2. Push the green ON/OFF button on the control cabinet to turn on the energy recovery filter system. 3. After cooking operations, push the green ON/OFF button on the control cabinet to turn off the Thermo Recovery filter system. 4. Turn off the fan for kitchen hood. Maintenance Cleaning filters Filters should be cleaned a minimum of once a week depending on the cooking equipment, cooking frequency, food type and quantity. When servicing or cleaning the filters, turn the pump power off (green button on control cabinet should not be lit). Close the ball valve in the cabinet that supplies the water to the filters. Then press the ‘Pressure Release’ button on the control cabinet for about 5-10 seconds. Do not wash coil with a high pressure washer, as it will damage the fins. Do not take filter apart and clean it unless you are a trained service technician. This is to prevent the coated aluminum fins from being damaged. When washing assembled filters in a dishwasher, it is recommended to use Ecolab® Solid Metal Pro® When serviced by untrained personnel: 1. Remove filter spacer from the hood. 2. Disconnect the quick connect couplers between the filter assemblies. 3. Remove the filters from hood. 4. Place the filters, assembled, into a deep sink or dishwasher and wash thoroughly. 5. Place the filters back into hood. 6. Hookup the quick couplers between the filters and to the connections on the hood. 7. Insert the filter spacer. If normal cleaning techniques are not adequately cleaning the filters, then a trained service technician should be requested to service as follows: 1. Remove the filter spacer from the hood. 2. Disconnect the quick connect couplers between filter assemblies. 3. Remove the filters from hood. 4. Position the filter on its back, face up, and unscrew the four truss head machine screws from filter face. 5. Turn the filter over so it lies on its face. Truss Head Filter Front 6.Machine Remove the filter back from assembly. 7. Screws Remove the coil section from assembly. 8. Wash all three parts (front, back, and coil) in a sink with mild detergent. 9. After all the parts are clean, lay the filter front face Coil down, and place the coil into the filter front. Make sure the hose connection is on the bottom of the filter. Hose 10. Place the filter back over the top of the coil. Connection 11. Turn the filter over so the face is now visible and Bottom of Filter replace the four machine screws. Quick assembly Connect 12. Place the filter back into the hood. 13. Hookup quick couplers between the filters and to Filter Back the connections in the hood. 14. Insert filter spacer. Filter Front Truss Head Machine Screws WARNING Make sure the “Pressure Release” button is pressed before disconnecting anything. If system is not purged properly, water spillage can occur, which can cause hot water burns. WASHING INSTRUCTIONS: 1. DISCONNECT QUICK CONNECT COUPLERS BETWEEN FILTER ASSEMMBLIES. 2. REMOVE FILTERS FROM HOOD. 3. POSITION FILTER ON BACK, FACE UP. UNSCREW THE FOUR TRUSS HEAD MACHINE SCREWS FROM FILTER FACE. 4. TURN FILTER OVER SO IT LAYS ON IT'S FACE. 5. REMOVE FILTER BACK FROM ASSEMBLY. 6. REMOVE COIL SECTION FROM ASSEMBLY. 7. WASH ALL THREE PARTS (FRONT, BACK AND COIL) IN DISHWASHER OR A SINK. DO NOT WASH COIL WITH HIGH PRESSURE WASHER, AS IT WILL DAMAGE THE FINS. 8. AFTER ALL THE PARTS ARE CLEAN. LAY THE FILTER FRONT FACE DOWN, PLACE THE COIL INTO THE FILTER FRONT. MAKE SURE THE HOSE CONNECTION IS ON THE BOTTOM OF THE FILTER. 9. PLACE THE FILTER BACK OVER THE TOP Coil Hose Connection Bottom of Filter Quick Connect Filter Back Thermo Recovery Filter System 5 Balancing and Testing Methods FIGURE 6.3 VELGRID ASSEMBLY Shortridge Method Place standoff spacers against face of outlet or inlet grill, filter, coil, etc. With all the filters in place, determine the total hood exhaust volume with a Shortridge meter as follows: 1. All of the cooking equipment should be on. If the hood has internal short circuit make-up air, it should be turned off. 2. Measure velocities • Set up the Shortridge meter. • For 20 in. (500 mm) wide filters, position the grid as shown in Fig. A and B. Average the two measurements. • Take velocity readings for each filter. 3. Calculate each filter’s volumetric flow rate as follows: Calculate each filter’s average velocity by summing the velocity readings and dividing by the number of readings for each filter. Multiply the average velocity by the conversion factor to obtain the volumetric flow rate for each filter. 4. Calculate the hood’s total volumetric flow rate by summing the volumetric flow rate of each individual filter in the hood as calculated in Step 3. Edge of outlet/inlet active face area Maintain 1½ inch (38.1 mm) margin Maintain 1½ inch (38.1 mm) margin Tubing harness Pressure input ports Swivel bracket Tubing connectors Neckstrap Extension rods External read jack Pushbutton handle and plug Handle bracket Captive knob screws Nominal Filter Size (H x L) NOTE For best accuracy, multiply the velocity of each filter by its conversion factor and sum the flow rates. Averaging the velocity measured for all filters may cause error. Inches Millimeters Imperial Conversion Factor 20 x 20 500 x 500 3.0 Metric Conversion Factor .279 Example: Measured velocities for a 20 x 20 filter = 185 and 189 ft/min. Average Velocity = (Imperial) (Metric) = = Sum of Velocity Readings 14 in. Number of Readings 185 + 189 2 3383 + 3456 2 Flow rate for one filter = (355.6 mm) 2.75 in. = 187.0 ft/min. = 10 in. (254 mm) Conversion Factor x Average Velocity 17.25 in. (2978.15 mm) 6 in. (Imperial) = 3.0 x 187.0 ft/min. = 561.0 cfm (Metric) = .279 x 3420 m/hr = 954 m3/hr (Imperial) (Metric) … + (Filter x Flow Rate) = 561.0 + 555.2 + 534.6 + 539.9 = 2190.7 cfm = 954 + 944 + 909 + 918 3725 m3/hr Thermo Recovery Filter System (69.85 mm) 3420 m/hr Total hood flow rate = (Filter 1 Flow Rate) + 6 Fig. A = (152.4 mm) Fig. B 10 in. (254 mm) Rotating Vane Method Calculate the average velocity for the filter. With all the filters in place, determine the total hood exhaust volume with a rotating vane anemometer as follows: Rotating Vane Anemometer Airflow 3. Determine the filter’s conversion factor from the table. 4. Calculate the filter’s volume in CFM (m3/hr) by multiplying the average velocity by the conversion factor. 5. Calculate the hood’s volume by repeating the process for the remaining filters and summing the individual filter volumes. 2 in. (50.8 mm) 1. All of the cooking equipment should be on. 2. Measure the velocities. Velocity X X measurements X should be taken at X X five locations per filter. These must L be over a filter slot Nominal Filter Size as shown. H/4 H H/2 H/4 Nominal Filter Size (H x L) Measure and record the velocity of each location. A digital 2.75 in. (69.85 mm) rotating vane anemometer or equivalent is suggested. The center of the anemometer should be held 2 in. (50.8 mm) from the face of the filters. It is helpful to make a bracket to keep the anemometer at the Rotating Vane Anemometer 2 in. (50.8 mm) distance Airflow and parallel to the 2 in. filter. Both squareness (50.8 mm) and distance are very important for accuracy. Inches Millimeters Imperial Conversion Factor 20 x 20 500 x 500 1.65 Example: Exhaust only hood with three 20 x 20H/4 filters X X Measured velocities in ft/min. for one 20 x 20 filter X Average Velocity = (Imperial) = (Metric) = (4572 m/h) 256 (4681.73 m/h) Sum of Velocity Readings 248 H/2 (4535.42 m/h) H/4 255 + 250 + 256 + 248 + 240 5 .153 250 255 (4663.44 m/h) H X X Number of Readings L Metric Conversion Factor 240 (4389.12 m/h) = 249.8 ft/min. 4663 + 4572 + 4681 + 4535 + 4389 5 = 4568 m/hr For a nominal filter size of 20 x 20, the conversion factor is 2.48 Imperial (.230 Metric) Volume for one filter = Conversion Factor x Average Velocity (Imperial) = 1.65 x 249.8 ft/min. = 412.2 cfm (Metric) = .153 x 4568 m/hr = 699 m3/hr Total hood volume = (Filter 1 Volume) + (Filter 2 Volume) + (Filter 3 Volume) (Imperial) = 412.2 + 430.9 + 410.7 = 1253.8 cfm (Metric) = 699 + 731 + 696 = 2126 m3/hr Thermo Recovery Filter System 7 Troubleshooting Replacement Parts Pump does not run. Part Number Description • Confirm the fans are running and the pump switch has been pressed to activate the pump. • Check voltage on terminals H1 and N1 in the electrical panel to confirm that there is 120 VAC. • Check voltage on terminals F-24A and F-24B and confirm that there is 24 VAC, OR check voltage on terminals F-120A and F-120B and confirm that there is 120 VAC. • Check voltage on terminals P1H and P1N and confirm that there is 120 VAC. • Inspect motor for disconnected wires. • Motor may be faulty or failing, service motor. Filter Part Numbers 18 inch (45.72 cm) Stainless Steel Hose 476411 Relief Valve 476409 Female Coupler 476410 Male Coupler 459010 Temperature/Pressure Gauge 381050 Solenoid Valve 381049 Coil for Solenoid Valve 476329 Pump System Parts (shipped loose) • Confirm that the panel is running during cooking operations/fan operation. • Confirm appliances are running. • Close off the throttle valve to help force more water through the filters. Do not close the throttle valve completely, as there may not be enough water supplied to the water heater. Core Heat Exchanger 476407 Cabinet Part Numbers Hot water heater inlet temperature is not hot enough. WARNING 475863 476408 24 inch (60.96 cm) Stainless Steel Hose 451167 3/8 inch (0.95 cm) UL Listed Hood Penetration Seal 476409 Female Coupler 476410 Male Coupler Codes and Standards Compliance • UL 1046 • NSF/ANSI Standard 2 – Food Equipment Pressure release button will not purge water to drain. • Confirm the ball valve that supplies water to the filters is closed. • While holding the button, check the voltage between SVH and SVN to confirm 120 VAC. • The pressure release solenoid valve may be faulty or failing, service solenoid valve. Our Commitment As a result of our commitment to continuous improvement, we reserve the right to change specifications without notice. Aqua Filters, LLC • Box 325 • Lakewood, WI 54138 • E-mail: [email protected] • Phone: 888-580-5559 Trademark Information: Dragon Fire Thermo Recovery Filter™ is the registered trademark of National Wholesale Supply, Inc. 8 477102 • Thermo Recovery Filter System, Rev. 2, February 2014 Copyright 2014 © Kitchen Ventilation Systems, LLC
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