Accurex Grease Trapper ESP™™ Kitchen Exhaust Pollution Control System

Introduction

The Grease Trapper ESP™™ is a pre-engineered electrostatic precipitator type pollution control unit designed to remove grease and smoke particles, as well as odor, from kitchen exhaust airstreams. This manual provides procedures for receiving, installing, operating, and maintaining the unit.

For integral exhaust fan information, refer to the fan nameplate and accurex.com.

Unit Certified to UL 8782. Control Panel Certified to UL 891.

General Safety Information

[DANGER]

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

[CAUTION]

To reduce the risk of fire, electric shock, and injury, be sure to follow these cautions:

• Before servicing, ensure the unit is properly grounded.
• Fan motors may be hot enough to cause pain or injury; allow to cool before servicing.
• Do not operate in an explosive atmosphere.
• Keep flammable materials away from the unit.
• Do not use flammable cleaners on or near the unit.
• Inspect frequently and clean unit/cells at proper intervals to prevent fire.
• Airstream operating temperatures should not exceed 130°F.

Installation should be performed by qualified personnel aware of general safety precautions. Improper installation can lead to electric shock, injury from moving parts, or other hazards. Consider high winds or seismic activity if present. Consult a licensed professional engineer for more information.

Follow all local electrical and safety codes, including the National Electrical Code (NEC) and National Fire Protection Agency (NFPA) standards. In Canada, follow the Canadian Electrical Code (CEC).

• Ensure fan wheel rotation is correct and free from obstruction.
• Fan motor must be securely and adequately grounded.
• Do not exceed maximum cataloged fan RPM; check motor load if RPM is changed.
• Prevent wires from kinking or contacting oil, grease, hot surfaces, or chemicals. Replace damaged wires immediately.
• Verify power source compatibility.
• Never open access doors to a duct while the fan is running.
• Do not attempt to defeat safety electrical interlock switches on maintenance access doors.

Receiving, Unpacking, Handling, and Storage

Receiving: Inspect crates for shipping damage before accepting delivery. Notify the carrier of any damage and document it on the delivery receipt and bill of lading. File a Carrier Inspection Report if necessary.

Unpacking: Verify all required parts are present. Report any shortages to your local representative. Not all items may ship together.

Handling: Use provided lifting brackets or skid for moving. Avoid scratching or chipping the coating to prevent corrosion.

Storage: Units are protected during shipment. For extended storage, maintain an indoor, low-humidity environment (30°F to 110°F). Avoid temperature swings that cause condensation. Store accessories indoors in a clean, dry atmosphere. Allow cold parts to reach room temperature to prevent sweating. Leave coverings loose for air circulation.

Outdoor Storage: If necessary, store on a level surface, elevated on blocks to stay above water/snow. Ensure adequate spacing for air circulation and inspection. Do not use plastic film or tarps that cause condensation.

NOTE: The main electrical panel must be stored indoors in a dry environment.

Inspection & Maintenance during Storage: Inspect monthly and record. Address moisture/dirt. Rotate fan wheel by hand monthly. Energize fan motor every three months. Address paint deterioration. Restore machined parts coated with rust preventive.

Removing from Storage: Inspect unit assembly before installation. Check fastener tightness and ensure fan wheel rotates freely without rubbing.

System Components

Unit Body: Shipped on mounting rails. Must be mounted indoors and protected from weather unless specified for outdoor use. Requires 1-inch water supply and 2-inch waste water drain lines. Power packs are self-protecting and self-regulating.

ESP Cells: Ship in a separate crate. Contain an ionizer section (12,000 VDC) and a collector section (6,000 VDC). Total current is below 6 mA.

Impingement Filters / Mist Eliminator Filters / Carbon Trays: Filters ship installed; carbon trays ship separately. Carbon filters are 20x20x2 inches, 12 lbs, and designed for a max velocity of 90 ft/min.

Component Quantities

Remote Mounted Detergent Dispenser: Includes a 5-gallon tank and control cabinet with a diaphragm pump. Requires indoor mounting, within 8 feet of the control cabinet and 30 feet vertical of the plumbing manifold.

System Control Panel: 115 VAC panel for interface, control, and monitoring. Available in NEMA-1 (indoor) and NEMA-4 (outdoor) options.

Fire Cabinet: Mount within 5 feet of the PCU. Requires adequate space and clearance for access and code compliance. Indoor/outdoor options available.

Installation

Rigging and Placing Equipment: Use lifting lugs for cranes. Field weight varies. Position on a suitable base/roof deck. Anchor unit securely. Allow 36 inches service clearance on the access door side. Maintain 12 inches clearance from combustible materials (top) and 6 inches (sides/bottom). Ensure fan is accessible.

Ductwork Connections: Must conform to IMC and SMACNA guidelines. Grease ductwork must meet ANSI/UL 1978 or NFPA 96 standards. Materials: carbon steel (min. 1.37mm) or stainless steel (min. 1.09mm). Seams, joints, and connections require liquid-tight external welds. Insulate ductwork to prevent condensation, which can short circuit cells.

Cells and Carbon Trays: Open access doors. Insert ESP cells with airflow arrow pointing towards the fan, pushing each cell in. Secure with cell pushers. Insert carbon trays with gasketing material oriented correctly for a seal. Re-latch doors securely.

Plumbing Connections

General: All water piping exposed to freezing must be trace heated and insulated. Plumbing connections should be made before electrical connections.

Detergent Dispenser: Locate indoor control cabinet and tank within 8 feet of each other. Requires 1-inch hot water line (140-180°F at 40 psi). Install ball valve and backflow preventer.

Approximate Water and Detergent Used Per ESP Wash Cycle (gallons)

*Water usage numbers assume factory default wash cycle times. Actual usage may vary.

The detergent dispenser uses a diaphragm pump to deliver detergent. A float in the tank monitors levels. Low detergent triggers an alarm and shuts off the pump.

Wash Manifolds: Connect 1-inch wash header inlet to the ESP module. Provide a 2-inch waste water drain with P trap. Refer to page 34 for plumbing schematic.

Required Plumbing Components (Provided by Others): Backflow Preventer, 1-inch Ball Valve, 1/2-inch Ball Valve, Check Valve.

Electrical

Electrical connections should be made after plumbing. All wiring must be done by qualified personnel according to equipment data plates, NEC, and local codes. Wiring must be in conduit; extension cords are prohibited. An earth ground must be provided. Field wiring is required for proper installation.

Fire System

The unit is furnished with factory pre-piped fire suppression nozzles. Field connections, tanks, controls, and detectors are installed based on order specifications. The Authority Having Jurisdiction (AHJ) may require additional protection. Fire cabinets (indoor/outdoor) should be mounted close to the PCU (within 5 feet) and securely fastened. Ensure adequate clearance for access and piping. Refer to unit fire drawings for cabinet dimensions and quantity.

Initial System Start-Up

Follow these steps for initial start-up:

1. Verify installation and connections.
2. Check ESP cell installation direction.
3. Close and fasten all unit doors.
4. Turn on electrical power to control cabinet and fan.
5. Turn on fan disconnect.
6. Turn on PCU terminal enclosure disconnect switch.
7. Press fan button on user interface to start fan. Normal arcing may occur initially.
8. Check for and correct any alarms.
9. System should be ready.
10. Turn on water supply.
11. Prime detergent pump via controller menu. Monitor line and stop when detergent reaches hot water line.

NOTE: The system operates only in NORMAL mode when all access doors are closed and the disconnect switch is ON. A FAULT light indicates a safety switch issue.

Sequence of Operation

The system operates in two main categories:

1. NORMAL Mode: Collects smoke and grease particulate. Started via keypad fan button or remote run contact. Fan must be off for wash to start. Air passes through impingement filter, ESP modules (electrostatic precipitation), mist eliminator, and finally carbon filtration for odor removal.
2. WASH Mode: Cleans dirty ionizing-collecting cells. Recommended daily. Automated wash down sequence removes grease. Times and frequency are adjustable based on cooking load. Can be started manually via keypad/touchscreen, external contact, or scheduled automatically. Wash sequence repeats for each module, followed by drip dry and fan dry for the entire unit. Wash can be overridden by pressing the wash button, or if the fan is turned on, or if the fire system is activated.

Wash Sequence Steps (Example for Rinse):

• Exhaust Fan: Off
• Main/ESP Module Solenoid Valve: Open
• Detergent Pump: Off
• Time: Varies by housing size (e.g., 3-8 minutes).

Other steps include Detergent, Soak, Drip Dry, and Fan Dry, each with specific conditions and timings.

Controller Setup and Tutorial

The DDC controller in the unit control panel has six buttons for viewing conditions and altering parameters. It is pre-programmed with user-friendly menus.

Keypad Navigation:

• [Escape]: Exit current menu.
• [Up]/[Down]: Scroll through screens, adjust parameters.
• [Alarm]: Indicates alarm condition; press to review.
• [Enter]: Moves cursor, confirms selections, saves changes.
• [Program]: Accesses Main Program Menu.

Example Parameter Adjustment: Cursor blinks in upper-left. Press [Enter] to move cursor. Use [Up]/[Down] to adjust value. Press [Left Arrow] to save. Cursor must be in upper-left to save and advance.

Main Menu Overview: Accesses Clock, Input/Output, Service, and Manufacturer sub-menus. System status screens display operating conditions.

Alarms: [Alarm] button flashes red. Press [Down] to review. Correct the cause to clear most alarms. Low detergent alarm requires manual reset.

Alarm List: Low Detergent, Exhaust Fan Fault, Door Safety Alarm, Power Supply Failure, Fire Detected, Wash Aborted.

Touch Screen Navigation

Icons on the touch screen allow momentary push actions. Blue-bordered icons are momentary push buttons.

• [Fan On/Off]: Turns the unit on/off. Icon spins when operating.
• [Wash On/Off]: Starts or stops the wash sequence. Tapping again aborts.
• [Detergent Indicator]: Monitors detergent level. Green for sufficient, displays "low" when alarm active.
• [Fire Status Indicator]: Gray = no fire, Red = fire detected.
• [Help]: Displays help menu and tips.
• [ESP Wash Status]: Navigates to wash status screen with timers. Indicators change color based on wash state.
• [Navigation Bar]: Pulls up a menu for alarms, home, and settings.

The alarm icon illuminates red and blinks when an alarm is triggered. The middle icon goes to the home screen. The right icon goes to settings/configuration.

Maintenance

Maintenance frequency varies by site conditions. Inspect cells weekly for the first month.

Impingement and Mist Eliminator Filters: Inspect monthly for grease/particulate build-up. Clean manually if apparent.

Ionizing-Collecting Cells: Inspect monthly for grease build-up. Clean manually. Remove cells every 6 months minimum.

Carbon Trays: Replace when odor breakthrough increases, typically every 3-6 months. Refill steps provided.

System Fan/Motor: Inspect, service, and clean annually per manufacturer instructions.

Wash System Detergent: Accurex recommends Zep X701 detergent. Dilute 1:1 with water. If cells are not fully cleaned, increase detergent add timer, adjust flow control, or increase strength. Zep X701 also for manual cleaning of filters. Using other detergents may void warranty.

Accessing Filters/Cells: Turn fan off. Turn off all power pack disconnects. Lock out system. Unlatch door fasteners. Short cells to ground with insulated screwdriver. Slide filters from tracks and clean. Unlatch ESP cell access. Loosen cell pushers, remove cells carefully (approx. 35 lbs each). Inspect for bent plates or residual grease. Reinstall cells and close doors.

Replacement Parts Ordering: Contact Accurex Parts Department or local representative. Part numbers are listed.

Troubleshooting

Cells Shorting Immediately: Run wash with full detergent. Clean cells. Ensure correct cell installation and wiring (Red=Ionizer, Blue=Collector, Black=Ground). If dry portion bypassed, run fan for 60-90 mins.

Green Indicator Flashes then Off: Power supply may be faulty or incorrectly programmed. Contact factory.

Indicator Lights Not Illuminating: Check LED wiring polarity. Test voltage to LEDs and power supply.

Cells Not Collecting Contaminants (Power Supplies On): Ensure proper connection of spark plug cables and cell pushers.

Cells Not Fully Clean After Wash: Check detergent level, ensure correct type (Zep X701), increase wash sequence times, or check water temperature/pressure (140°F, 40 psi).

Wash Cycle Won't Start: Ensure fans are off. Check fire micro-switch wiring. Confirm hot water shut-off valves are open.

Unit Not Washing: Review wash history pages on controller.

Our Commitment

Accurex reserves the right to change specifications without notice. Product warranties are available online at accurex.com.

Accurex
P.O. Box 410 Schofield, WI 54476
Phone: 800.333.1400 | Fax: 715.241.6191
Parts: 800.355.5354 | accurex.com

Document 482584 Grease Trapper ESP™™ Pollution Control, Rev. 8, November 2021

© 2021 Accurex, LLC