Greenheck Grease Trapper ESP™ Kitchen Exhaust Pollution Control System

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 the cautions below:

• Before servicing, make sure the unit is properly grounded.
• When servicing the fan, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.
• Do not operate this unit in an explosive atmosphere.
• Keep all flammable materials (such as gasoline) away from the unit.
• Do not use flammable cleaner on or near the unit.
• The unit should be inspected frequently and the unit and cells should be manually cleaned at proper intervals to prevent a fire.
• Operating temperatures of the airstream should not exceed 130°F.

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electrical Code (CEC) in Canada.

2. The rotation of the fan wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.

3. Fan motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum cataloged fan rpm. Adjustments to fan speed significantly affects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

5. Do not allow the wires to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace immediately if damaged.

6. Verify that the power source is compatible with the equipment.

7. Never open access doors to a duct while the fan is running.

8. The precipitator contains safety electrical interlock switches at all maintenance access doors. Do not attempt to defeat these interlocks.

Receiving

Upon receiving the product, check to make sure all items are accounted for by referencing items shown on the packing list. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make a notation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be filled out by the carrier upon arrival and filed with the Traffic Department. If damaged upon arrival, file claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of manufacturer.

Unpacking

Verify that all 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 to only items on the packing list. Remove all other shipping/packing materials including fan tie down straps.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged finish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit 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.

INDOOR Storage

The ideal environment for the storage of units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories (including the main control panel and the keypad/touchscreen user interface) must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid "sweating" of metal parts, allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

OUTDOOR Storage

Units designed for outdoor applications may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed. The unit should be placed on a level surface to prevent water from leaking into it. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic film or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

NOTE: The main electrical panel, if stored, shall be stored indoors only in a dry environment protected from the elements.

Inspection & Maintenance during Storage

While in storage, inspect equipment once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to fifteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or fine emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

Removing from Storage

As units are removed from storage to be installed in their final location, they should be protected and maintained in a similar fashion, until the equipment goes into operation. Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.
2. Rotate the fan wheel(s), where applicable, by hand and assure no parts are rubbing.

Table of Contents

The table of contents lists the sections and their corresponding page numbers. Key sections include:

• Grease Trapper ESP System Function
• System Components (Unit Body, ESP Cells, Filters, Control Panel, Fire Cabinet)
• Installation (Rigging, Ductwork, Plumbing, Electrical, Fire System)
• Initial System Start-Up
• Sequence of Operation (Normal, Wash)
• Controller Setup and Tutorial (Keypad, Touch Screen, VFD, BMS)
• Maintenance
• Troubleshooting

Grease Trapper ESP System Function

The Grease Trapper ESP is an electrostatic precipitator pollution control unit (PCU), with an additional carbon filtration module designed for two specific functions:

• Remove smoke/grease particles from kitchen exhaust
• Remove odor from kitchen exhaust

NOTE: Grease Trapper ESP must be connected to a listed exhaust hood assembly and must be installed in accordance with local building codes, NFPA 96 and NEC.

A mechanical impingement pre-filter removes large airborne particles from the incoming airstream prior to reaching the ionizer cell. The permanent electrostatic collector section removes grease and smoke particles from the airstream using a high voltage ionizer cell(s). The ionizer imparts a positive charge on the grease and smoke particles as they pass. These particles are then repelled by positively charged plates and collected on negatively charged plates. Upon completion of each cooking day, a wash sequence is initiated for the self-cleaning function of the electrostatic cell and impingement modules via the control panel. The mesh mist eliminator filter prevents wash water from entering the carbon filtration section(s) of the unit.

NOTE: Do not use this unit for applications with high concentrations of water vapor, or other matter, that is highly conductive if condensed in the airstream. Heavy water vapor can cause continuous electrical shorting within the ESP cells, which does not allow the unit to collect cooking particulate and perform as designed.

There are two configuration options for the Grease Trapper ESP PCU’s. The standard unit will have two ESP modules and one carbon filtration section for use with light, medium and heavy duty cooking. For solid fuel applications which will contain a greater quantity of grease, smoke and odors, the solid fuel unit should be selected. The solid fuel unit will contain three ESP modules and two carbon filtration modules.

NOTE: This unit should NOT be installed in applications where incoming airstream at the inlet of the unit is capable of exceeding 130°F.

NOTE: Grease Trapper ESP is designed to remove sub-micron, airborne particulate generated from cooking processes. This system is NOT INTENDED to eliminate regular hood and ductwork cleaning and service. Improper care and maintenance of this system and associated hoods and ductwork may present a fire hazard.

System Components

NOTE: The installation criteria for each of the system components shown below should be considered when selecting a site for install. For further detail on installing the components, refer to the INSTALLATION section on page 7.

Unit Body

The unit body is shipped on mounting rails ready for installation. If the unit was ordered with an exhaust fan, typically the fan will also be mounted on the same set of rails as part of the PCU assembly. Unless specified and built for outdoor use, the PCU must be mounted indoors and be protected from weather. The unit should be easily accessible for service personnel. A one-inch water supply line and a two-inch waste water drain line is required at the unit for the system's wash function.

Power packs (power supply boxes) are attached to hinged cell access doors of the cabinet assembly which are wired directly back to the main control panel via quick connect plug and play cables. By default, these will be factory wired when the main control panel is mounted on the rails. The high voltage from the power packs is wired directly to the cells through a spark plug style cable passing through the unit via UL listed compression seals. Power supplies are self-protecting against overloads (which can be caused by contaminant build up that leads to short circuits in ionizer and collector sections) and are self-regulating from AC input voltage variations from 108 - 264 VAC.

ESP Cells

ESP cells will ship in a separate crate to protect them during shipping. Cell quantities for each stage are based on unit size.

Cells have an ionizer section and collector section. The ionizer section includes spiked ionizer plates that are charged with 12,000 VDC. The collector section includes alternating plates between ground (0 VDC) and 6,000 VDC potential. Cells are fed voltage through high voltage spark plug-style cables that are insulated from the unit housing. These pins contact brass plungers located on the side of the cell near the bottom.

Diagram Description (Universal Unit Cell): A diagram shows a universal unit cell with labels pointing to the Airflow Direction Indicator, Collector Section, Ground Spark Plug Connector, Collector Spark Plug Connector, Ionizer Spark Plug Connector, and Ionizer Section. It also illustrates how power is passed from cell to cell via brass plungers.

The total current to both the ionizer section and collector section is below 6 mA.

Impingement Filters / Mist Eliminator Filters / Carbon Trays

Impingement filters and mist eliminator filters will ship installed in the unit. Carbon trays will ship in a separate container. Filter quantities for each stage are based on unit size.

Each carbon filter is a 20 x 20 x 2 inch, 12 lbs., and contains coconut shell carbon, standard. Max designed velocity across each filter is 90 ft/min.

Component Quantities

Remote Mounted Detergent Dispenser

A 5-gallon remote mounted detergent tank and remote mounted detergent control cabinet, equipped with a diaphragm pump and terminals is included as part of the electrostatic collector self-wash system. A backflow preventer is to be provided by others. The detergent tank must be mounted indoors on a solid, level foundation, within 8 feet of the detergent control cabinet, and in a freeze protected location accessible to maintenance personnel. The detergent control cabinet must be mounted within 30 feet vertical to the loose, factory provided, plumbing manifold. Refer to the PLUMBING section for details on plumbing connections.

System Components - continued

System Control Panel

The 115 VAC system control panel fed from a 15A building breaker allows the user to interface with the unit and controls operation, as well as monitors wash and other functions. Field wiring connects the system control panel to the power pack enclosures on the unit, and works in conjunction with the unit's power supplies and high voltage ESP cells. The system control panel will now have both indoor (NEMA-1) and outdoor options (NEMA-4) that will be standard mounted on the unit rails. Follow 110-26 of the National Electrical Code in allowing adequate room for electrical servicing as well as allowing clearance for opening any access or service doors.

Fire Cabinet

The fire cabinet should be mounted as close to the Pollution Control Unit as possible, typically within 5 feet. Unless the fire cabinet was provided with an outdoor cabinet and heater, the cabinet should be mounted indoors and must be kept above freezing.

NOTE: System control panel may be mounted on the PCU rails or shipped loose for remote mounting. If mounted on rails, all control wiring between the panel and the PCU will be factory wired.

PCU Field Assembly - if applicable

If unit is shipped in sections, each section will need to be welded in the field.

Unit Modules

1. Remove (4) 5/16 inch mechanical fasteners that attach each module to the rails.
2. Remove 5/16 inch mechanical fasteners that attach each module to the next adjacent module. PCU housing size can be found in the model number on tag on side of unit.

NOTE: Doors will have to be opened and/or removed to access fasteners inside of modules.

3. After rails and modules have been moved to desired location, the modules and rails can be reassembled.
4. It is recommended to reattach the fasteners from step 2 to properly align the modules with each other, but fasteners are not required when the modules are welded together from the outside. Fasteners will need to be removed again to perform step 7.
5. Make sure all control boxes, access doors, filters and cells are removed from the modules before welding modules together.
6. Fully weld modules together on all four sides on the outside of the unit. Welds must be liquid tight.
7. Install seam covers on all flanges inside of shell where modules connect. Tack weld each seam cover on each end and minimum once in the middle.

Attaching Fan

The ESP fan is shipped bolted to unit body and rails. If the unit was requested to be disassembled in the field, the unit body-to-fan connection has not been sealed.

1. To disassemble in the field, remove mechanical fasteners that attach the companion flange and fan to the unit body.
2. Remove mechanical fasteners that attach the fan to the isolators on the rails.

After fan and unit body have been moved to desired location, the fan can be sealed and reattached to the unit body and rails.

3. To seal the fan to unit body connection, apply fire rated caulk (3M Fire Barrier Sealant CP25WP+ or equivalent) to fan inlet flange. Make sure to apply caulk around each bolt hole. Caulk to be located outside of silicon gasket mounted during step 4.
4. Attach 1/2 inch silicone gasket around fan inlet flange. Silicone gasket to be located inside of caulk applied in step 3 (seam of gasket to be located on the side of unit).
5. To reassemble locate fan on isolators on rails.
6. Reattach fasteners for companion flange removed in step 1.
7. Reattach fasteners attaching fan to isolators removed in step 2.

Installation

Rigging and Placing Equipment

1. The unit is furnished with lifting lugs at the four corners. For corner weights, reference the unit's submittal drawings.
2. Use a crane and a set of spreader bars hooked to all four factory lifting lugs to lift the unit.
3. Field weight will vary depending upon final selections such as fan type, accessories, etc. Approximate weights are shown in the table.
4. The unit can be positioned on a base or roof deck suitable for this purpose.
5. The unit must be anchored to its base/roof deck.
6. Alternatively, the unit may be suspended from an adequate overhead structure, using suitable undercarriage or hanging rods (by others). If suspended, a cradle or support structure must be provided by others to support unit from bottom. All hanger brackets/lifting lugs must be used to ensure proper support. The unit must also be hung level to ensure proper operation.
7. A service clearance of 36 inches must be provided on the access door side of the unit.

Diagram Description (Approximate Weight Table): Tables show approximate weights for Standard Unit and Solid Fuel Unit configurations across different housing sizes (15 to 135), listing weights in pounds (lbs) and kilograms (kg).

8. A minimum 12 inch clearance must be maintained between the top and 6 inches on each side and bottom of this unit and any combustible material.

9. Ensure the fan is located in an easily accessible area, of adequate size and clearance to allow for service or removal.

Ductwork Connections

Ductwork must conform to IMC and SMACNA guidelines. All factory-built grease duct needs to be constructed in accordance with ANSI/UL 1978 and should be manufactured and installed in accordance with their listing.

All field-built grease ductwork must be constructed in the following manner per NFPA 96, unless otherwise specified by the local authority having jurisdiction (AHJ):

Materials - Ducts shall be constructed of and supported by carbon steel not less than 1.37 mm (0.054 in.) (No. 16 MSG) in thickness or stainless steel not less than 1.09 mm (0.043 in.) (No. 18 MSG) in thickness.

Installation - All seams, joints, penetrations, and duct-to-hood collar connections shall have a liquid-tight external weld.

Units intended for indoor mounting have an outlet mounting flange provided on the outlet of the fan. Outlet ductwork from the exhaust fan is required to be per the above mentioned methods unless otherwise specified by the local authority having jurisdiction (AHJ).

NOTE: Ductwork should be properly insulated to prevent formation of condensation through temperature change. Condensation that occurs in ductwork will short circuit ionizing-collecting cells.

Cells and Carbon Trays

Open ESP cell and carbon tray access doors by turning and releasing all latches on the door.

Insert cells into the ESP module(s) in the units, making sure the airflow arrow stamped on each cell is pointing towards the fan. ESP cells should be pushed in by the next one in the row. For example, the second cell pushes the first cell, the third cell pushes the second, etc. The last cell installed should be no more than 4 inches (+/-1/8 inch) from the edge of the cell to the edge of the frame.

After inserting the last cell in a row, install the two (2) cell pushers to secure the cells. These pushers should be hanging from the above rack. Insert the cell pusher between the cell and the vertical c-channel of the cell rack, hooking the end of the pusher around the c-channel. Locate the pusher low enough on the c-channel that the attached wire is taut. Then, fasten the bolt until it's tight against the face of the cell. Repeat for each cell pusher on each row.

Insert carbon trays into the carbon module(s) in the unit. Make sure trays are inserted where gasketing material is orientated on the left and right hand side, NOT the top and bottom, so there is a seal against the filter next to them.

After all cells and filters are properly installed, re-latch unit doors by closing the door and turning the hand-latches until secured.

Plumbing Connections

NOTE: All water piping exposed to freezing temperatures must be trace heated and insulated to prevent damage to the unit.

Once all system components are installed, plumbing connections for the system can be made. It is recommended that plumbing connections be done prior to making electrical connections.

Locate a suitable indoor location for the mounting of the remote detergent control cabinet and remote detergent tank, within 8 feet of each other.

From the building, a 1-inch (refer to drawings) hot water line is required for connecting the wash system. Recommended water temperature is 140-180°F at 40 psi pressure. Refer to the chart for information on water and detergent quantity requirements. Install the quarter turn ball valve (by others) at the incoming water source to allow the water to be turned off for servicing. Next, install the backflow preventer (by others), and factory provided inlet manifold. Locate these items along the incoming water line in a location convenient for inspection/servicing, and within 30' vertical of the detergent control cabinet.

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

*Water usage numbers shown above are assuming factory default wash cycle times. Actual water and detergent required may be different based on the cooking load, appliance type, and cooking frequency/time. *Assuming 40 psi water pressure

Detergent Dispenser

The detergent dispenser supplies detergent to the wash system during the WASH mode.

Diagram Description (Detergent Dispenser): A diagram shows the detergent dispenser assembly, illustrating the connection of float sensor wires to the control cabinet, the detergent pump, the detergent line from the pump to the wash manifold, the detergent line from the tank to the pump, and the 5-gallon detergent tank. It also shows the wash manifold connected to the hot water supply.

NOTE: Upon the float detecting no detergent, the system will go into a low detergent alarm and the detergent pump will be immediately shut off. The low detergent fault can be manually reset (see page 14 for details), or it will automatically reset if the float detects detergent upon the next wash cycle when detergent injection is taking place.

Plumbing Connections - continued

Wash Manifolds

The unit is supplied with a single 1-inch wash header inlet located at the top of the ESP. Connect the hot water supply line from the outlet of the inlet manifold to the wash header at the top of the ESP module. Bring a 2-inch waste water drain piping connection with P trap to the drain pipe, located centered below the inlet of the PCU. The trap drain line water column for the drain should be sized for the total system resistance plus 1 in. wg.

For more information, refer to the plumbing schematic located on page 34.

The Grease Trapper ESP PCU will be supplied with a detergent tank, detergent control cabinet, wash inlet manifold, solenoid valves, and connection headers on each module. Follow all applicable plumbing codes and best practices when installing system.

Required Plumbing Components (Provided by Others)

Electrical

Once all system components are installed, electrical connections for the system can be made. It is recommended that plumbing connections be done prior to making electrical connections.

CAUTION: RISK OF ELECTRIC SHOCK. All wiring to be done by qualified personnel only.

NOTE: All wiring must be done according to the equipment data plate information, NEC (National Electrical Code NFPA 70), and local codes.

NOTE: All wiring must be permanently installed in conduit. Under no circumstances should extension cords be used to connect the source of electrical supply to the equipment.

NOTE: An earth ground must be provided to the unit assembly housing and main control panel. The detergent pump motor and solenoid valve must also be appropriately grounded.

The Grease Trapper ESP PCU will require additional field wiring for proper installation. The main control panel will be shipped loose or mounted on the unit rails and is designed for either indoor or outdoor applications. A typical field wiring diagram is shown on page 32. Refer to the unit specific wiring diagram located on the inside of the door of the system control panel for unit specific wiring that is required.

Fire System

The Pollution Control Unit (PCU) is furnished with factory pre-piped fire suppression nozzles. Field connection, tanks, controls, fusible link detectors, and commissioning is provided and installed, based on specifications at time of order. The Authority Having Jurisdiction (AHJ) may require additional protection.

The PCU may be provided with one or more cabinets, shipped loose for field install, containing the fire suppression components. If a fire cabinet(s) are provided, locate an area as close to the PCU as possible (within 5 feet from the PCU), with enough space to mount the fire cabinet(s), and fasten to wall. If provided with indoor cabinet(s), fasten to wall using 1/4" holes located along all four sides of the back wall of the cabinet. If provided with outdoor (NEMA4) cabinet(s), fasten to wall using 5/16" bolts at the four (4) holes located 3/4" offset from the corners of the back face of each cabinet. Size and type of fastener are the responsibility of installer. Ensure 36" of horizontal clearance in front of the cabinet(s) for access and code compliance. Ensure sufficient clearance above cabinet(s) for fire system piping to the PCU. Cabinet(s) may be provided with heater if mounted outdoors, refer to Fire System Cabinet Wiring Outdoor for details. Cabinet dimensions and quantity will vary based on the PCU size and mounting location (Indoor/Outdoor); see image and table for reference. Refer to unit fire drawings for final cabinet dimension and quantity.

Diagram Description (ESP Fire Cabinet Quantity and Size): A table lists the quantity and size of ESP fire cabinets (Indoor and Outdoor NEMA4) based on the PCU Housing Size (15 through 135) and whether it's a 4 or 6 Module Unit.

Diagram Description (Typical Drawing): Illustrates indoor and outdoor PCU cabinets with agent tanks and brackets, showing typical placement and clearance requirements.

• Do not install fire piping in front of doors on module. Must have 36 inches of clearance.

Initial System Start-Up

1. Verify unit is installed properly and all field water and electrical connections have been made.
2. Check that all ESP cells have been installed properly. There is a directional arrow that indicates the direction of the proper airflow. If cells are not installed in the proper direction, the unit will not operate correctly.
3. Close and properly fasten the doors on the unit to ensure the door limit switches are closed.
4. Turn on electrical power to control cabinet and exhaust fan.
5. Turn on fan disconnect.
6. Turn on the disconnect switch on the PCU terminal enclosures to energize the power packs.
7. Press the fan button on the user interface to start the fan. Some electrical arcing (audible snapping and cracking) is normal at initial power up as leftover debris in the duct and unit may occasionally get caught inside the cells. Arcing should subside after a short period of time. If arcing continues, reference page 35 for troubleshooting assistance.
8. Check for alarms on the system controller. Correct any alarms that may be displayed (See page 14 for details).
9. System should now be ready for operation.
10. Turn on water supply.
11. Prime the detergent pump. On the CAREL controller, navigate to Service > Wash Settings > "Prime Detergent Pump" menu screen. Changing "OFF" to "ON" will start the detergent pump. Monitor the detergent line and press the ESC key once the detergent reaches the hot water line. This will stop the detergent pump.

NOTE: As a safety precaution, the system will only operate in the NORMAL mode when the access doors of the unit are completely closed and the terminal box disconnect switch is in the ON position.

If the plunger of the safety switch on all of the doors is not fully depressed, the red FAULT light on the main controller (PLC) will illuminate and the unit will not start. Do not attempt to operate the unit with the access doors open or bypass the safety.

Sequence of Operation

The operation of the Grease Trapper ESP system falls into two main categories:

1. NORMAL: System collects smoke and grease particulate from the airstream.

The unit can be started by pressing the fan button on the user interface or by closing the remote run contact (terminals RE-1A and RE-1B). The remote run command is a contact that can be wired to the kitchen control panel, timeclock, or any other contact closure desired to call for the system to run.

NOTE: BOTH the keypad fan button needs to be disengaged AND the remote run contact needs to be open in order for the fan to shut off. A call for the fan to run will not allow for a wash to start, which will prevent the cells from being cleaned.

During normal operation, as the grease enters the unit, it will pass through an impingement filter that is designed to remove the large grease particles. After passing through the impingement filter, it will enter the ESP module(s) which will remove the grease particles and smoke from the airstream through a process of electrostatic precipitation. Upon leaving the ESP modules, the air then passes through a mist eliminator filter which stops water from entering the carbon filters during the wash down process and also helps protect the carbon filter section from grease build-up. The air then enters the carbon filtration section which removes the odors from the airstream.

Normal Mode

• Exhaust Fan - Running
• Main Solenoid Valve - Closed
• Detergent Pump - Off

2. WASH: System goes through cycles to clean and dry dirty ionizing-collecting cells

The wash cycle is recommended to be performed daily on the unit and uses an automated wash down sequence to remove the grease that has been collected on the impingement filters and ESP cells. The length of time and frequency of washing will be determined by the grease load in the airstream. The times shown are the factory settings but can be adjusted as needed based on site conditions.

The wash cycle can be started three different ways:

1. User presses the wash button on the keypad or touch screen.
2. An external wash contact is closed (terminals WS-1A and WS-1B).
3. The controller can be set up to wash the unit automatically based on a schedule set up on the controller.

The wash sequence will wash each impingement and ESP module using the steps below. For units with multiple ESP modules, the wash sequence will repeat itself for each module with the exception of the drip dry and fan dry sequence. The drip dry and fan dry portion will start once all of the modules have completed washing and are used to dry the entire unit before placing it back into service. An optional, up to 2-hour delay between each module's wash sequence can be set on the controller to allow water heaters or grease interceptors time to recover between wash sequences.

Wash Override: The wash sequence can be stopped by pressing the wash button on the user interface. This will cancel the wash sequence and return the PCU to normal operation. When calling for a wash or during the wash sequence if the fan is turned on either by the fan button, remote fan enable contact, or the fire system is activated the wash sequence will stop and the exhaust fan will turn on.

Rinse

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Open
• Detergent Pump - Off
• Time - 3 minutes (Housing sizes 15, 30, 45, 60 and 90) / 6 minutes (Housing size 135)

Detergent

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Open
• Detergent Pump - On
• Time - 1 minute (Housing sizes 15, 30, 45, 60 and 90) / 2 minutes (Housing size 135)

Soak

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Off
• Detergent Pump - Off
• Time - 3 minutes (Housing sizes 15, 30, 45, 60 and 90) / 6 minutes (Housing size 135)

Rinse

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Open
• Detergent Pump - Off
• Time - 4 minutes (Housing sizes 15, 30, 45, 60 and 90) / 8 minutes (Housing size 135)

Detergent

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Open
• Detergent Pump - On
• Time - 1 minute (Housing sizes 15, 30, 45, 60 and 90) / 2 minutes (Housing size 135)

Soak

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Closed
• Detergent Pump - Off
• Time - 3 minutes

Rinse

• Exhaust Fan - Off
• Main and Impingement or ESP Module Solenoid Valve - Open
• Detergent Pump - Off
• Time - 4 minutes (Housing sizes 15, 30, 45, 60 and 90) / 8 minutes (Housing size 135)

Drip Dry

• Exhaust Fan - Off
• Drain Solenoid - Open
• Impingement or ESP Module Solenoid Valve - Closed
• Detergent Pump - Off
• Time - 1 minute

Fan Dry

• Exhaust Fan - On
• Drain Solenoid - Open
• Impingement or ESP Module Solenoid Valve - Closed
• Detergent Pump - Off
• Time - 60 minutes

Controller Setup and Tutorial

The DDC controller is located in the unit control panel. The face of the controller has six buttons, allowing the user to view unit conditions and alter parameters. The DDC controller is pre-programmed with easy to use menus.

To change the display contrast, hold the Alarm [!] and Program [⊚] buttons simultaneously while pressing the [↑] and [↓] arrows. The [↓] arrow will make the screen lighter and the [↑] arrow will make the screen darker.

The user can access the main menu by pressing the [⊚] button.

Within the programmable logic controller, factory set points can be modified to configure the system for specific functions if necessary. All parameters are shown in this section.

Some of the menus require the user to enter a password in order to enter the menu. The service password is 1000 and is entered by pressing the [↑][↓] to change the number and to advance the cursor, press the [←] button.

If equipped, the keypad user interface connects via a factory-provided RJ-25 cable to the J10 port on the controller. Information regarding most of the settings within the Controller U1 are provided in this Installation, Operation and Maintenance Manual.

Keypad Navigation

• Escape: Allows the user to exit the current menu, jumping to the Main Menu.
• ↑ | ↓ (Up | Down): The arrow buttons allow the user to scroll through different screens and adjust parameters.
• ! (Alarm): Button will blink red, indicating an alarm condition. Press to review current alarms. To review previous alarms, access the DATA LOGGER in the alarm menu.
• Enter:
  1. In screens with adjustable parameters, pressing the Enter button moves the cursor from the upper left corner of the screen to the parameter. The arrow buttons can then be used to adjust the parameter.
  2. To move to the next parameter on the same screen, press the Enter button.
  3. To save the change, press the Enter button until the cursor moves back to the upper left corner of the screen.
• ⊚ (Program): Pressing the Program button allows the user to enter the Main Program Menu.

Example of Parameter Adjustment

Once you enter into a menu that has adjustable parameters, the cursor always begins in the upper left corner of the display and will be blinking. Press the [↓] button to move the cursor down for parameter adjustment.

Once the cursor has reached the desired parameter, press the [↑] [↓] buttons to adjust the value.

When satisfied with the adjustment, press the [←] button to save the parameter. When finished, make certain the cursor is in the upper left corner. If the cursor is not in the upper left corner, the changes will not be saved. The cursor must be in the upper left corner to enable screen advancement.

Exhaust 1 Setpoints Example: Shows sample setpoints for Temperature and Speed, with Low, High, and Current values.

Main Menu Overview

Pressing the [⊚] button will bring you into the main menu. Scrolling up/down with [↑] [↓] buttons will bring you to different sub-menus including A: Clock, B: Input/Output, C: Service, and D: Manufacturer.

Exiting the main menu (using the [⊚] button) will first bring you to the system status screen loop. This loop includes several screens to view the operating conditions of the unit. Scroll through the menu screens by using [↑] [↓] buttons. Screens with dashed line border are dependent upon the configuration and may not appear for every system.

PCU Exhaust Fan Status

This screen will display the status of the PCU exhaust fan as well as display the fan speed (if applicable). A system status will show items like whether the unit is in a wash or a door was left open.

PCU ESP Pass #1, #2, #3 Status

These screens will display the status of PCU ESP pass 1, 2, and 3, providing statuses of all power supplies on that pass.

Example of Alarms

If an alarm occurs, the [!] button will flash red on the controller and the keypad (if connected).

To navigate to the alarm menu, press the [!] button once. Press the [↓] button to scroll through any current alarms. Once the problem causing the alarm has been corrected, all alarms except “Wash Aborted” alarm will automatically clear. Pressing the [!] button will clear the low detergent fault if it needs to be manually cleared. If the alarm cannot be cleared, the cause of the alarm has not been fixed.

Alarms List

A. Clock

The Clock menu allows the user to view and alter the time and date. The user can also adjust the daylight savings time setting.

THE CLOCK SCREEN ALLOWS THE USER TO ADJUST THE TIME AND DATE. The time/date will not be adjustable on the controller if the user interface is the touch screen.

Daylight Savings Time Setting: This feature can be adjusted to meet current daylight savings time requirements.

Holiday Configuration: The user can add up to 16 holidays. Adding holidays will prevent the wash and fan scheduler controlling the wash/fan during the days selected.

B. Input/Output

The Input/Output menu allows the user to quickly view the status of the controller inputs and outputs. To manually control I/O values, go to the Service menu > Service settings > I/O Manual Control.

Similar screens appear for all controller inputs and outputs. Your controller may not utilize the input shown. See unit wiring diagram for your specific configuration.

• Analog Input (e.g., Fan Speed): Shows status like input value.
• Digital Input (e.g., On/Off): Shows status like Open/Closed.
• Relay Output (e.g., Exhaust Relay): Shows status like OFF/ON.
• Analog Output (e.g., Fan Speed): Shows output value.

C. Service

The Service menu allows the user to access several sub-menus regarding controller information, controller overrides, operating hours, BMS configuration, I/O manual management and wash settings. By accessing the BMS Configuration sub-menu, the user can adjust BMS protocol settings (BACnet®, LonWorks®, Modbus).

a. System Information

The System Information sub-menu displays information about the controller and the program loaded on the controller. This screen shows version, boot, and BIOS information pertaining to the controller's firmware and operating system.

b. Power Supply

The Power Supply sub-menu allows the user to view and adjust the power supply settings.

Power Supply Settings 1, 2, 3: Allows viewing/adjusting output signal power to power supplies and corresponding kV output. Also allows setting initial reset attempts and reset delay after a power supply alarm.

NOTE: Control voltage is not adjustable if provided with JC099 power supplies (fixed 12kV operating voltage).

c. Wash Settings

The Wash Settings sub-menu allows the user to view and adjust the wash times. Default times are provided on page 12 of this manual.

Wash Settings 1:

Allows adjustment of Pre-Soak, Detergent, Soak, Rinse, Dry, Drain Time, and Delay Time.

Wash Settings 2:

Allows adjustment of Auto Wash feature (Enable/Disable), Auto Wash Time, and Days/Week for auto wash. It also displays Last Washes (Complete and Aborted) and the Reason for abortion.

Wash Log History:

Allows viewing of last completed successful wash cycles with date and time stamps. The log can store up to 100 washes.

Clear Wash Log History:

Option to clear the wash log history.

Low Det Settings 1, 2:

View low detergent information, including washes during alarm and last wash details. Allows resetting the detergent count.

Wash Settings 3:

Adjusts the delay time before cells can be powered again if a wash cycle is stopped prematurely (default 60 minutes).

Test Wash Setup:

Allows adjustment of settings for a unit test wash and starting a test wash.

Wash Settings 4:

Provides total calculated wash time from start of wash until the end of the fan dry.

d. BMS Configuration

Allows selection of BMS protocol (BACnet MSTP, BACnet IP/Eth, Modbus). Requires a communications card. For BACnet, BIOS screens must be accessed to adjust parameters. For Modbus, parameters like Address and Baud Rate are set.

Diagram Description (BACnet IP vs BACnet MSTP): Shows configuration screens for BACnet IP and BACnet MSTP, detailing settings like DHCP, IP Address, Netmask, Gateway, DNS, BACnet ID, MAC, Baud Rate, Max Masters, Max Frames, and PCONET CONFIG ENABLE.

e. Service Settings

a. Fan Operation

Auto Fan Off Settings: Enable/disable auto fan off feature. Adjust Run Hours before automatic shut-off.

b. I/O Manual Control

Allows manual override of analog and digital inputs/outputs for troubleshooting. Requires factory advice.

c. Sensor Calibration

Adjustable value to calibrate analog inputs with an offset value.

d. User Save/Restore

Allows saving and restoring default parameters stored in memory.

e. Alarm History Reset

Clears the alarm history log.

D. Manufacturer

Accesses sub-menus for controller configuration, I/O configuration, factory settings, initialization, and factory save/restore pages. These changes should be completed under factory advisement only.

Keypad Navigation

Details the functions of the keypad buttons (FAN, WASH, MENU, NAV, etc.).

FAN Button: Turns the PCU unit on/off. Pressing momentarily turns it on; pressing again turns it off.

WASH Button: Starts the automatic washdown sequence. Pressing again cancels the sequence.

Display Functionality and Control: Instructions on changing display contrast.

System Fault Indicator: A red LED flashes upon any alarm. It stops flashing when alarms are corrected and low detergent alarms are reset.

System status messages include Current alarms, Power Supply Status, Exhaust Fan Status, and Wash Sequence.

Accessing the main menu requires pressing and holding the button next to the Program [⊚] icon for five seconds.

Touch Screen Navigation

Describes the touch screen interface and its icons.

Icons: FAN ON/OFF, WASH ON/OFF, DETERGENT INDICATOR, FAN STATUS, POWER SUPPLY STATUS, DOOR SAFETY STATUS, WASH STATUS, FIRE STATUS.

• FAN ON/OFF: Turns the unit on and off. The fan icon spins when operating.
• WASH ON/OFF: Starts or stops the wash sequence.
• DETERGENT INDICATOR: Monitors detergent level and flow. Green indicates sufficient detergent.
• FAN STATUS INDICATOR: Gray for OFF, Green for ON.
• POWER SUPPLY STATUS INDICATOR: Gray for OFF, Green for ON, Red for failure. Flashing Red indicates a pass has not functioned long enough.
• DOOR SAFETY STATUS INDICATOR: Green for closed doors, Red for open doors.
• WASH STATUS INDICATOR: Gray for OFF, Green for ON.
• FIRE STATUS INDICATOR: Gray for no fire, Red for fire detected.
• HELP: Displays help menu and navigation tips.
• ESP WASH STATUS: Navigates to wash status and countdown timers.
• NAVIGATION BAR: Pulls up a hidden menu for alarms, home, and settings/configuration/information screens.

The alarm icon directs to the alarms screen (illuminates red and blinks when triggered). The middle icon directs to the home screen. The right icon navigates to settings/configuration/information.

Variable Frequency Drive (VFD) Information

Details Yaskawa V1000 and A1000 VFDs used for exhaust fan control. These are factory programmed with minimal adjustment needed. For more information, refer to the Quick Start Guide or Yaskawa website.

Parameter Description Table:

Lists parameters like LOCAL/REMOTE Run Selection, Run Command at Power Up, Acceleration/Deceleration Time, Input Voltage, Motor Rated Current, Momentary Power Loss Operation Selection, and Number of Auto Restart Attempts, with Default and Factory Adjustment values.

Resetting the VFD Faults:

To reset a VFD fault, first determine and correct the cause. Then, shut off power to the drive from the breaker, wait for discharge, and restore power. For minor faults, pressing RESET then pressing it twice may suffice.

Model V1000 / A1000 Changing Parameters:

Step-by-step instructions are provided for changing parameters using the digital operator, including selecting menus, parameters, and values.

Monitor Motor Frequency and Motor Current:

Instructions on how to view motor frequency and current while the drive is running.

BMS Points List

Provides a list of Modbus / BACnet® points for the Grease Trapper ESP v2.00 system, including Analog and Digital inputs/outputs, their instance, name, units, Modbus address, read/write capability, and description.

Maintenance

NOTE: Maintenance frequency will vary based on site conditions. Adjust frequency as needed.

NOTE: It is recommended to visually inspect the cells at least once a week for the first month of the unit operation. Increase or decrease the wash times based on how clean the cells are upon inspection.

Routine service is required to ensure optimum performance and reliability.

Impingement and Mist Eliminator Filters:

Inspect monthly for grease and particulate build-up. Clean manually if apparent. Access filters by opening module door, releasing cell pushers, and sliding filters from tracks. Clean with hot water and Zep X701 detergent solution.

Ionizing-Collecting Cells:

Inspect monthly for grease build-up. Clean manually. Cells should be removed and manually cleaned every 6 months minimum. Access involves opening module door, releasing cell pushers, and using a cell removal tool. Handle cells carefully as they weigh approximately 35 lbs.

Carbon Trays:

Changeout frequency depends on cooking volume. Replace when odor breakthrough increases, typically every 3 to 6 months. May need more frequent changes for heavy grease applications. Refill steps are provided.

System Fan/Motor:

Inspect, service, and clean annually according to manufacturer's instructions.

Wash System Detergent:

Manufacturer recommends Zep X701 detergent, diluted 1:1 with water. If cells are not fully cleaned, adjust detergent timer, flow control, or strength. Zep X701 should also be used for manual cleaning of filters. Substituting detergents may decrease performance, cause shut down, or void warranty.

Accessing Filters and ESP Cells:

1. Turn fan off using keypad.
2. Turn all power pack disconnect switches to off. Follow lock and tag-out procedures.
3. Unlatch door fasteners to open access door to filters.
4. Short cells to ground using an insulated screwdriver to remove residual charge.
5. Slide metal mesh filters from tracks.
6. Clean filters with hot water and Zep X701 detergent.
7. Reinstall filters.
8. Unlatch door fasteners to access ESP cells.
9. Loosen and unhook cell pushers.
10. Carefully remove cells.
11. Inspect cells for bent collector plates; straighten with needle-nose pliers.
12. Inspect cells for residual grease; excessive buildup may require increased wash times or manual cleaning.

Replacement Parts Ordering

Replacement parts can be obtained through the Greenheck Parts Department or local authorized Greenheck Sales Representative. Contact information is provided.

Unit Layout - Elevation Views

Diagram Description (Unit Layout - Elevation Views): Two diagrams show the elevation views of the Standard Unit and the Solid Fuel Unit. They illustrate the arrangement of components such as the Impingement filter, ESP Pass modules (multiple for Solid Fuel), Carbon Filter, and the Main Control Box, indicating airflow direction.

Field Wiring Diagrams

Field diagrams are provided as general drawings. For unit specific drawings, consult wiring diagrams found on the unit control panels.

Diagram Description (Field Wiring Diagrams): Diagrams show general field wiring for Standard Unit and Solid Fuel Unit configurations. They illustrate connections between the Main Control Panel, Power Packs, ESP Passes, Solenoids, Door Limit Switches, Status Lights, and the Fan. Signals like Fire System Signal, Detergent Tank Assembly, Main & Drain Solenoids, Kitchen Control Panel Fan Signal, and Fan Power are indicated as field wired or factory supplied/wired.

FIRE SYSTEM CABINET WIRING OUTDOOR

Details wiring for the outdoor fire system cabinet, including control input, cabinet heater, thermostat programming instructions, and field wiring labels.

Thermostat Programming Instructions: Lists parameters and their descriptions for thermostat setup, including setpoints, differentials, modes, timing, calibration, and keypad protection.

FIRE SYSTEM WIRING - ANSUL ELECTRIC RELEASE: Shows wiring for the Ansul electric release system, including connections for fire system microswitches, cabinet heater, and power for electric release.

Troubleshooting

Provides a table of common problems and their solutions.

• Cells shorting immediately (Green indicator light continually flashes): Check if cells are dirty/clogged (run wash, clean manually), not installed correctly (ensure tight cell pushers), or wiring is incorrect (verify spark plug cable connections). If dry portion of wash cycle was bypassed, run fan for 60-90 minutes to dry cells.
• Green indicator on terminal enclosure illuminates, then turns off, then repeats: Power supply may not be providing correct voltage. Contact factory.
• Indicator lights (LEDs) not illuminating: Check wiring polarity or replace faulty LEDs/power supply.
• Power supplies operating (green), but cells not collecting contaminants: Check for insufficient connection between cells or plugs. Ensure spark plug style cables and cell pushers are properly installed.
• Cells not fully clean after completed wash cycle: Check detergent level, ensure correct detergent (Zep X701) is used, increase wash sequence times, or verify water temperature/pressure (140°F, 40 psi).
• Wash cycle won't start: Ensure fans are off, system is not in fire mode (check micro-switch wiring), and hot water shut-off valves are open.
• Unit not washing: Review wash history pages on controller for details on what might be preventing the wash.

Maintenance Log

A log for recording maintenance activities with fields for Date, Time, and Notes.

Our Commitment

Greenheck reserves the right to change specifications without notice as part of its commitment to continuous improvement. Product warranties can be found online at Greenheck.com. Additional information on the Grease Trapper ESP™ Pollution Control Unit is available in their catalog. AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, is also recommended.

Contact information for Greenheck (Phone, Fax, Parts, Email, Website) is provided.