Accurex Grease Trapper Kitchen Exhaust Pollution Control Unit

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 these instructions will result in voiding of the product warranty and may result in personal injury and/or property damage.

Unit certified to UL 8782

The Grease Trapper Pollution Control Unit (PCU) is a pre-engineered mechanical filtration pollution control unit with integral exhaust fan (available without exhaust fan as an option). The unit is designed to remove grease and odor molecules from the kitchen exhaust airstream. This installation manual covers procedures for receiving, installing, and maintaining the filtered section of the unit. For additional instructions and maintenance information on the integral exhaust fan, when applicable, refer to the fan nameplate to determine model type and visit accurex.com to download the corresponding manual.

Table of Contents

• Receiving, Unpacking, Handling, Storage: 2
• Grease Trapper System Function: 3
• System Components: 4
• PCU Field Assembly: 5
• Filter Installation: 6
• Unit Modules: 7
• Attaching Fan: 7
• Installation: 7
• Rigging and Placing Equipment: 7
• Ductwork & Plumbing Connections: 7
• Remote Filter Status Indicator Panel: 8
• Electrical Connections: 9
• Fire System: 10
• Operation: 11
• Start-Up: 11
• Remote Filter Status Indicator: 11
• Filter Replacement: 11
• Carbon Tray Replacement: 11
• Controller Setup and Tutorial: 12-18
• Keypad Navigation: 19
• Maintenance: 20
• Variable Frequency Drive (VFD): 20
• Regular Scheduled Maintenance: 23
• Replacement Filter - Parts Ordering: 23
• Unit Layout - Elevation Views: 24
• Wiring Diagrams: 25-27
• Our Commitment: 28

General Safety Information

Only qualified personnel should install this system. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

• Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), and the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.
• The rotation of the fan wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.
• Fan motor must be securely and adequately grounded.
• Do not spin fan wheel faster than maximum cataloged fan rpm. Adjustments to fan speed significantly effects 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.
• Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.
• Verify that the power source is compatible with the equipment.
• Never open access doors to a duct while the fan is running.

DANGER: Always disconnect power before working on or near a fan. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION: When servicing the fan, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.

CAUTION: Precaution should be taken in explosive atmospheres.

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 bill of lading. Remove all other shipping/packing materials including fan tie down straps.

Handling

All units can be rigged and moved by the lifting brackets provided on the rails. Smaller units, including housing sizes 30 and 45, are shipped on a skid and can also be moved around with a forklift. 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

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 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 buildup. Leave coverings loose to permit air circulation and to allow for periodic inspection.

OUTDOOR

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.

Inspection and Maintenance during Storage

While in storage, inspect fans 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. 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.

Grease Trapper System Function

Grease Trapper is a multistage mechanical air filtration unit, with an optional carbon filter module. It is designed for two specific functions:

1. Remove grease particulate from kitchen exhaust.
2. Remove odor molecules from kitchen exhaust.

NOTE:

• Grease Trapper must be connected to a listed exhaust hood assembly and must be installed in accordance with local building codes, NFPA 96 and NEC.
• The unit must be installed with a minimum 12 inch clearance to combustible materials on top of unit, and six inches on the sides and bottom.

Each mechanical filter stage is monitored by an individual pressure switch that signals when a particular filter stage needs filters to be replaced. When a filter stage requires replacement, a signal from the pressure switch(es) illuminates an indicator light located on the Remote Filter Status Indicator Panel (if provided), or triggers a fault to be displayed on the keypad (if provided), or sends a signal to the BMS over a communication protocol (if configured).

NOTE:

Grease Trapper is designed to remove submicron, 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

Unit Body

The unit body is shipped on a common mounting rail ready for installation. If the unit was ordered with an exhaust fan and the housing size is not 180 or 270, the fan will also be mounted on the unit. If the unit was ordered with an exhaust fan and the housing size is 180 or 270, the fan will ship separate from the unit. If unit must be disassembled in the field, refer to instructions on page 5.

Filters

Filter quantity for each filter stage is based on unit size. A consistent quantity of filters is provided for each stage of filtration.

Remote Filter Status Indicator Panel (if provided)

A remote filter status indicator panel may be provided depending on the unit configuration. This panel provides indicator lights which illuminate when a module's filters are completely loaded. This item must be mounted remotely in the cooking area prior to unit start-up, so that it can be monitored by the cook staff. See page 27 for wiring information.

Fire Cabinet (if provided)

If provided, 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. See pages 26 and 27 for heater controller schematics and programming information.

System Control Panel (if provided)

The system control panel fed from a 15A building breaker allows the user to interface with the unit and controls operation, and monitors wash and other functions. Unless factory mounted on the rails of the unit, pressure tubing needs to be run from unit modules to system control panel in the field. The system control panel has both indoor (NEMA-1) and outdoor (NEMA-4) enclosure options that can be mounted on the unit rails or shipped loose. Follow 110-26 of National Electrical Code in allowing adequate room for electrical servicing as well as allowing clearance for opening any access or service doors.

Ship Loose VFD (if provided)

If configured to include a VFD and fan HP is greater than 25HP, the unit will be provided with a ship loose VFD to be remote mounted. VFD will come pre-mounted inside a NEMA 3R outdoor rated enclosure. See wiring diagram provided with unit for wiring details to connect main PCU control panel to VFD. See unit specific wiring diagram for field wiring/connection details.

Keypad (if provided)

Unit may be provided with a ship loose push button keypad. Keypad will be provided with a 35, 75, or 150 foot RJ25 cable to field connect the keypad to the main control panel.

PCU Field Assembly - if applicable

If unit is shipped in sections, each section will need to be assembled 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. Install gasket to applicable cells as shown below.

MODULE FLANGE GASKETING DETAIL

1/2" SILICONE GASKET

ENDS OF SILICONE GASKET TO BE ON THE SIDE LOCATED ON THE TOP HALF OF THE UNIT. **DO NOT PUT SEAMS ON BOTTOM**

NOTES: 1. GASKETING IS MOUNTED TO ONLY 1 MATING SURFACE. 2. CLEAN ALL FLANGED SURFACES WITH ALCOHOL BEFORE INSTALLING GASKET

1" CERAMIC GASKET (479977) ATTACHED TO FLANGE WITH FIRE CAULK (HAZ2727)

4. Reattach the fasteners from step 2 as shown in the drawing below, ensuring proper gasket and seam cover installation.

1/2" SILICONE GASKET

MODULE TO MODULE ASSEMBLY DETAIL

5/16" X 1" SS BOLT

SS WASHER W/NEOPRENE GASKET

5/16" SS HEX NUT

SS WASHER W/NEOPRENE GASKET

1" CERAMIC GASKET

1/2" SILICONE GASKET

Attaching Fans

NOTE: For housing sizes 180 and 270, the unit and fan will always be mounted on separate rails.

The PCU 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.

1. To seal the fan to unit body connection, apply fire rated caulk (3M Fire Barrier Sealant CP25WB+ 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.
2. 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).
3. To reassemble locate fan on isolators on rails.
4. Reattach fasteners for companion flange removed in step 1.
5. Reattach fasteners attaching fan to isolators removed in step 2.

Transition collar

Fan

Companion flange

1/2 inch silicone gasket

U-CLIP

TOP/BOTTOM

SIDES

Transition are evenly spaced around fan inlet

Fasteners attach the fan to the isolators on each corner of the fan

Installation

Rigging and Placing Equipment

1. The unit is furnished with lifting lugs at the four corners.
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 (4 module unit with mounted utility set fan as basis) 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, units from housing sizes 30 to 120 may be suspended from an adequate overhead structure, using suitable undercarriage or hanging rods (by others). If the unit is suspended by hanging rods, minimum 1/2 inch (12.7 mm) diameter threaded rod is to be used. All hanger brackets/lifting lugs must be used to ensure proper support of the unit. 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.

NOTE: If unit is suspended using hanging rod, make sure rods do not interfere with opening/closing all module doors.

36 inches

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.

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

9. The Remote Filter Status Indicator Panel (see page 8 and 11) should be located in an area convenient for monitoring by the cook staff. For details on wiring this item, refer to the Wiring Diagrams on page 27.

Ductwork Connections

Ductwork must conform to the 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).

Plumbing Connections

Each module is provided with a drain to allow any grease or washing solution to be removed from the unit. The drains must be connected to a grease receptacle ensure proper unit operation.

The units are provided with a 1-inch nipple from the factory located in the middle of each module to be used as a drain connection. The drains can be manifolded together and a ball valve is recommended on each module drain.

All plumbing components are provided by others and must be installed based on local plumbing codes.

1" FNPT HALF COUPLING (472803) FULLY WELDED TO SHELL. FIELD TO REMOVE 1" PLUG (457083) BEFORE CONNECTING DRAIN PLUMBING.

Remote Filter Status Indicator Panel (if provided)

Locate spot on the wall for Remote Filter Status Indicator panel and fasten to wall. See Electrical Connections sections for wiring details.

4.72

7.87

7.80

3.54

MOUNTING TYPE SHIP LOOSE, NEMA4/4X/6/6P INDICATOR LIGHTS WILL ILLUMINATE RED WHEN FILTER STAGE IS DIRTY

Filter Installation (see Figure 1 on page 23)

The mechanical filters are shipped in the unit (Metal Mesh, Standard Pleated, High Efficiency). The carbon filters are shipped loose, and are typically located on the end of the shipping pallet.

Care must be taken to ensure filters are installed in the proper sequence and proper direction of airflow.

Open the access doors. Slide filters into filter racks in stages 1, 2, 3 and 4. Close and secure access doors.

System Control Panel (if provided and shipped loose)

Locate an area with enough space to mount the control box and fasten to the wall. See unit specific drawings for enclosure dimensions.

Ship Loose VFD (if provided)

Locate an area near the unit with enough space to mount the VFD and fasten to the wall. Follow VFD IOM provided with the VFD for more detailed mounting instructions.

Keypad Mounting (if provided)

NOTE: The keypad may be factory mounted. If so, continue to the Electrical Connections section.

1. For systems with remote controls or keypad, a 35, 75, or 150 foot RJ25 cable is supplied to connect the keypad to the controls. The cable is plenum rated and does not need to be run through conduit unless required by local codes. If the keypad is to be mounted further away than the cable that is received, additional cable will be needed. Additional cable is available at the lengths mentioned above.

Keypad Mounting Diagram

Keypad Dimensions

7.625 inches

5.25 inches

Front View

2.25 inches

7.0 inches

Top View

4.625 inches

-00.875 inches

Side View

Electrical Connections

Once all system components are installed, electrical connections for the system can be made.

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: 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 main control panel (if provided).

The Grease Trapper Filtered PCU will require additional field wiring for proper installation. If configured with a main control panel, it will be shipped loose or mounted on the unit rails and is designed for either indoor or outdoor applications. A typical field wiring schematic is shown on page 25. Refer to the unit specific wiring diagram located on the inside of the door of the system control panel for the unit specific wiring that is required.

In some cases, no system control panel will be provided, and instead the Remote Filter Status Indicator Panel will be provided. For wiring details for Remote Filter Status Indicator Panel, refer to diagram on page 27.

Wiring from fan disconnect to fan motor will be done by the factory if the disconnect switch is mounted to the fan or to the unit.

Wiring from the output of the VFD to the fan disconnect switch will be done by the factory if the VFD is mounted inside the system control panel, and the system control panel is mounted on the unit rails.

If the fire system cabinet(s) are provided with a cabinet heater, separate single phase power is required to be operate to the cabinet heater controls.

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 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.

PCU Fire Cabinet Quantity and Size

TYPICAL DRAWING

FIRE SYSTEM DISTRIBUTOR / FIRE SYSTEM INSTALLER: There are four quik-seals on each module. Two are on the top and two are on the bottom. Connection to only one of the quik-seals on each module is required. Multiple quik-seals are provided for situations where there are obstructions to the connection point.

• Do not install fire piping in front of doors on module. Must have 36 inches of clearance.
• Do not install fire piping such that it interferes with the drain plugs & piping on the bottom of the modules.

Operation

NOTE: Prior to starting the fan, remove fan tie down straps. These are used only to prevent shipping damage. After removing the tie down straps, the fan should float freely on the isolators. Confirm that the installation is completed as shown in the Installation section.

Initial System Start-Up

1. Verify unit is installed properly and all plumbing and electrical connections have been made.
2. Close and properly fasten the doors on the unit.
3. Turn on electrical power to control cabinet (if provided) and exhaust fan.
4. Turn on fan disconnect.
5. Turn the fan on momentarily, then turn off. If a fan button exists on the user interface, press the button to start the fan. If a fan button does not exist on the user interface, or the unit wasn't configured with a user interface, the fan will need to be turned on by external means. Remove fan drive access cover and verify proper fan wheel rotation. If rotation is backwards, reverse the fan motor electrical input leads.
6. If provided with a system controller, check for alarms on the controller. Correct any alarms that may be displayed (see page 13 for details).
7. System should now be ready for operation.

Remote Filter Status Indicator (if provided)

As the mechanical filters load with grease particles, resistance to airflow increases and the exhaust air volume decreases. Pressure switches continuously read the resistance across each filter stage. Each pressure switch is factory preset to transmit an alarm signal when that stage of filter has reached its terminal resistance and needs replacing with new filters. This terminal resistance setting is based on the filter manufacturers rating. The alarm signal illuminates an indicator light located on the face panel of the Remote Filter Status Indicator Panel (if provided).

IMPORTANT: Replace filters immediately if Remote Filter Status Indicator indicates a filter is loaded, or if provided with keypad and Dirty Filter Alarm fault is present, or if BMS is triggered that a filter is loaded. Failure to do so may cause reduced exhaust air volume allowing smoke to escape into the kitchen, or may cause filters to rupture, or both. The terminal resistance for each stage of filters is factory set. Altering these settings without first contacting Accurex will void the manufacturer's warranty.

Filter Replacement

Determine which stage(s) of filter needs replacing as shown by either Remote Filter Status Indicator Panel, or fault on Keypad, or via BMS integration.

1. Have the correct type and quantity of filters available at the unit.
2. Turn off and lockout power to the fan.
3. Open the appropriate access door(s).
4. Remove the spent filter(s) by sliding them out of the housing access door opening.
5. Replace with the proper new filter(s) making sure direction of airflow is correct.
6. Close and secure access door(s).
7. Turn on power to the fan.

CHANGE STAGE 1 FILTERS

CHANGE STAGE 2 FILTERS

CHANGE STAGE 3 FILTERS

Remote Filter Status Indicator Panel

Proper filter disposal is important to the environment. Refer to local landfill codes.

Carbon Tray Replacement

Unlike particulate filters, technology has yet to develop a cost-friendly method of determining when the carbon trays need replacing. So, the industry standard is the human sniff test. As the carbon begins to lose its effectiveness, odor breakthrough gradually occurs and odor concentration increases. Based on a variety of cooking applications/installations, life of the carbon trays can range from a few months to one year.

Replace carbon trays when odor breakthrough is first noticed. When replacing carbon trays, follow the instructions in the Operation section, Filter Replacement, Steps 2 thru 8.

Controller Setup and Tutorial - if provided with System Control Panel

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 button) this will first bring you to 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

Exhaust: Off

Speed: 0.0%

PCU EXHAUST FAN STATUS: This screen will display the status of the PCU exhaust fan as well as display the fan speed (if applicable).

Fan Enable Status

Fan ON by DI: Off

Fan ON by Fire: Off

Fan ON by BMS: Off

Fan ON by BTN: Off

PCU FAN ENABLE STATUS: This screen will display what is currently responsible for turning the exhaust fan on.

Filter Module Status

Filter Module 1: OK

Filter Module 2: Dirty

Filter Module 3: OK

Filter Module 4: OK

Filter Module 5: OK

PCU FILTER MODULE STATUS: This screen will display current status of each filter module present on the unit (whether filters are okay, or dirty and need to be replaced). Filter module status is provided for all non-carbon (odor) modules present on the unit.

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.

Example of Alarms

*** ALARM ***

Exhaust Fan Alarm

Check exhaust starter or VFD for fault code.

This is an example of an exhaust fan fault.

Alarms

No active alarm

Press ENTER key to access ALARM HISTORY log.

This screen appears if there are no active alarms. To view all saved alarms, press the button to enter the DATA LOGGER. For more information, see the Data Logger menu.

Controller Setup and Tutorial - if provided with System Control Panel

A. Clock

Clock

02:00:00PM 04/11/25

Date: 04/11/25

Hour: 2:00pm

Day: Friday

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.

DST: Enable

Transition time: 60min

Start: LAST SUNDAY in MARCH at 2.00

End: LAST SUNDAY in OCTOBER at 3.00

THIS SCREEN ALLOWS THE USER TO ADJUST DAYLIGHT SAVINGS TIME SETTING. The Daylight Savings time feature can be adjusted to meet the current daylight savings time requirements.

Holiday Configuration

Number: 4

Wash and fan schedules will not operate during holidays.

Holiday X

1: 0/0 - 0/0

2: 0/0 - 0/0

3: 0/0 - 0/0

4: 0/0 - 0/0

THIS SCREEN ALLOWS THE USER TO ADD AND ADJUST HOLIDAY TIMES. 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.

Analog Input

Fan Speed (AIN1)

Input B001: 0.0%

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.

Digital Input

On / Off (DIN1)

DI 1 Status: Open

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.

Relay Output

Exhaust Relay (DOUT1)

Relay 1 Status: OFF

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

Analog Output

Fan Speed (AOUT1)

Output: 5.00vdc

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

Controller Setup and Tutorial - if provided with System Control Panel

C. Service

a. System Information

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

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. BIOS AND BOOT PERTAIN TO THE CONTROLLER'S FIRMWARE AND OPERATING SYSTEM.

Information

Accurex

Version: 1.00.001

Date: 06/10/25

Bios: 6.40 11/17/15

Boot: 5.02 09/30/13

b. BMS Configuration

BMS Configuration

Protocol: BACnet MSTP

To adjust BACNET settings press & hold ALARM & ENTER keys to access BIOS screens.

The BMS Configuration sub-menu allows the user to view and alter BMS protocol settings. If the BMS protocol is BACnet or Modbus, additional screens allow further configuration. See below for details. To access the BMS Configuration sub-menu, enter the service password (Default=1000).

BMS Configuration

Control Fan Speed via BMS: No

(Otherwise, controlled via analog input term SPD-+ and SPD-C)

THIS SCREEN WILL BE VISIBLE IF FAN CONTROL SPEED REFERENCE IS SELECTED IN FACTORY SETTINGS AS "VARIABLE".

If selecting “Yes”, fan speed will be controlled via BMS point. Otherwise, if selecting “No” fan speed will be controlled via analog input terminal blocks SPD-+ and SPD-.

MODBUS SETUP

BMS Card Address: 1

Baudrate: 19200

THIS SCREEN ALLOWS THE USER TO ADJUST MODBUS PARAMETERS. This screen only appears if the selected BMS protocol is set to Modbus. The address is the Modbus address of the card installed in the SERIAL CARD port located on the face of the controller. (Factory Default = 1). The Baud Rate should be set to the BMS baud rate. (Factory Default = 19200).

TO ACCESS/ADJUST BACNET MSTP AND IP PARAMETERS, PERFORM THE FOLLOWING STEPS...

1. Press together for 3 seconds the (alarm) and (enter) to enter the BIOS menu. Press ↓ (down) arrow to select SYSTEM INFORMATION, LOG DATA, >OTHER INFORMATION, FLASH/USB MEMORY and press (enter) to confirm.
2. Press (down) arrow to select PCOWEB/NET CONFIG and press (enter) to confirm.
3. Select either PCOWEB Settings for BACnet IP or PCONET Settings for BACnet MSTP and press ←← (enter) to confirm.

>PCOWEB settings

>PCONET settings

4. Once reaching the PCO Settings, adjust each BMS parameters and press enter to cycle through them all. Once finished adjusting all the parameters, be sure to have save the parameters by navigating to the screen that shows “PCONET CONFIG ENABLE” and changing “NO” to “YES” next to “Update pCOnet?”. Then follow the prompts on the screen to cycle power on the controller.

Make sure to cycle power when prompted to cycle power to the controller by unplugging the G/GO orange plug on the bottom of the controller, then plugging it back in. Skipping this step will not save parameters that were adjusted.

BACNET IP

DHCP: OFF (off = static)

IP Address: --0. --0. --0. --0

Netmask: (subnet) --0. --0. --0. --0

Gateway: --0. --0. --0. --0

DNS1: --0. --0. --0. --0

DNS2: --0. --0. --0. --0

BACnet ID: (instance) 77000

BACnet Type: IP or Ethernet

PCONET CONFIG ENABLE UPDATE pCOweb? YES

BACNET MSTP

BACnet ID: (instance) 77000

BACnet baud: 38400

BACnet MAC: 127

Max Masters: --0

Max Frames: --20

PCONET CONFIG ENABLE UPDATE: PCOweb? YES

C. Service

c. Service Settings

a. Fan Operation

The Service Settings sub-menu allows the user to adjust fan operation settings, set a fan on/off schedule, manually enable/disable input and outputs, calibrate sensors, create or restore user settings and the alarm history log.

a. Fan Operation

The Fan Operation sub-menu allows the user to adjust fan settings.

Auto Fan Off Settings

Auto Fan Off? No

Run Hours: 8 hours

Note: This will only shut the fan off if the fan was powered on by the keypad (NOT DI)

THIS SCREEN ALLOWS THE USER TO ADJUST SETTINGS REGARDING THE AUTO OFF FEATURE WHICH STOPS THE FAN IF STARTED FROM THE USER INTERFACE AFTER A SPECIFIC AMOUNT OF TIME.

Auto Fan Off?: Enable or disable the auto fan off feature. (Default is No).

Run Hours: Adjust fan run time before the fan automatically shuts off. (Default = 8 hours).

Fan Scheduling

Fan On: NO 8:00am

Fan Off: NO 10:00pm

Days/Week Mo Tu Wd Th Fr Sa Su

THIS SCREEN ALLOWS THE USER TO SET A FAN ON/OFF SCHEDULE FOR THE WEEK.

Fan On: Enable or disable the fan turning on at a specific time. Time can be adjusted below for fan on setting. (Default is NO, with 8:00am start time).

Fan Off: Enable or disable the fan turning off at a specific time. Time can be adjusted below for fan off setting. (Default is NO, with 10:00pm start time).

Days/Week: Adjust which days per week the auto wash should occur. Black (filled in) boxes indicate enabled for that day, white (open) boxes indicate disabled for that day.

C. Service

c. Service Settings

b. I/O Manual Control

IN I/O MANUAL Control, THE USER WILL BE ABLE TO ADJUST INPUTS/OUTPUTS.

NOTE: The manual adjustment of these input and/or outputs should only be adjusted in the event of troubleshooting. We suggest these parameters only be changed with the advice of factory personnel.

Analog Input

Fan Speed (AIN 1)

Manual Control: B001:OFF

Manual Position: 0.0

Value: 100.0

Manual Control: Allows the user to override the analog input for troubleshooting. Manual Position: The value to force the input to when in an override state. Value: The current value of the analog input.

Digital Input

On / Off (DIN 1)

Manual DI 1: CLOSED

Manual Position: OFF

DI 1 Status: Open

Manual DI: Allows the user to override the digital input for troubleshooting. Manual Position: The value to force the input to when in an override state. Status: The current value of the digital input.

Relay Output

Exhaust Relay (DOUT 1)

Manual Relay 1: OFF

Manual Position: OFF

Relay 1 Status: OFF

Manual Relay: Allows the user to override the relay output for troubleshooting. Manual Position: The value to force the output to when in an override state. Status: The current value of the relay output.

Analog Output 1

Fan Speed (AOUT 1)

Mode: Auto

Manual Value: 0.00vdc

Output: 0.00vdc

Mode: Allows the user to override the analog output for troubleshooting. Manual Value: The value to force the output to when in an override state. Output: The current value of the analog output.

C. Service

c. Service Settings

c. Sensor Calibration

IN SENSOR CALIBRATION, THE USER WILL BE ABLE TO ADJUST ANALOG INPUTS OFFSETS.

Analog Input

Fan Speed (AIN1)

Input B01 Offset: 0.0

Value: 100.0

Offset: This adjustable value can be used to calibrate the input with an offset value. (Factory Default = 0.0)

Value: This is the current value of the input. (Offset adjustment is added). Similar screens are available for the remaining analog inputs.

C. Service

c. Service Settings

d. User Save/Restore

User Save/Restore

Save? No

Restore? No

Enable Auto Save: Yes

IN USER SAVE/RESTORE MODE, THE USER WILL BE ABLE TO SAVE AND RESTORE THE DEFAULT PARAMETERS STORED IN MEMORY.

If the user would like to save their settings, move the cursor to the SAVE position and change to YES. This will save all of the current parameters into memory as Service Settings. If the user would like to restore to these values at some point in the future, moving the cursor to the RESTORE position and selecting ON, will restore the controller to the user-saved defaults.

e. Alarm History Reset

Alarm History Reset

This will clear the alarm history.

Continue? NO

THIS SCREEN ALLOWS THE USER TO CLEAR THE ALARM FROM MEMORY.

If the user would like to clear the alarm log, move the cursor to the OFF position and change to YES.

D. Manufacturer

The Manufacturer menu allows the user to access several sub-menus regarding controller configuration, I/O configuration, factory settings, controller initialization pages, and factory save/restore pages. These changes are to be completed under factory advisement only!

Keypad Navigation

ACCUREX

SYSTEM FAULT

FAN

MENU

NAV

↓

When 'BUTTON(S)' are mentioned in the description below, we are referring to the 'squares' on the keypad. The following information details the Daily Operations of the Grease Trapper Filtered PCU keypad buttons and their functions.

FAN - Momentarily pressing the 'FAN' button will turn on the PCU unit. If the fan is on, the background behind 'FAN' text will be dark. To turn the system off, press the 'FAN' button.

Display functionality and control:

To change the display contrast, hold the buttons next to the Alarm and Program icons simultaneously while pressing the buttons next to the ↓ and ↑ arrows. The down arrow will make the screen lighter and the up arrow will make the screen darker.

Upon any alarm, the ‘SYSTEM FAULT' red LED light on the face of the keypad starts flashing. Once all alarms are corrected and any low detergent alarm is manually reset, this LED will stop flashing and no longer be illuminated.

Through the middle of the screen, system status messages will be displayed as a reference. These system statuses will include:

• Current alarms
• Overall unit filter status

The keypad also includes indicators next to the buttons that correspond to the buttons on the controller. These can be used to navigate through the controller using the keypad. To access the main menu, simply press and hold the button next to the Program icon for five seconds or until the screen changes to the main menu.

Variable Frequency Drive (VFD) Information

A Yaskawa V1000 or GA500 (200-230 and 460 VAC, 25HP or lower) or Yaskawa A1000 (575 VAC) or HV600 (30HP or larger) variable frequency drives (VFDs) will be provided if the PCU is configured to use a VFD to control the exhaust fans. These drives will come programmed from the factory, and little to no adjustment will be necessary in most cases. For more in-depth information on wiring and programming these drives, please utilize the Quick Start Guide provided with the package. This quick start guide and other technical manuals can also be found on the Yaskawa website at www.yaskawa.com.

*See PCU wiring diagram for more information.

Resetting the VFD Faults

Upon a VFD fault, first determine the cause of the fault and correct. Typically, if the drive detects a fault, it will remain inoperable until that fault has been corrected and the drive has been reset.

Once a fault has been corrected, the easiest way to clear the displayed fault on the VFD is to shut off power to the drive from the power source (breaker). Wait for the VFD to fully discharge and then restore the power.

Upon correcting a minor fault, recycling power may not be necessary. Simply press RESET then press twice.

Model V1000/GA500

Changing Parameters

Step 1: V1000 Digital Operator power-up state.

Step 2: Select Parameter Menu Press two times until the digital operator show the parameter menu (PAr) then press ENTER

Step 3: Select Parameter Press RESET to select the digit you would like to change. Next use and to select the parameter group, sub-group or number. Once the parameter you wish to change is displayed on the screen and the digit furthest to the right is flashing, press ENTER

Step 4: Change Parameter Value Press RESET to select the digit of the parameter value you would like to change. Modify the parameter value using and ✓ and press ENTER to save the new value.

Monitor Motor Frequency and Motor Current

Step 1: V1000 Digital Operator power-up state:

Step 2: Output Frequency Press until the FOUT LED turns on. The display now shows the actual drive output frequency in hertz (Hz).

Step 3: Motor Current Press again will show the motor output current. The 'A' behind the value means 'Amps'.

Model A1000

Changing Parameters

Step 1: A1000 Digital Operator power-up state.

Step 2: Select Parameter Menu Press two times until the digital operator shows the programming menu, then press ENTER

Step 3: Select Parameter Press to select the digit you would like to change. Next use and to select the parameter group, sub-group or number. One the parameter you wish to change is displayed on the screen and the digit furthest to the right is flashing, press ENTER

Step 4: Change Parameter Value Press RESET to select the digit of the parameter value you would like to change. Modify the parameter value using and and press ENTER to save the new value.

Monitor Motor Frequency and Motor Current

With the drive running, press A until reaching the Monitor Menu. This will display output frequency and amperage of the motor.

Grease Trapper Filtered v1.00 Modbus / BACnet® Points List

Maintenance

Regular Scheduled Maintenance

1. Replace filter(s) immediately after the Remote Filter Status Indicator lights up.
2. Replace carbon trays at the first sign of odor breakthrough.
3. Remove all filters and carbon trays and pressure wash/clean the housing interior as needed or as dictated by local code. Only use degreasers that are compatible with stainless steel surfaces. Use caution so as to not damage static pressure tips, tubing or fire system nozzles and detectors. Verify drain connections on are not clogged. Dry the housing interior and replace Stage 1 thru 4 filters, close and secure access doors.
4. Remove/open fan scroll access door and pressure wash/clean all internal surfaces of the fan every 6 months. Check sheave-belt alignment and belt tightness.
5. If provided with a fan, refer to the utility set or inline fan Installation, Operation and Maintenance (IOM) manual provided with unit for maintenance requirements.

Replacement Filter - Parts Ordering

Replacement filters and carbon panels can be obtained through the Accurex Parts Department, 800-371-6858, Parts@Accurex.com or your local authorized Accurex Sales Representative. To locate your local Accurex Representative, visit accurex.com

Unit Layout - Elevation Views

NOTE: Unit layout views are typical. Filter pass quantity and type vary based on the unit configuration. Reference actual unit drawings for unit specific details.

FIGURE #1: ACCESS DOOR SIDE

FIGURE #2: ACCESS DOORS REMOVED

FIGURE #3: VIEW OF A NON ACCESS DOOR SIDE

Field Wiring Diagrams

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

Unit with Remote Filter Status Indicator

FILTER MODULE 1 FILTER MODULE 2 FILTER MODULE 3 FILTER MODULE 4

FAN POWER (V/HZ/PH # FLA AMPS) FROM FAN CONTROLS (FAN CONTROLS NOT PROVIDED WITH UNIT)

REMOTE STATUS INDICATOR POWER (V/50-60/1 15 AMP)

MAIN CONTROL PANEL ON PCU RAILS (ON UNIT)

REMOTE FILTER STATUS INDICATOR PANEL SHIPPED LOOSE

FIELD WIRED

FACTORY SUPPLIED AND WIRED

Unit with System Control w/ VFD

FILTER MODULE 1 FILTER MODULE 2 FILTER MODULE 3 FILTER MODULE 4

CONTROL PANEL MAIN POWER (V/HZ/PH 15 AMP)

BUILDING COMMUNICATIONS

KEYPAD - 150 FT CABLE PROVIDED

NORMALLY CLOSED CONTACT FROM FIRE SUPPRESSION SYSTEM

MAIN CONTROL PANEL ON PCU RAILS (ON UNIT)

KITCHEN CONTROL PANEL FAN SIGNAL

FAN POWER (V/HZ/PH # FLA AMPS)

FAN

FIELD WIRED

FACTORY SUPPLIED AND WIRED

Field Wiring Diagrams

Fire Cabinet Heater Wiring Detail (Dwyer Controller)

Dwyer Digital Controller Settings (for Cabinet Heater)

PARAMETER PROGRAMMING

• Press and hold Set for 30 seconds or until 00 appears blinking
• Press Set key to enter parameter list
• With and go to the desired parameter on the list of parameters
• Press Set to see the current set value
• Press either or to set the desired new value
• Press Set to confirm it and exit to the parameter list
• Press Set plus to quit programming or wait 1 minute (keyboard timeout).

Fire System Wiring - Ansul Electric Release

FS1

NC NO COM

FS2

NOT USED

NC NO COM

NOT USED

120/1 POWER FOR ELECTRIC RELEASE (FROM KITCHEN FIRE SYSTEM)

ACTUATION LINE (TO/FROM KITCHEN FIRE SYSTEM)

TO ELECTRIC RELEASE SOLENOID

Remote Filter Status Indicator Wiring (if provided)

BUILDING BREAKER PANEL

115/1 15 AMPS

HOT NEUTRAL

SYSTEM CONTROLS (ON UNIT RAILS OR SHIPPED LOOSE)

HOT

FH

CONTROL POWER

115/1 15 AMPS

NEUTRAL

NON-SHUNTED

PCF1 PCF2 PCF3

REMOTE FILTER STATUS INDICATOR PANEL

MODULE 1 DIRTY FILTER STATUS

X1 X2 LT10

MODULE 2 DIRTY FILTER STATUS

X120X2

MODULE 3 DIRTY FILTER STATUS

X10 LT30X2

Our Commitment

As a result of our commitment to continuous improvement, Accurex reserves the right to change specifications without notice.

Product warranties can be found online at accurex.com, either on the specific product page or in the Warranty section of the website at Accurex.com/Resources/Warranty.

ACCUREX

P.O. Box 410 Schofield, WI 54476

Phone: 800.333.1400 • Fax: 715.241.6191

Parts: 800-371-6858 • accurex.com

28 479928 • Grease Trapper, Rev. 8, June 2025

© 2025 Accurex, LLC