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1. Continue adding media until module is full Caution Do not overfill as it may cause the sides to bulge Replace cover plate and install securing screw Optional some dusting may occur on initial start up of the unit To mini mize this vacuum or blow out the modules Slide the modules back into the rack being cautious that the airflow label is matching the FILTER PANELS 1 25 INCH DEPTH airflow of the unit Step 10 Close the odor control media access door Pour new media into the media monitoring tube and re install Record the date on the label MEDIA MONITORING TUBE SFT 95 925 S 99 LIMITED WARRANTY THE GAYLORD ClearAir POLLUTION CONTROL UNIT LIMITED WARRANTY The Gaylord ClearAir Pollution Control Unit is warranted by GAYLORD INDUSTRIES to be free from defects of material and workmanship under normal use when installed operated and serviced in accordance with factory recommendations GAYLORD INDUSTRIES obligation under this warranty shall be limited to repairing or replacing at its option any part of said equipment which GAYLORD INDUSTRIES examination shall disclose to its satisfaction to be thus defective for a period of one 1 year from the date of installation provided proper and acceptable evidence of such installation is recorded at the factory or 18 months from date of shipment which ever occurs first GAY2. chart provides data for ordering filters Service and Maintenance The KOR48 carbon media is deep purple in color when new turning to a dark brown during use and light tan when ex pended Carbon media is black at the time of delivery It is recommended that both medias be checked in accordance with the table below The ClearAir unit incorporates an Odor Control Media Monitoring Tube to facilitate inspection refer to page 16 Using an open end wrench turn the tube nut counter clock wise and remove the monitoring tube assembly If the KOR48 Carbon media is dark brown break a granule open and if the inside is light tan there is very little life left and it should be replaced If the outside of the granules are light tan the me dia is completely expended and must be replaced If you are unable to determine the status send a small sample one teaspoon to Cameron Great Lakes noting the date of instal lation They will conduct a life test and advise the results by fax or phone within 2 days of receipt For further details con tact Cameron Great Lakes Cameron Great Lakes 2335 NW 29th Portland OR 97210 800 777 4044 630 377 0711 The label next to the monitoring tube includes an area where the date of initial fill and the date of inspection can be filled in with a grease pencil ODOR CONTROL MEDIA MONITORING TUBE USE GREASE PENCIL LAST REFILL DATE LAST INSPECTION INITIAL DATE INITIAL FORM NO OCMM 79
3. 03 691 2010 1 800 547 9696 Fax 503 692 6048 email info gaylordusa com LOCAL SERVICE AGENCY FORM NO TMCA CO COPYRIGHT 2010 GAYLORD INDUSTRIES LITHO USA
4. 7 ODOR CONTROL SECTION MEDIA BED TYPE Replacing the Media There are two methods of replacing the media the Advanc ing Program or Site Refill Advancing Program This is a program offered by Cameron Great Lakes Inc where they will ship recycled pre filled modules in exchange for used modules The pre filled modules are shipped two to a box box size 25 x 25 x 13 which weigh approximately 90 165 The boxes are palletized 36 to a pallet and are shrink wrapped Three primary advantages of the Advancing Program are 1 vir tually no requirement for storage except for the short period of time needed to switch the new modules for the expended ones 2 minimizes unit down time and 3 avoids filling on site Step 3 Step 4 Step 5 To participate in the Advancing Program proceed as follows 1 Contact the local Cameron Great Lakes distributor and order the number of modules required Step 6 2 Upon receipt remove the depleted modules and replace with the new modules 3 Empty the media from the depleted modules into con Step 7 tainers for disposal 4 Pack the empty used modules into the boxes the new A d Step 8 ones came in and ship back to the distributor 5 Fill the media monitoring tube with new media and mark the date on the monitoring tube label Site Refill Site refill involves the purchase and storage of new media emptying and refilling the modules and disposing of the s
5. ENT LIFTING PROCEDURE 2433444 3444 2 tetris 6 MEDIA BED ODOR CONTROL SECTION T WARRANTY nien eee Inside back cover RECEIVING amp INSTALLATION RECEIVING Most ClearAir units are shipped in one piece However some units because of size or special jobsite conditions may be shipped in multiple sections Follow the instructions that are provided with the unit to join sections back together If the unit includes media bed odor control the KOR48 carbon odor control media is packaged separately Verify against the ship ping documents that you have received all items and note any shipping damage obvious or hidden to your carrier and on your Bill of Lading If damage is found immediately file a claim with the transport company All units are thoroughly inspected and fully operation tested at the factory prior to shipment Verify that the electrical and air flow ratings on the unit name plate agrees with jobsite requirements If a contradiction arises notify the factory prior to proceeding with installation SAFETY CONSIDERATIONS Installing and servicing the ClearAir unit can be hazardous due to the presence of electrical components Only trained and qualified service personnel should install or service this equipment Untrained personnel can perform basic maintenance such as cleaning and replacing filters All other operations should be performed by trained service personnel Whe
6. Effective Date 7 10 GAYLORD TECHNICAL MANUAL FOR INSTALLATION OPERATION AND MAINTENANCE OF THE GAYLORD ClearAir MODEL OCU FF SERIES POLLUTION CONTROL UNITS WARNING Improper installation adjustment alteration service or main tenance can cause property damage injury or death Read the installation operation and maintenance instructions thor oughly before installing or servicing this equipment Only trained and qualified service personnel should install or ser vice this equipment GAYLORD INDUSTRIES 10900 S W AVERY STREET TUALATIN OR 97062 USA PHONE 503 691 2010 TOLL FREE 800 547 9696 FAX 503 692 6048 email info gaylordusa com www gaylordusa com GAYLORD INDUSTRIES Undisputed W orld Leader in World Headquarters 10900 S W Avery Street Tualatin Oregon 97062 U S A Engineered 5 ystems for Commercial K itchens tm To Our Customers Congratulations on your recent purchase of a Gaylord ClearAir Pollution Control Unit We are proud to be able to provide you with a quality product that exemplifies our long standing dedication to quality engineering Your unit is assembled from some of the very finest com ponents available and is designed for years of efficient effective and trouble free operation In addition this unit has undergone rigorous quality control inspections and was fully operationally tested prior to shipment If you have further questions pleas
7. LORD INDUSTRIES SHALL NOT BE RESPONSIBLE FOR INCIDENTAL OR CON SEQUENTIAL DAMAGES RESULTING FROM A BREACH OF THIS WARRANTY All replacement parts furnished under this warranty shall be F O B Gaylord Industries of Tualatin Oregon The owner shall pay the necessary freight delivery charges and necessary labor for removal and installation of parts and any federal state or local taxes SPECIFIC ITEMS NOT COVERED BY THIS WARRANTY Fan belts if equipped with an exhaust fan Pre filters bag filters final filters after filters and KOR48 carbon media if equipped with odor control Routine maintenance and cleaning as spelled out in The Gaylord ClearAir Model OCU FF Series Unit echnical Manual Malfunction or improper operation caused by fluctuating electrical or power surges or improper installation This is the sole warranty with respect to the aforesaid items NEITHER GAYLORD INDUSTRIES OR ANY OTHER PARTY MAKES ANY OTHER WARRANTY OF ANY KIND WHATSOEVER EXPRESSED OR IMPLIED AND ALL IMPLIED WARRAN TIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE AFORESAID OBLIGATIONS ARE HEREBY DISCLAIMED AND EX CLUDED FROM THIS AGREEMENT GAYLORD WORLDWIDE SALES MANUFACTURING AND SERVICE FOR THE NAME AND LOCATION OF THE NEAREST CERTIFIED SERVICE AGENCY VISIT OUR WEB SITE WWW GAYLORDUSA COM OR CONTACT US AT GAYLORD INDUSTRIES 10900 S W AVERY STREET TUALATIN OREGON 97062 U S A Phone 5
8. MEDIA BED TYPE General Description ClearAir units that include media bed odor control have an SO suffix for single pass and DO suffix for double pass odor control in the model number Refer to the nameplate on the unit see page 20 for sample As shown in the illustration below the odor control section consists of two major compo nents Odor control media and 30 after filters il PF FF SO AF Odor Conirol Media bed type The odor control media furnished with your Gaylord ClearAir unit is a product trade named KOR48 Carbon Blend and manufactured by Cameron Great Lakes Inc of Portland Oregon KOR48 Carbon Blend is made from a unique 50 aluminosilicate compound impregnated with 6 potassium permanganate and 50 activated carbon or 100 activated carbon The granules are approximately 10 inch diameter and are poured into metal modules see page 16 which slide into racks in the odor control section of the unit As the air is drawn through the modules the KOR48 the media oxidizes the lighter odor molecules and chemically changes them into harmless solids which remain in the media and the carbon absorbs the heavier odor molecules This combination pro vides very effective odor control The 100 carbon is lower cost alternative that must have fire suppression system in stalled to protect it as it is flammable This material a
9. bsorbs odor and will gradually decrease in effectiveness until it starts to release the odors it has absorbed The life of the odor control media is dependent upon sev eral factors such as the type of odor amount of odor mol ecules grease loading and air temperature KOR48 media has a flat efficiency curve meaning that the efficiency or ODOR CONTROL MEDIA INSPECTION FREQUENCY CHART TYPE OF COOKING FREQUENCY EQUIPMENT IN DAYS LIGHT DUTY ciae crees 120 Ovens steamers and kettles MEDIUM DUTY euren 90 Braising pans Tilting skillets fryers griddles grooved griddles open burner ranges hot top ranges and conveyor ovens HEAVY DUTY riniicuiusioa rezar uo orioneu 60 Gas and electric char broilers upright broilers woks and conveyor broilers EXTRA HEAVY DUTY 30 Solid fuel broilers effectiveness stays constant until the media has expended and then the efficiency drops off rapidly The carbon portion of the media s efficiency drops continually during its life Thus a regular schedule of change out needs to be established and followed Filters Smoke control filters in the odor control section of the sys tem requires the replacement prior to them becoming loaded It is recommended that the filters be inspected in accordance with the Odor Control Media Inspection Frequency Chart on this page and replaced if necessary The following
10. compartment door for ser vice and routine maintenance SHORT TERM STORAGE Units that include media bed odor control are provided with KOR48 carbon media which is shipped separate from the unit KOR48 carbon media must be stored in a dry place with less than 95 relative humidity LONG TERM STORAGE OVER ONE MONTH If the unit is equipped with an exhaust fan it must be relubricated as soon as it arrives To prevent corrosion all bear ings should receive grease and be rotated the first of every month Turn the wheel by hand while greasing bearings A clean 1 16 bead of grease must appear on each side of each bearing Refer to specific bearing lubricating instructions on the fan Also refer to bearing lubricating instructions found in the exhaust fan section of this manual Bearings which are to be stored or idle for an extended pe riod of time should be wrapped in a neutral grease proof pa per foil or plastic film Compounds can be recommended by the bearing manufacturer to provide protection for sever al months to several years After long term storage grease should be purged EQUIPMENT LIFTING PROCEDURE SPREADER BAR uFTNG LUGS 1 All units are provided with a minimum of four lifting points for rigging attachment All lifting points must be used 2 Spreader bars are mandatory to prevent contact and damage to the unit by lifting hooks straps cables or chains ODOR CONTROL SECTION
11. e contact us toll free at 1 800 547 9696 or info amp gaylordusa com We are more than happy to help Sincerely Gaylord Industries STREET ADDRESS 10900 SW Avery Street Tualatin Oregon 97062 8549 US A PHONE 503 691 2010 800 547 9696 FAX 503 692 6048 email info amp gaylordusa com wwwgaylordusa com COMMERCIAL KITCHEN EXHAUST SYSTEMS FIRE PROTECTION HEAT RECLAIM UTILITY DISTRIBUTION ROOF TOP UNITS POLLUTION CONTROL AIR HANDLING UNITS TECHNICAL MANUAL FOR INSTALLATION OPERATION AND MAINTENANCE OF THE GAYLORD ClearAir MODEL OCU FF SERIES POLLUTION CONTROL UNITS Published by GAYLORD INDUSTRIES Tualatin Oregon 97062 U S A First Printing July 2010 Copyright 2010 Gaylord Industries ALL RIGHTS RESERVED NO PART OF THIS BOOK MAY BE REPRO DUCED STORED IN A RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM BY AN ELECTRONIC MECHANICAL PHOTOCOPYING RECORD ING MEANS OR OTHERWISE WITHOUT THE WRITTEN PERMISSION OF GAYLORD INDUSTRIES COPYRIGHT 2010 The manufacturer reserves the right to modify the materials and specifications resulting from a continuing program of product improvement or the availability of new materials Additional Copies 15 00 The Gaylord ClearAir Unit is designed and engineered by GAYLORD INDUSTRIES 10900 S W Avery Street Tualatin Oregon 97062 TABLE OF CONTENTS RECEIVING amp 5 EQUIPM
12. exhaust duct to the inlet and outlet of the ClearAir unit must be fully welded to comply with NFPA 96 INSTALLATION PRECAUTIONS 1 The services of qualified contractors are essential for safe and proper installation of this equipment 2 The air volumes and external static pressures that are listed on the unit are for the middle of the operating range of the filters The initial air volume should be at least 10 higher than the listed CFM As the filters load up the air volume will drop This is inherent to this type of unit If the unit is set up at or below the design CFM as the filters load up the kitchen hood may experience smoke loss problems Please consult the factory if you have questions 3 The unit is designed for installation on a level surface 4 When installed in an enclosed space a fire rated enclo sure may be required for the unit and associated duct work Consult the Authority Having Jurisdiction 5 Consult the Authority Having Jurisdiction regarding re quirements covering the point of termination of the exhaust outlet of this unit Minimum distances must usually be maintained between the exhaust outlet and any outside air intakes and or adjacent structures or property lines 6 Do not apply power to the unit until all electrical con nections have been made and a pre start up preliminary inspection has been completed 7 Allow a minimum of 36 inches clearance in front of the filter access door and electrical
13. n installing or servicing observe precautions in literature and on tags and labels attached to unit Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extin guisher available Read these instructions thoroughly WARNING Before installing or servicing system always turn off main power to system There may be more than one disconnect switch Electrical shock can cause personal injury or death RIGGING All units are provided with a minimum of four 4 lifting points for rigging attachment WARNING Use all lifting points pro vided Refer to Page 12 Spreader bars are mandatory to prevent contact and damage to the unit by lifting hooks straps cables or chains Consult the mechanical or structural engi neer before moving the unit across the roof deck INSTALLATION CODES This unit requires external plumbing and electrical connections to be made in the field It is recommended that the Authority Having Jurisdiction AHJ be consulted regarding local codes and installation procedures Gaylord Industries is not respon sible for obtaining necessary approvals and permits which may be required for installation nor is it responsible for verifying that the unit has been installed in accordance with national state and local codes In the absence of locally adopted codes use the latest editions of the national electrical code and the uniform mechanical code Connections of the
14. pent media New media may be purchased from your local Cameron Great Lakes distributor For the name and phone number of the local distributor call Cameron Great Lakes New media comes in standard five gallon buckets which weigh 40 Ibs each One bucket will refill approximately 1 33 mod ules It is recommended that new media is purchased no more than 2 weeks in advance of its use The buckets should be protected against physical damage as KOR48 carbon will begin to oxidize any odor molecule when exposed to atmo sphere The buckets should be stored in a cool dry area Step 9 Removing the Modules Caution each module weighs approximately 30 Ibs and may be awkward to handle particularly in the upper racks It is highly recommended that a heavy duty steel wheeled ladder be used when removing the upper modules Caution Exhaust fan must be off before opening the odor control media access door Refilling the modules is a relatively simple task not requiring Step 11 any special tools Follow steps 1 11 Step 1 Set the module on end so the securing screw is on top Step 2 Remove the securing screw and slide the cover plate off FLOW gt MEDIA FILL PORT TYP 6 PLACES TOP SLIDES OUT TO EXPOSE MEDIA FILL PORTS SECURING SCREW SLIDE TOP Place the filling jig over opening Pour the media into the module To eliminate voids shake or vibrate the module to ensure that the media settles
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