GREENHECK 482585 Grease Trapper ESP Kitchen Exhaust Pollution Control System Installation Guide
- June 13, 2024
- GREENHECK
Table of Contents
482585 Grease Trapper ESP Kitchen Exhaust Pollution Control System
Product Information:
The Grease Trapper ESPTM is a pre-engineered electrostatic
precipitator type pollution control unit with an integral exhaust
fan. It is designed to remove grease, smoke particles, and odor
from the kitchen exhaust airstream. The unit is certified to UL
8782 and the control panel is certified to UL 891.
Key Features:
-
Pre-engineered electrostatic precipitator type pollution
control unit -
Integral exhaust fan for efficient airflow
-
Removes grease, smoke particles, and odor from kitchen
exhaust -
Certified to UL 8782
-
Control panel certified to UL 891
Product Usage Instructions:
-
1. **Receiving:**
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. Remove all shipping/packing materials including fan tie-down
straps.
-
1. **Installation:**
Only qualified personnel should install this system. Personnel
should have a clear understanding of the instructions and general
safety precautions.
-
1. * Follow all local electrical and safety codes, as well as theNational Electrical Code (NEC), the National Fire Protection Agency
(NFPA), where applicable. Follow the Canadian Electrical Code (CEC)
in Canada.-
Ensure the rotation of the fan wheel is free and does not
strike or rub against any stationary objects. -
The fan motor must be securely and adequately grounded.
-
Do not spin the fan wheel faster than the maximum cataloged fan
RPM. Adjustments to fan speed can affect motor load, so check the
motor current to ensure it does not exceed the motor nameplate amps
if the fan RPM is changed. -
Do not allow the wires to kink or come in contact with oil,
grease, hot surfaces, or chemicals. Replace 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. -
Do not attempt to defeat the safety electrical interlock
switches at all maintenance access doors in the precipitator.
-
-
Maintenance:
Regular maintenance is essential for optimal performance and
longevity of the Grease Trapper ESPTM.
-
* Refer to the maintenance information on the integral exhaustfan, if applicable, by checking the fan nameplate for model type
and downloading the corresponding manual from greenheck.com.- Always disconnect power before working on or near this
equipment. Lock and tag the disconnect switch or breaker to prevent
accidental power up.
- Always disconnect power before working on or near this
Document 482585
Grease Trapper ESPTM
®
Kitchen Exhaust Pollution Control System
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully
before attempting to assemble, install, operate or maintain the product
described. Protect yourself and others by observing all safety information.
Failure to comply with these instructions will result in voiding of the
product warranty and may result in personal injury and/or property damage.
Grease Trapper ESPTM
The Grease Trapper ESPTM is a pre-engineered electrostatic precipitator type
pollution control unit with integral exhaust fan (available without exhaust
fan as an option). The unit is designed to remove grease and smoke particles
as well as odor from the kitchen exhaust airstream. This installation manual
covers procedures for receiving, installing, and maintaining 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 greenheck.com to download the corresponding manual.
Unit Certified to UL 8782 Control Panel Certified to UL 891
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.
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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 1
®
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
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
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 lintfree 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.
2 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Table of Contents
Grease Trapper ESP System Function . . . . . . .3 System Components Unit Body
. . . . . . . . . . . . . . . . . . . . . . .4 ESP Cells . . . . . . . . . . .
. . . . . . . . . . . .4 Impingement Filters / Mist Eliminator / Filters /
Carbon Trays . . . . . . . . . . . . . . . . . . . . .4 Component Quantities .
. . . . . . . . . . . . . . .4 Remote Mounted Detergent Dispenser. . . . . . .
.4 System Control Panel. . . . . . . . . . . . . . . . .5 Fire Cabinet . . . .
. . . . . . . . . . . . . . . . . .5 PCU Field Assembly Unit Modules . . . . .
. . . . . . . . . . . . . . . .5 Attaching Fan . . . . . . . . . . . . . . . .
. . . . .6 Installation Rigging and Placing Equipment . . . . . . . . . . .6
Ductwork Connections . . . . . . . . . . . . . . . .7 Cells and Carbon Trays .
. . . . . . . . . . . . . . .7 Plumbing Connections Detergent Dispenser . . .
. . . . . . . . . . . . . .8 Wash Manifolds . . . . . . . . . . . . . . . . .
. . .9 Electrical . . . . . . . . . . . . . . . . . . . . . . .9 Fire System
Ansul® . . . . . . . . . . . . . . . . . . . . . . . 10 Initial System Start-
Up . . . . . . . . . . . . . . . 11 Sequence of Operation Normal . . . . . . .
. . . . . . . . . . . . . . . . 11 Wash . . . . . . . . . . . . . . . . . . .
. . . . . 12 Controller Setup and Tutorial . . . . . . . . . 13-14 A. Clock. .
. . . . . . . . . . . . . . . . . . . 15 B. Input/Output . . . . . . . . . . .
. . . . . . 15 C. Service. . . . . . . . . . . . . . . . . . 16-21 D.
Manufacturer . . . . . . . . . . . . . . . . 21 Keypad Navigation . . . . . .
. . . . . . . . . . . 22 Touch Screen Navigation . . . . . . . . . . . 23-26
Variable Frequency Drive Information . . . . 27-28 BMS Points List . . . . . .
. . . . . . . . . . . . . 29 Maintenance . . . . . . . . . . . . . . . . . .
30-31 Unit Layout . . . . . . . . . . . . . . . . . . . . . 31 Field Wiring
Diagrams . . . . . . . . . . . . . 32-33 Wash Water Plumbing Schematic Drain
Line Plumbing . . . . . . . . . . . . . . . . 34 Detergent Dispenser Assembly
. . . . . . . . . . . 34 Troubleshooting . . . . . . . . . . . . . . . . . .
35 Maintenance Log . . . . . . . . . . . . . .Backcover Our Commitment . . . .
. . . . . . . . . .Backcover
Grease Trapper ESP System Function
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.
· 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.
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 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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 3
®
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 a 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. (1) One-
inch water supply line and (1) 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 the 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 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. Ionizer section includes
spiked ionizer plates that are charged with 12,000 VDC. 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.
Universal Unit Cell
If a module has multiple cells, power is passed from cell to cell through
these brass plungers coming into contact with the pins on next cell.
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
STANDARD UNIT
Housing Impingement ESP
Size
Filter
Cell
15
1
2
30
2
4
45
3
6
60
4
8
90
6
12
135
9
18
SOLID FUEL UNIT
15
1
3
30
2
6
45
3
9
60
4
12
90
6
18
135
9
27
Mist Eliminator Filter
1 2 3 4 6 9
1 2 3 4 6 9
2″ Deep Carbon Trays
6 12 18 24 36 54
12 24 36 48 72 108
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.
4 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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.
Housing Size
15 30, 45 60, 90
135
Number of Mechanical Fasteners
3 4 6 6
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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 5
®
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
1/2 inch silicone gasket
Liberally apply fire caulk to outside portion of companion flange and around each individual bolt hole
located outside
of silicon gasket mounted during
Seam on gasket to be located on side of unit
step 4.
4. Attach 1/2 inch
Fire rated caulk
silicone gasket
around fan inlet
flange. Silicone
gasket to be
located inside Transition collar
Fan
of caulk applied
Companion flange
1/2 inch silicone gasket
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.
Fasteners attaching fan to ESP transition are evenly spaced around fan inlet
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
Approximate Weight
such as fan
Housing STANDARD UNIT
type, accessories, etc.
Size lbs
kg
Approximate weights are
15
1410 641
shown in the table.
4. The unit can be positioned on a base or roof deck suitable for this
purpose.
30
1710 777
45
2120 964
60
2765 1257
90
3315 1507
135 5000 2268
5. The unit must be anchored Housing SOLID FUEL UNIT
to its base/roof deck.
6. Alternatively, the unit may be suspended from an adequate overhead
structure, using suitable
Size lbs
kg
15
1860 845
30
2295 1043
45
2860 1300
60
3660 1664
90
4390 1995
undercarriage or hanging
135 8000 3629
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.
36 inches
Fasteners attach the fan to the isolators on each corner of the fan
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.
6 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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 ductto-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 handlatches until secured.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 7
®
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)*
Housing Size
STANDARD UNIT
Water
Detergent
SOLID FUEL UNIT
Water
Detergent
When the unit is washing and the wash sequence is calling for detergent, a
diaphragm pump housed within the remote detergent control cabinet pumps the
detergent into the factory provided inlet manifold. A float, located in the
remote mounted detergent tank, determines detergent levels.
From the bottom of the pump located within the detergent control cabinet use
the provided compression fittings to connect the provided 1/4″ tubing to the
lid of the remote mounted detergent tank located within 8′ vertical of the
detergent control cabinet.
From the top of the pump located within the detergent control cabinet, use the
provided compression fittings to connect the provided 1/4″ tubing to the 1/2″
detergent connection on the check valve on the provided inlet manifold located
within 30′ vertical of the detergent control cabinet.
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.
15
85
0.15
120
0.20
30
169
0.15
239
0.20
45
254
0.15
358
0.20
60
279
0.15
389
0.20
90
418
0.15
583
0.20
135
761
0.25
1074
0.35
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.
8 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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)
Quantity
Item Description
1
Backflow Preventer
1
Ball Valve, 1 Inch for Supply Line
1
Ball Valve, 1/2 Inch for Detergent Line
1
Check Valve, for Detergent Valve
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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 9
®
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.
ANSUL
ESP Fire Cabinet Quantity and Size
Indoor Cabinet Outdoor (NEMA4) Cabinet
Housing
Size
4 or 6 Module Unit
4 Module Unit 6 Module Unit
15 See Drawings (1) 42″
(1) 60″
30 See Drawings (1) 42″
(1) 60″
45 See Drawings (1) 42″
(1) 60″
60 See Drawings (1) 60″
(2) 42″
90 See Drawings (1) 60″
(2) 42″
135 See Drawings (1) 60″ (1) 42″ (1) 60″ (2) 42″
· Do not install fire piping in front of doors on module. Must have 36 inches of clearance.
10 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 11
®
Sequence of Operation – continued
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 can be set on the
controller to allow water heaters or grease interceptors time to recover.
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 · Impingement · 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
12 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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
The user can access the main menu by pressing the
button.
Program buttons simultaneously while pressing the and arrows.
Within the programmable logic controller, factory set
points can be modified to configure the system for
specific functions if necessary. All parameters are
If equipped, the keypad user interface connects via a factory-provided RJ-25 cable to the J10 port on the controller.
shown in this section.
Information regarding most of the settings within the
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.
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 Enter
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.
A. 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.
B. To move to the next parameter on the same screen, press the Enter button.
C. 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.
Exhaust 1 Setpoints
Temp
Low:
90.0°F
High:
115.0°F
Current Temp:
Speed 50.0% 100.0% 70.0°F
Exhaust 1 Setpoints
Temp
Low:
90.0°F
High:
115.0°F
Current Temp:
Speed 50.0% 100.0% 70.0°F
Exhaust 1 Setpoints
Temp
Low:
90.0°F
High:
115.0°F
Current Temp:
Speed 50.0% 100.0% 70.0°F
®
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
adjust the value.
buttons to
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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 13
Pressing
Main Menu Overview
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
Exhaust: Speed: System Status:
Off 0.0% Wash
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
unit is in a wash or a door was left open.
PCU ESP Pass #1
Power Supply
Status A:
On
Status B:
On
Status C:
On
PCU ESP Pass #2
Power Supply
Status A:
On
Status B:
On
Status C:
On
PCU ESP PASS #1 This screen will display the status of PCU ESP pass 1,
providing statuses of all power supplies on that pass.
PCU ESP PASS #2 (IF APPLICABLE) This screen will display the status of PCU ESP
pass 2, providing statuses of all power supplies on that pass.
PCU ESP Pass #3
Power Supply
Status A:
On
Status B:
On
Status C:
On
PCU ESP PASS #3 (IF APPLICABLE) This screen will display the status of PCU ESP pass 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).
Alarms
Press DOWN to review current alarm(s). Press ESC to exit. Press ALARM to
reset.
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.
ALARM
Exhaust Fan Alarm Check exhaust starter or
VFD for fault code.
Alarms No active alarm
Press ENTER key to access ALARM HISTORY log.
This is an example of an exhaust fan fault.
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.
Alarm
Low Detergent Exhaust Fan Fault Door Safety Alarm Power Supply Failure Fire
Detected Wash Aborted
Alarm Description
No detergent flow or empty detergent tank Failure of the exhaust fan One of
the doors to the unit is open Power supply has failed Indicates fire in either
the kitchen or PCU unit Wash cycle was stopped short
14 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
A. Clock
Clock 02:00:00PM
Date: Hour: Day:
01/01/18 MM/DD/YY
15:30 Monday
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.
Clock
DST:
Enable
Transition time:
60min
Start:
LAST SUNDAY
in MARCH
at 2.00
End:
LAST SUNDAY
in OCTOBER
at 3.00
Holiday Configuration
Number:
4
Wash and fan schedules will not operate during holidays.
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.
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.
Holiday X
1: 2: 3: 4:
0/ 0 – 0/ 0 0/ 0 – 0/ 0 0/ 0 – 0/ 0 0/ 0 – 0/ 0
B.
Input/Output
Analog Input
Fan Speed (AIN1)
Input B001:
0.0%
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.
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.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 15
C. Service
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 and wash settings. By accessing the BMS
Configuration sub-menu, the user can adjust BMS protocol settings. (BACnet®,
LonWorks®, Modbus)
The System Information sub-menu displays information about the controller and
the program loaded on the controller.
Information Greenheck Fan Corp.
Version: Date
Bios: 6.40 Boot: 5.02
2.00.000 09/21/20
11/17/15 09/30/13
C. Service
b. Power Supply
THIS SCREEN SHOWS VERSION, BOOT AND BIOS INFORMATION. BIOS AND BOOT PERTAIN TO
THE CONTROLLER’S FIRMWARE AND OPERATING SYSTEM.
The Power Supply sub-menu allows the user to view and adjust the power supply
settings.
Power Supply Settings 1
Power Supply Operating Voltage (JC062)
Pass1: Pass2: Pass3:
3.0vdc (12.0kV) 3.0vdc (12.0kV) 3.0vdc (12.0kV)
Power Supply Settings 2
Power supply initial reset attempts before alarm: 15
THIS SCREEN ALLOWS THE USER TO VIEW/ADJUST OUTPUT SIGNAL JC062 POWER TO THE
POWER SUPPLIES AND THE CORRESPONDING KV OUTPUT. This should only be adjusted
on factory advisement only. Default is 3.0vdc (12kV).
NOTE If provided with JC099 power supplies, control voltage is not adjustable
(fixed 12kV operating voltage).
THIS SCREEN ALLOWS THE USER TO ADJUST JC062 POWER SUPPLY RESET ATTEMPTS UPON A
FAULT BEFORE ENTERING ALARM. Default is 15 attempts.
NOTE This screen is not visible if provided with JC099 power supplies.
Power Supply Settings 3 Power supply alarm reset delay: 10 min
C. Service
c. Wash Settings
THIS SCREEN ALLOWS THE USER TO ADJUST POWER SUPPLY RESET DELAY AFTER A POWER
SUPPLY ALARM HAS OCCURRED. Default is 10 minutes.
NOTE This screen is not visible if provided with JC099 power supplies.
The Wash Settings sub-menu allows the user to view and adjust the wash times.
Wash Settings 1
Pre-Soak: Detergent: Soak: Rinse: Dry: Drain Time: Delay Time:
180 sec 60 sec
180 sec 240 sec 60 min
60 sec 0 min
THIS SCREEN ALLOWS THE USER TO ADJUST SETTINGS FOR A UNIT WASH. DEFAULT TIMES
ARE PROVIDED ON PAGE 12 OF THIS MANUAL.
Pre-Soak: Time for spraying cell(s) with water. Detergent: Time for spraying
cell(s) with water with detergent injected into the water line. Soak: Time to
allow the cells to soak (water and detergent stop). Rinse: Time for spraying
the cell(s) with water to remove debris and detergent. Drain: Time to drain
the remainder of the water in the unit before starting the dry portion of the
wash cycle. Dry: Time for turning on the fan after a wash to dry out the
cells. Delay: Time to allow water heater/grease interceptor to recover between
each module’s wash sequence.
16 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Wash Settings 2
Auto Wash:
Auto Wash Time:
Days/Week Mo Tu Wd Th Fr
Yes 2:00am
Sa Su
Last Washes
Last Complete Wash 00:00:00am 00/00/00 Last Aborted Wash 00:00:00am 00/00/00
Reason: None
Wash Log History
Press ENTER key to access log history of completed washes.
THIS SCREEN ALLOWS THE USER TO ADJUST SETTINGS REGARDING THE AUTO WASH FEATURE
WHICH STARTS A WASH AUTOMATICALLY AT A SPECIFIC TIME A DAY.
Auto Wash: Enable or disable the auto wash feature. Auto Wash Time: Adjust the
time of day the wash will start. Note the wash will only begin if the fan is
not on. 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.
THIS SCREEN ALLOWS THE USER TO VIEW LAST COMPLETED SUCCESSFUL WASH CYCLE, LAST
WASH CYCLE THAT WAS STOPPED SHORT, AND THE REASON WHY THE LAST WASH CYCLE WAS
STOPPED SHORT.
Last Complete Wash: Date and time stamp of last completed, successful wash
cycle. Last Aborted Wash: Date and time stamp when last wash cycle was
stopped. Reason: Reason for the last wash cycle stopping short OR prevented
from starting. Reasons can include: a. Keypad Wash Bn Wash button on keypad
was pressed, stopping the wash
cycle b. Open Unit Door Door on unit body was left open or opened during the
wash
cycle c. Keypad Fan Run Fan button on keypad was pressed before the wash
cycle
was attempted to start, or pressed while the wash cycle was in process,
overriding the fan to turn on and therefore stopping the wash cycle d. DI Fan
Run Digital input (Fan On/Off, Digital Input 1) was detected as closed
before wash cycle was attempted to start, or closed while the wash cycle was
in process, overriding the fan to turn on and therefore stopping the wash
cycle e. Program Change If wash control is disabled in the factory settings,
this will stop a wash from completing f. Fire Active If kitchen fire is
detected, it will prevent a wash from occurring or stop a wash from completing
THIS SCREEN ALLOWS THE USER TO VIEW LAST COMPLETED SUCCESSFUL WASH CYCLES,
PROVIDED WITH A DATE AND TIME STAMP.
Pressing enter will bring up the successful wash log history. Pressing up/down
arrows will cycle through each successful wash date/time stamp. The log only
records successfully completed wash cycles. All aborted wash cycles will not
be recorded.
NOTE
The log is capable of logging up to 100 washes. Once 100 is reached, the
program will overwrite the oldest wash date/time stamp logged.
Clear Wash Log History
This will clear the wash log history. Continue? NO
THIS SCREEN ALLOWS USER TO CLEAR THE WASH LOG HISTORY. PRESSING ENTER TO NAVIGATE DOWN TO “NO”, AND CHANGING TO “YES” ON THIS SCREEN WILL CLEAR ALL RECORDED SUCCESSFUL WASH CYCLE DATE/TIME STAMPS.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 17
®
Low Det Settings 1 Washes during low detergent alarm: 0 Last wash on low det:
00:00:00am 00/00/00 Reset Det Count: OFF
Low Det Settings 2
Det Alm Delay: 15s
THIS SCREEN ALLOWS USER TO VIEW LOW DETERGENT INFORMATION RECORDED WITH WASH
SYSTEM. Washes during low detergent alarm: Counts number of times wash cycle
was completed during a low detergent alarm. Last wash on low detergent: Date
and time stamp when last wash cycle was stopped short OR prevented from
starting. Reset detergent count: Changing this from “OFF” to “ON” will change
the count for “Washes during low detergent alarm” back to 0.
THIS SCREEN ALLOWS THE USER TO ADJUST THE DELAY TIME TO INITIATE A LOW
DETERGENT FAULT AFTER DETECTING NO DETERGENT FLOW. Default is 15 seconds.
Wash Settings 3
ESP cell power supply
delay time after wash
cycle is aborted:
60 min
THIS SCREEN ALLOWS THE USER TO ADJUST THE DELAY TIME BEFORE CELLS CAN BE
POWERED AGAIN IF A WASH CYCLE IS STOPPED PREMATURELY.
Default setting is 60 minutes.
Test Wash Setup
Pre-Soak: Detergent: Soak: Rinse: Dry: Drain: Start Test Wash?
10 sec 10 sec 10 sec 10 sec 1 min 10 sec
NO
Wash Settings 4
Total Calculated Wash Time (with Fan Dry):
176 min
THIS SCREEN ALLOWS THE USER TO ADJUST SETTINGS FOR A UNIT TEST WASH AND ALSO
START A TEST WASH. TEST WASHES ALLOW FOR EXPEDITED SEQUENCE TIMES TO QUICKLY
MONITOR A FULL WASH SEQUENCE. CHANGING “NO” TO “YES” WILL START A TEST WASH.
DURING A TEST WASH, PRESS THE BACK BUTTON TO ABORT THE TEST WASH SEQUENCE.
THIS SCREEN PROVIDES TOTAL CALCULATED WASH TIME FROM START OF WASH UNTIL THE
END OF THE FAN DRY. THIS CAN BE USED AS A HELPER TO DETERMINE WHAT TIME TO
SCHEDULE THE WASH CYCLE TO START, TO MAKE SURE THE ENTIRE WASH CYCLE CAN BE
PERFORMED WITHOUT COOKING INTERRUPTION.
C. Service
d. 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).
THIS SCREEN ALLOWS THE USER TO SELECT THE BMS PROTOCOL. ALL BMS PROTOCOLS
REQUIRE A COMMUNICATIONS CARD INSTALLED IN THE SERIAL CARD PORT, LOCATED ON
THE FACE OF THE CONTROLLER.
If the protocol is BACnet MSTP or BACnet IP/Eth, the user must enter into the
operating systems (BIOS) screens to adjust BACnet parameters.
MODBUS SETUP
BMS Card Address: Baudrate
1 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).
18 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
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 OTHER INFORMATION and press (enter) to confirm.
SYSTEM INFORMATION LOG DATA >OTHER INFORMATION FLASH/USB MEMORY
(down) arrow to select
2. Press (down) arrow to select PCOWEB/NET CONFIG and press
ID/PRODUCT CODE >PCOWEB/NET CONFIG MEMORIES STATUS CHIP IO VERSION
(enter) to confirm.
3. Select either PCOWEB Settings for BACnet IP or PCONET Settings for BACnet MSTP and press to confirm.
PCOWEB settings >PCONET settings
(enter)
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
BACNET MSTP
BACnet ID: (instance) 77000
BACnet baud: 38400
Netmask: (subnet) –0. –0. –0. –0 Gateway: –0. –0. –0. –0
BACnet MAC: 127 Max Masters: –0 Max Frames: –20
DNS1: –0. –0. –0. –0 DNS2: –0. –0. –0. –0
PCONET CONFIG ENABLE UPDATE PCOweb? YES
BACnet ID: (instance) 77000
BACnet Type: IP or Ethernet
PCONET CONFIG ENABLE UPDATE pCOweb? YES
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 19
®
C. Service
e. Service Settings a. Fan Operation b. I/O Manual Control c. Sensor
Calibration d. User Save/Restore e. Alarm History Reset
C. Service
e. Service Settings a. Fan Operation
Auto Fan Off Settings
Auto Fan Off? Run Hours:
No 8 hours
Note: This will only shut the fan off if the fan was powered on by the keypad (NOT DI)
Fan Scheduling
Fan On: NO 8:00am
Fan Off: NO 10:00pm
Days/Week Mo Tu Wd Th Fr
Sa Su
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.
The Fan Operation sub-menu allows the user to adjust fan settings.
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).
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
e. Service Settings b. I/O Manual Control
Analog Input
PS1 Status (AIN 2)
Manual Control B002:OFF
Manual Position
0.0
Value
2.50vdc
Digital Input
On / Off (DIN 1) Manual DI 1: Manual Position: DI 1 Status:
OFF CLOSED
Open
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.
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.
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.
20 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Relay Output
Exhaust Relay Manual Relay 1: Manual Position Relay 1 Status:
(DOUT 1) OFF OFF OFF
Analog Output 1
Fan Speed Mode: Manual Value Output:
(AOUT 1) Auto
0.00vdc 0.00vdc
C. Service
e. Service Settings c. Sensor Calibration
Analog Input
Fan Speed (AIN1) Input B01 Offset Value
0.0 100.0
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.
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.
IN Sensor Calibration, THE USER WILL BE ABLE TO ADJUST ANALOG INPUTS OFFSETS.
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
e. 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.
C. Service
e. Service Settings 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!
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 21
Keypad Navigation
SYSTEM FAULT
EXHAUST FAN FAULT POWER SUPPLY 3 OFF IF PRESOAK TLEFT: 172s
FAN
WASH
MENU NAV
When BUTTON(S)’ are mentioned in the description below, we are referring to thesquares’ on the keypad.
The following information details the Daily Operations of the Grease Trapper
ESP keypad buttons and their functions.
FAN – Momentarily pressing the FAN’ button will turn on the PCU unit. If the fan is on, the background behindFAN’ text will be dark. To turn the system
off, press the FAN’ button. WASH – Momentarily pressing theWASH’ button will start the automatic
washdown sequence. If the wash sequence is in process, the background behind
WASH’ text will be dark. To cancel the wash sequence, press theWASH’
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 · Power Supply Status · Exhaust Fan Status · Wash Sequence
The keypad also includes indicators next to the buttons that correspond to the
buttons on the controller. These
can be used to navigate through thecontroller 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.
22 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Touch Screen Navigation
GREASE TRAPPER ESP MAIN PAGE
10:11 AM
FAN ON/OFF
WASH ON/OFF
DETERGENT INDICATOR
FIRE STATUS
FIRE STATUS INDICATOR gray indicates no fire, and red indicates fire
detected.
HELP displays a help menu and navigation tips.
FAN STATUS
POWER SUPPLY STATUS
POWER SUPPLY 6 ON
DOOR SAFETY STATUS
WASH STATUS
FIRE STATUS
ESP WASH STATUS – navigates to a screen showing wash status and countdown
timers.
ESP Wash Status Indicators: As the system is in the wash mode, the indicators
will change colors based on the state of washing. Green indicates the mode of
operation.
Momentarily press or tap to access the menu or enable or disable the action of the associated icon. All icons surrounded by blue are momentary push buttons.
GREASE TRAPPER ESP WASH STATUS
IMP FILTER PRESOAK TIME LEFT:
176 s
FAN ON/OFF
FAN ON/OFF – turns the unit on and off. When the unit is in operation, the fans in the icon will spin indicating the unit is operating. Tapping the icon again will cause the unit to turn off.
WASH ON/OFF
WASH OFF – starts or stops the wash sequence. Pressing the button will begin the automated wash sequence to clean the unit. Tapping the icon again will abort the wash sequence.
DETERGENT DETERGENT INDICATOR – monitors the
INDICATOR
detergent level in the detergent tank and flow of the detergent pump. Green
will indicate there is sufficient detergent in the tank. When the detergent
alarm is active, the icon will display low across it. Refill the tank or check
detergent lines for blockages as needed to remove low detergent alarm.
FAN STATUS INDICATOR gray indicates OFF status, and green indicates ON status.
FAN STATUS
POWER SUPPLY STATUS INDICATOR –
Gray indicates power supplies are OFF.
Green indicates all power supplies are ON
POWER SUPPLY STATUS
and operating. Red indicates at least one
power supply is not functioning. Flashing
red icon indicates a pass has not functioned long
enough and has triggered a power supply failure alarm.
DOOR SAFETY STATUS
DOOR SAFETY STATUS INDICATOR green indicates all doors on the PCU are closed, and red indicates at least one PCU door is open (PCU door fault alarm).
WASH STATUS
WASH STATUS INDICATOR gray indicates wash is OFF, and green indicates wash is ON.
WASH STATUS
DETERGENT INJECTION
SPRAY PASS 1
SPRAY PASS 2
SPRAY PASS 3
DRAIN OFF
DRY CYCLE
NAVIGATION BAR pulls up a hidden menu allowing access to alarms, home, and
settings/configuration/information screens. This is available on every screen.
RESET ALARMS
The alarm icon directs you to the alarms screen. This icon will illuminate red
and blink when an alarm has been triggered. The middle icon directs you to the
home screen. The icon on the far right allows navigation to the
settings/configuration/information menu screen. Pressing either of the black
arrows to the right and left of these three buttons will hide the navigation
menu bar.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 23
®
Service Password Screen NOTE
The Service Password must be entered to access the SETTINGS, CONFIGURATION and
INFORMATION screen. The default service password is 1000.
Service Password Verification Required Insert Password:
0
Settings
· Fan Settings
FAN SETTINGS
AUTO FAN OFF: YES
RUN HOURS:
1
NOTE: THIS WILL ONLY SHUT THE FAN OFF IF THE FAN WAS POWERED ON BY THE KEYPAD.
THIS WILL NOT
OVERRIDE THE FAN ENABLE INPUT (RE1A AND RE-1B).
VERIFY
For technical support, please call:
1-800-371-6858. Have your serial number
ready.
Active Alarms Example
ACTIVE ALARMS
DATE/TIME
DESCRIPTION
3/17/2018 11:12:25 AM Fire Detected – Fire system discharged or issue with microswitch (terminals C1 & NC1).
3/17/2018 11:12:16 AM Exhaust Fan Alarm – Check exhaust motor starter(s) or VFD(s) for fault.
RESET ALARMS
General Information
Any field surrounded by a box with a white fill indicates that it is editable.
If an editable field displays a numerical value and the user taps the field, a
number keypad will display. After entering the desired value, press the Enter
button. If the editable field is an alphanumeric value, a standard keyboard
will display. After entering the desired value, press the Enter button. The
field may also display a multiple choice ON/OFF, or a checkmark box. For the
ON/OFF fields, press the box opposite of the checked box to change the option
from either OFF to ON or vice versa.
Auto Fan Off: Enable or disable the auto fan off feature.
Run Hours: Adjust fan run time before the fan automatically shuts off.
· Power Supply Settings
POWER SUPPLY SETTINGS
POWER SUPPLY TYPE: JC062
POWER SUPPLY OPERATING VOLTAGE
POWER SUPPLY ALARM RESET DELAY:
PASS 1: 3.0 VDC 12.0 KV
10 MINUTES
PASS 2: 3.0 VDC 12.0 KV
PASS 3: 3.0 VDC 12.0 KV
POWER SUPPLY INITIAL RESET ATTEMPTS BEFORE ALARM
15
Power Supply Operating Voltage: Adjustable output signal power to power
supplies and the corresponding kV output. This is adjustable only if provided
with JC062 power supplies.
Power Supply Initial Reset Attempts before Alarm: (If provided with JC062
power supplies) Adjustable power supply reset attempts upon a fault before
entering an alarm for the power supplies.
Power Supply Alarm Reset Delay: (If provided with JC062 power supplies)
Adjustable time delay after a power supply alarm has occurred in which the
system attempts to retry the power supplies.
· General Wash Settings
SETTINGS, CONFIGURATION & INFORMATION
SETTINGS
FAN SETTINGS
POWER SUPPLY SETTINGS
GENERAL WASH SETTINGS
CONFIGURATION DATE/TIME
FAN SCHEDULE
INFORMATION SYSTEM ALARMS
GENERAL WASH SETTINGS
SETTINGS
WASH SCHEDULE AND TIMING
TEST WASH
TEST WASH SETUP
Navigating to the Wash Schedule and Timing screen will allow the user to
adjust the auto wash settings and the timing sequences within the wash cycle.
Navigating to the Test Wash Setup screen will allow the user to adjust test
wash timing sequences and start a test wash.
24 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
· Wash Schedule and Timing Settings
WASH SCHEDULE AND TIMING SETTINGS
AUTO WASH ACTIVE: YES AUTO WASH TIME: 2 : 00 AM
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
PRE-SOAK TIME
180
SECONDS
DETERGENT TIME
60
SECONDS
SOAK TIME
180
SECONDS
RINSE TIME
240
SECONDS
DRY TIME
60
SECONDS
DRAIN TIME
60
SECONDS
Configuration
· Date/Time
DATE / TIME
03/17/16 11:06:51 AM
ADJUST DATE: ADJUST TIME:
3 / 17 / 16 11 : 06 AM
UPDATE DATE/TIME
Auto Wash Active: Enable or disable the auto wash feature.
Auto Wash Time: Adjust the time of day the wash will start. Note the wash will
only begin if the fan is not on.
Days/Week: Adjust which days per week the auto wash should occur. Boxes with
check marks indicate enabled for that day, white boxes without check marks
indicate disabled for that day.
Wash Sequence Timers: The times for the various wash sequences can be adjusted
as needed based on site conditions. To adjust the time press the white area
that contain the numbers. A pop-up window will open with a keypad to allow
adjustment to the start time.
· Test Wash Setup
TEST WASH SETUP
START/STOP TEST WASH
PRE-SOAK TIME
10
SECONDS
DETERGENT TIME
10
SECONDS
SOAK TIME
10
SECONDS
RINSE TIME
10
SECONDS
DRY TIME
1
SECONDS
DRAIN TIME
10
SECONDS
Press the “START/STOP TEST WASH” button to start or stop a test wash.
Test Wash Sequence Timers: The times for the various wash sequences can be
adjusted as needed for the test wash cycle. To adjust the time press the white
area that contain the numbers. A pop-up window will open with a keypad to
allow adjustment to the start time.
Adjust Date: Adjust the date. DD/MM/YY format. Adjust Time: Adjust the time.
To store the adjusted date and time in both the touch screen and the main
controller, press “UPDATE DATE/ TIME’.
· Fan Schedule
FAN SCHEDULE
FAN ON: NO FAN ON TIME: 8 : 00 AM
FAN OFF: NO FAN OFF TIME: 10 : 00 PM
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
Fan On: Enable or disable the fan turning on at a specific time. Fan On Time:
Time during the day when fan will turn on. Fan Off: Enable or disable the fan
turning off at a specific time. Fan Off Time: Time during the day when the fan
will turn off. Days/Week: Adjust which days per week the auto wash should
occur. Boxes with check marks indicate enabled for that day, white boxes
without check marks indicate disabled for that day.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 25
®
Information
· System Information
SYSTEM INFORMATION
GREENHECK FAN CORPORATION VERSION: 2.00 DATE OF RELEASE: 09/21/2020
BOOT: 5.02 BIOS: 6.40 FOR TECHNICAL SUPPORT, PLEASE CALL:
1-800-371-6858 HAVE YOUR SERIAL NUMBER
READY.
Displays important system information including firmware and software versions.
· Alarms
ACTIVE ALARMS
DATE/TIME
DESCRIPTION
3/17/2018 11:12:25 AM Fire Detected – Fire system discharged or issue with microswitch (terminals C1 & NC1).
3/17/2018 11:12:16 AM Exhaust Fan Alarm – Check exhaust motor starter(s) or VFD(s) for fault.
RESET ALARMS
This screen will display all current alarms. In the event of an alarm, the
alarm screen will automatically be displayed. The alarm description, date and
time are provided for each fault. If no faults exist, No Active Alarms’ will be displayed. Once a fault is corrected, all alarms will automatically be cleared EXCEPT for the low detergent alarm. The low detergent alarm needs to be manually reset by pressing theRESET ALARMS’ button.
26 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Variable Frequency Drive (VFD) Information
A Yaskawa V1000 (200-230 VAC and 460 VAC) or Yaskawa A1000 (575 VAC) 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.
Parameter Description b1-07 LOCAL/REMOTE Run Selection b1-17 Run Command at
Power Up C1-01 Acceleration Time 1 C1-02 Deceleration Time 1 E1-01 Input
Voltage E2-01 Motor Rated Current L2-01 Momentary Power Loss Operation
Selection L5-01 Number of Auto Restart Attempts
*See PCU wiring diagram for more information.
Default Value 00 00 10.00 seconds 10.00 seconds Dependent on drive type Dependent on drive type 00 00
Factory Adjustment 01 01 30.00 seconds 30.00 seconds Dependent on motor voltage Dependent on motor FLA (full load amperage) 02 10
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
LO RE
twice.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 27
®
Model V1000
Changing Parameters
Step 1: V1000 Digital Operator power-up state.
F 0.00 ALM REV DRV FOUT
LO
ESC
RE
RESET RUN
ENTER STOP
Step 2: Select Parameter Menu Press two times until the digital operator show
the parameter menu
(PAr) then press . ENTER
PAr ALM REV DRV FOUT
ESC
LO RE
RESET RUN
ENTER STOP
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.
C 1-01 ALM REV DRV FOUT
ESC
LO RE
RESET RUN
ENTER STOP
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.
0010.0 ALM REV DRV FOUT LO ESC RE
RESET RUN
ENTER STOP
Modify the parameter value using and ENTER to save the new value.
and press
Model A1000
Monitor Motor Frequency and Motor Current
Step 1: V1000 Digital Operator power-up state:
F 0.00 ALM REV DRV FOUT
LO
ESC
RE
RESET RUN
ENTER STOP
Step 2: Output Frequency
Press until the FOUT LED turns on. The display now shows the actual drive
output frequency in hertz (Hz).
16.56 ALM REV DRV FOUT
LO
ESC
RE
RESET RUN
ENTER STOP
Step 3: Motor Current
Press again will show the motor output current. The A’ behind the value means Amps’.
0.8A ALM REV DRV FOUT
LO
ESC
RE
RESET RUN
ENTER STOP
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
DIGITAL OPERATOR JVOP-180
ALM
– MODE –
DRV Rdy
Fref Ref (AI)
U1-01=
0.00 Hz
U1-02 U1-03
JOG
0.00 Hz 0.00A
FWD
RSEQ RREF
F1
F2
LO
ESC
RE
RESET RUN
ENTER STOP
DIGITAL OPERATOR JVOP-180
ALM
– MODE –
PRG
Programming
HELP FWD F1
ESC
DATA
F2 LO RE
RESET RUN
ENTER STOP
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.
One the parameter you wish to change is displayed on the screen and the digit
furthest to the right is flashing, press . ENTER
DIGITAL OPERATOR JVOP-180
ALM
– PRMSET –
PRG
C1-01=
10.0 sec
Accel Time 1
FWD
F1
F2
LO
ESC
RE
RESET RUN
ENTER STOP
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.
DIGITAL OPERATOR JVOP-180
ALM
– PRMSET –
PRG
Accel Time 1
C1-01= 0 0 1 0 . 0 s e c (0.0 – 6000.0) “10.0 sec”
FWD
F1
F2
ESC
LO RE
RESET RUN
ENTER STOP
Monitor Motor Frequency and Motor Current
With the drive running, press until reaching the Monitor Menu. This will display output frequency and amperage of the motor.
DIGITAL OPERATOR JVOP-180
ALM
– MODE –
DRV Rdy
Fref Ref (AI)
U1-01=
60.00 Hz
U1-02 U1-03
60.00 Hz 2.07A
RSEQ RREF
JOG
FWD
F1
F2
LO
ESC
RE
RESET RUN
ENTER STOP
28 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
Type
Analog Analog
Digital Digital Digital Digital Digital Digital Digital Digital Digital
Digital Digital Digital
Grease Trapper ESP v2.00 Modbus / BACnet® Points List
BACnet Device Instance: 77000 (default) Analog = AV, Integer = AV, Digital = BV
Instance
Name
Units
20 Exhaust_Fan_Speed
percent
21 BMS_Exhaust_Fan_Speed percent
Inactive Text
101 Remote_Enable
Off
102 Fire_Status
Off
103 Wash_Enable
Off
104 Detergent_Low
Off
105 Exhaust_Fan_Fault
Off
106 Door_Switches
Off
130 Exhaust_Active
Off
131 Pass1_Power_Supply
Off
132 Pass2_Power_Supply
Off
133 Pass3_Power_Supply
Off
134 Wash_Sequence_Active
Off
138 GLOBAL_ALARM
Off
Active Text On On On On On On On On On On On Alarm
Modbus – RTU/TCP Address: 1 (default)
Register 40021 40022
Read Write
Description
R Exhaust Fan Speed Percentage R/W BMS Exhaust Fan Speed Percentage
10102 10103 10104 10105 10106 10107 10108 10109 10132 10133 10134 10138
R/W Remote Fan Enable (0: Off; 1: On) R Fire System Status (0: Ok; 1: Fire)
R/W Wash Enable (0: Off; 1: On) R Detergent Status (0: Ok; 1: Empty) R Exhaust
Fan Fault R Door Interlock Switches (1: Ok; 0: Door Open) R Exhaust Fan Status
(0: Off; 1: On) R Power Supply Pass 1 Status (0: Off; 1: On) R Power Supply
Pass 2 Status (0: Off; 1: On) R Power Supply Pass 3 Status (0: Off; 1: On) R
Wash Status (0: Off; 1: Wash Cycle Active) R Global Alarm
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 29
®
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 in order to ensure optimum performance and
reliability of the system.
Impingement and Mist Eliminator Filters: These metal filters should be
inspected for grease and particulate build-up on a monthly basis. This monthly
inspection should be done after the system has competed a wash cycle. If
grease or particulate build-up is apparent, remove filters and clean manually.
Ionizing-Collecting Cells: The ionizing-collecting cells should be inspected
for grease build-up on a monthly basis. This monthly inspection should be done
after the system has completed a wash cycle. If grease build-up is apparent,
remove cells and clean manually. After opening the module door, release the
(2) cell pushers, and use the cell removal tool to hook onto the handle of the
ESP cell and remove from module. The cells should be removed and manually
cleaned every 6 months minimum.
Carbon Trays: Carbon tray changeout frequency is dependent on volume of
cooking. Replace when an increase in odor breakthrough is first noticed.
Change out should range between 3 and 6 months for typical cooking
applications. Change out may be more frequent for heavy grease applications.
If opting to refill carbon trays instead of replacing them, follow the below
steps:
1. Locate and remove fastener on 2-inch prefilled carbon tray.
2. Slide the filter tray top out of the filter.
3. Remove the old charcoal, and replace.
4. Replace tray top and fastener.
System Fan/Motor: Fan, motor and drives should be inspected, serviced and
cleaned according to the manufacturer’s instructions, annually.
Wash System Detergent: Manufacturer recommends Zep X701 detergent,
manufactured by Zep Incorporated. This detergent has been specifically
formulated for this type of equipment, and will help ensure successful
operation and optimum performance. In normal applications, the X701 cleaning
solution can be diluted at a 1:1 ratio of chemical to water. Upon inspection
of the cells, if it appears they are not being fully cleaned during the wash
cycle, it is recommended the detergent add timer be increased, the detergent
flow control valve adjusted, or the detergent strength increased. Zep X701
should also be used to manually clean the impingement and mist eliminator
filters. Substituting other types of detergent may result in decreased system
performance, system shut down and voiding of the unit warranty.
To access the impingement and mist eliminator filters and ESP cells, follow
these instructions.
1. Turn fan off using keypad.
2. Turn all power pack mounted disconnect switches to off. Follow all
applicable lock and tag-out procedures to safely “Lock Out” the system to
avoid potential injury.
3. Unlatch all fasteners on the door to open the access door to filters.
4. Short the cells to ground, using the shaft of an insulated screwdriver, to
ensure any residual charge is removed before handling the cells.
5. Slide the metal mesh filters from the tracks.
6. Thoroughly clean the metal mesh filters using hot water and a Zep X701
detergent solution.
7. Reinstall the filters in the tracks.
8. Unlatch the door fasteners to access the ESP cells.
9. Loosen and unhook the (2) cell pushers from the ESP cell.
10. Carefully remove cells from the module. Each cell weighs approximately 35
lbs.; use caution when handling. Use care not to bend or dent the collecting
plates or framework.
11. Carefully inspect the cell for bent collector plates. Bent plates may be
carefully straightened by hand, using needle-nose pliers.
12. Inspect the cell for residual grease that was not removed during the wash
process. Excessive grease buildup indicates that wash times may need to be
increased on the units. For excessive buildup the cells may need to be removed
from the cabinet and manually cleaned.
30 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
13. Reinstall the cell to the location from which it was removed. There is an
airflow arrow on the cell end plate. Re-insert the cell pushers by hooking the
pusher between the cell and the c-channel of the cell rack and tighten until
the cable is taught or the cell is fastened.
14. Close the access door completely to ensure the door limit switches are
closed and install the door fasteners.
Unit Layout – Elevation Views
Maintenance
Replacement Parts Ordering
Replacement parts can be obtained through the Greenheck Parts Department,
800-355-5354 or your local authorized
Greenheck Sales Representative. To locate your local Greenheck Representative,
visit greenheck.com
Description
Part Number
Main Control Panel Fuse, 3A
380750
Main Control Panel Fuse, 20A
380341
Main Control Panel Fuse, 30A
380295
Main Control Panel Fuse Block
385762
Main Control Panel Fuse Block Cover
384006
20 x 20 x 1-inch Impingement Filter
913732
20 x 20 x 1-inch Mist Eliminator Filter
482432
20 x 20 x 2-inch Pre-Filled Carbon Tray
483439
Power Supply
386767
High Voltage Spark Plug Harness
386765
Plastic Isolator for ESP Cell
386759
5 Gallon Container of Detergent
HAZ2882
Diaphragm Detergent Pump
484148
ESP Cell
881099
120V Green Indicator Light
382282
Door Limit Switch
386245
*Door access is determined by standing at unit inlet with
air hitting you in back.
STANDARD UNIT
SOLID FUEL UNIT
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 31
®
Field Wiring Diagrams
Field diagrams are provided as general drawings. For unit specific drawings,
consult wiring diagrams found on the unit control panels. STANDARD UNIT
SOLID FUEL UNIT
32 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System ®
FIRE SYSTEM CABINET WIRING OUTDOOR
CABINET HEATER CONTROL
L1
CONTROL INPUT: 115VAC, 15AMPS FROM BREAKER
N
BK
H
T1
1
2
11
TC1
12
TC1 23 24
CH
L
N
THERMOSTAT PROGRAMMING INSTRUCTIONS
PARAMETER St1 St2 St3 r01 r02 r03 r4 r5 c01 c02 c03 c11 c12 c13 c21 c22 c23 c31 c32 c33 c41 c42 c43 PO P11 P12 P13 P2 P31 P32 P33 H2 H4 H5 H6
SETTING 40.0 3.0 3.0 5.0 1.0 1.0 -50.0 150.0 inu inu inu 0.0 0.0 0.0 5.0 0.0 0.0 10.0 0.0 0.0 0.0 0.0 0.0 F 0.0 0.0 0.0 YES YES NO NO NO 0 0 Pt1
DESCRIPTION Setpoint Value Probe 1 Setpoint Value Probe 2 Setpoint Value Probe 3 Differential Probe 1 Differential Probe 2 Differential Probe 3 Minimum Setpoint Value Maximum Setpoint Value Mode Probe 1 Mode Probe 2 Mode Probe 3 Minimum Output 1 Stop Time Minimum Output 2 Stop Time Minimum Output 3 Stop Time Minimum Output 1 On Time Minimum Output 2 On Time Minimum Output 3 On Time On Time Fault Probe 1 Cycle On Time Fault Probe 2 Cycle On Time Fault Probe 3 Cycle Off Time Fault Probe 1 Cycle Off Time Fault Probe 2 Cycle Off Time Fault Probe 3 Cycle Temp Scale Probe 1 Calibration Probe 2 Calibration Probe 3 Calibration Decimal Point Probe 1 Present Probe 2 Present Probe 3 Present Keypad Protection Serial Communications Address Keypad Code Type of Probe
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).
TORQUE:
TERMINAL BLOCKS = 8 LB.IN GROUNDING BLOCKS = 8 LB.IN
FIELD WIRING:
USE MINIMUM 60° Copper Wire
FACTORY WIRING FIELD WIRING
LABEL DESCRIPTION
TC1 Dwyer Controller
T1
PT1000 Temperature Sensor
VFD Variable Frequency Drive
CH
Cabinet Heater (250 Watts)
DS1 Disconnect
PS# Pressure Switch
LT#
Status Light
FS1
Fire System Microswitch 1
FS2
Fire System Microswitch 2
WIRE COLOR
BK – black BL – blue BR – brown OR – orange PR – purple RD – red YW – yellow
WH – white
BK
N BK CABINET HEATER THERMOSTAT BK HEATER
FIRE SYSTEM WIRING – ANSUL ELECTRIC RELEASE
FS1
NC
NO
COM
FS2
NOT USED
115/1 POWER FOR ELECTRIC RELEASE (FROM KITCHEN FIRE SYSTEM)
ACTUATION LINE (TO/FROM KITCHEN FIRE SYSTEM)
NC
NO
COM
NOT USED
TO ELECTRIC RELEASE SOLENOID
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 33
®
Wash Water Plumbing Schematic (not to scale)
STANDARD UNIT
SOLID FUEL UNIT
Plumbing Notes:
1. Trapped drain line water column to be sized for total system loss + 1.0
in. wg Drain shall be plumbed to an approved grease interceptor.
2. Water supply and drain piping exposed to freezing must be trace heated and
insulated.
3. All piping, backflow preventer, pressure gauges, ball valves and solenoid
valves (24 VAC) are provided by others.
4. All solenoid valves provided in the field shall be equipped for outdoor or
indoor environment, based on whether the unit is mounted indoors or outdoors.
DETERGENT DISPENSER ASSEMBLY 34 Grease Trapper ESPTM Kitchen Exhaust Pollution Control System
Detergent Dispenser Notes: 1. Detergent dispenser must be located
indoors in a freeze proof area. These components must also be located in an
area convenient for monitoring/servicing. 2. Reservoir shall be polypropylene
with removable lid. 3. Maximum allowable horizontal distance from detergent
pump to unit = 30 feet. 4. Maximum allowable vertical distance from detergent
pump to unit = 30 feet.
®
Troubleshooting
Problem: Cells shorting immediately (Green indicator light continually flashes)
Cells are dirty/clogged
Run through a wash, making sure detergent level is full. If cells are still dirty, safely removing cells and manual cleaning/spraying may be necessary. If air compressor is available on site, spray out cells thoroughly of any dust and debris.
Cells are not installed correctly
Safely remove cells and make sure they are installed correctly, ensure the cell pushers are installed tightly with no slack in the cable. Cable could short out on collector ionizer rods to the ground if installed incorrectly, see page 7.
Cell wiring incorrect
IONIZER should be connected to the RED spark plug cable (Ionizer is the spiked smaller plates that face the inlet of the unit) COLLECTOR should be connected to the BLUE spark plug cable. GROUND cable should be connected to the BLACK spark plug cable. Cells have been labeled by the laser to indicate each spark plug connection.
Dry portion of wash cycle was bypassed
If the unit dry portion of the wash cycle was bypassed, the cells may still be wet. Run the fan for 60 90 minutes to dry out the cells.
Problem: When running unit, green indicator on terminal enclosure illuminates, then after a few seconds turns off, then repeats
Power supply is not providing correct voltage Possible faulty or incorrectly programmed power supply. Contact factory for
back to control panel
further troubleshooting assistance.
Problem: Indicator lights (LEDs) on terminal enclosures not illuminating
Wiring not matching polarity of LEDs
Switch the leads on the LEDs located on the cover of the terminal enclosure(s).
Faulty LEDs or faulty power supply
Test voltage to LEDs and to input power of power supply when unit is on. Replace LEDs/power supply if faulty.
Problem: Power supplies operating (green), but cells don’t appear to be collecting contaminants
Insufficient connection between cells or plugs
Ensure spark plug style cables are properly connected, and that the cell pusher is properly installed.
Problem: Cells not fully clean after completed wash cycle
Detergent empty
Check to see if there is a low detergent alarm, refill detergent if empty
Incorrect detergent used
Make sure detergent used is the recommended Zep X701
Wash sequences are too short for cooking duty
Increase wash sequence times
Water temperature or pressure incorrect
Make sure water temperature is 140°F and 40 psi
Problem: Wash cycle won’t start via button, digital input, nor the wash scheduler
Fans are running
Fans need to be turned off before wash can be started
System in fire mode
Check for fire micro-switch wiring (normally-closed contact between C1 and NC1).
Wash cycle is starting, but water isn’t turned Confirm wash is running by referencing keypad/touchscreen. Check hot water
on to unit
shut off valves feeding the unit.
Problem: Unit not washing
Something is preventing the wash from occurring
Review wash history pages on controller, see page 17-18 for more details.
Grease Trapper ESPTM Kitchen Exhaust Pollution Control System 35
®
Maintenance Log
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Date ___Time _ AM/PM Notes:
Our Commitment
As a result of our commitment to continuous improvement, Greenheck reserves
the right to change specifications without notice.
Product warranties can be found online at Greenheck.com, either on the
specific product page or in the literature section of the website at
Greenheck.com/Resources/Library/Literature.
Greenheck’s Grease Trapper ESPTM Pollution Control Unit catalog provides additional information describing the equipment and available accessories.
AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at www.amca.org.
®
Phone: 715.359.6171 · Fax: 715.355.2399 · Parts: 800.355.5354 · E-mail: gfcinfo@greenheck.com · Website: www.greenheck.com
36 482585 · Grease Trapper ESPTM Pollution Control, Rev. 12, June 2023
Copyright 2023 © Greenheck Fan Corporation
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>