Air Boss ATS(Air Treatment Systems)

ATS SERIES

• INSTALLATION• OPERATION• SERVICE

Electrostatic Precipitators forCommercial & Industrial

Applications

101 McNeill Road • Sanford, NC 27330(919) 775-2201 • Fax: (919) 774-8771

(800) 884-0002www.trioninc.com

MANUAL PART NO. 147207-001 • December 2002

A i r P u r i f i c a t i o n S y s t e m s

TABLE OF CONTENTS

SECTION I DESIGNFor The System Design Engineer Page

1. Introduction ................................................................................................................................ 12. General Description ................................................................................................................... 13. System Design and Layout........................................................................................................ 2

SECTION II INSTALLATIONFor The Installing Contractor

1. Unpack and Inspect ................................................................................................................... 32. Position Air Cleaner Cabinet ..................................................................................................... 33. Connect Adjoining Ductwork .................................................................................................... 34. Mount Detergent System ........................................................................................................... 35. Connect Drain............................................................................................................................. 36. Connect Wash Water Supply..................................................................................................... 37. Mount Control............................................................................................................................. 48. Complete Wiring

A. High Voltage Wiring................................................................................................................ 4B. Primary Wiring ........................................................................................................................ 4

9. Fire Suppression System (when factory supplied).................................................................. 410. Checkout for System Start-up .................................................................................................. 4

SECTION III OPERATION AND SERVICEFor The Maintenance Engineer

1. Introduction and Principle of Operation ................................................................................... 52. Initial Start-up............................................................................................................................. 63. Wash Control and Detergent System Settings......................................................................... 84. Routine Maintenance ................................................................................................................. 95. Preventative Maintenance ......................................................................................................... 9

SECTION IV TROUBLESHOOTINGFor The Maintenance Engineer

1. Trouble Shooting ..................................................................................................................... 112. Spare Parts ............................................................................................................................... 123. Trouble Reference Chart ......................................................................................................... 13

SECTION V REFERENCEIllustrations and Drawings

Figure 1 General Component Arrangement...................................................... 14Figure 2 Unit Outline .......................................................................................... 15Figure 3 Control Outline..................................................................................... 16Figure 4 Detergent System Outline ................................................................... 17Figure 5 Piping Schematic................................................................................. 18Figure 6 Field Wiring Diagram........................................................................... 19Figure 6a Second Wash Section Field Wiring Diagram ................................... 19aFigure 7 Fire Control System Outline................................................................ 20Figure 8 ATS Control Schematic Page 1........................................................... 21Figure 9 ATS Control Schematic Page 2........................................................... 22Figure 10 AIR BOSS Control Schematic Page 1................................................. 23Figure 11 AIR BOSS Control Schematic Page 2................................................. 24Figure 12 ATS Remote Box Schematic Page 1................................................... 25Figure 13 ATS Remote Box Schematic Page 2................................................... 26Figure 14 Standard Single Section Sequence Timing ....................................... 27

1

SECTION I DESIGN

FOR THE SYSTEM DESIGN ENGINEER

1. IntroductionATS units are Air Treatment Systems designed toefficiently remove a variety of contaminants from an airstream. These contaminants my range from those foundin normal kitchen ventilation air to weld fumes or oilsand effluents from various manufacturing processes. Arange of units is available to clean specific air volumes.

Each unit is made up of mechanical and electronic “dirt”collecting modules and efficient, trouble free operationis absolutely dependent upon the periodic removal ofthe collected contaminate from the cleaning elements.Unit design simplifies this requirement.

When properly installed, operated and maintained, theATS unit will effectively and efficiently perform itsdesigned task.

2. General DescriptionThe standard major components supplied with eachATS unit are as follows:• Base unit consisting of five modular sections: 1)

impinger, 2) electronic air cleaner 3) bag type mediafilter 4) activated carbon adsorber and 5)blower/motor.

• Washer control including high voltage powersupply(s) to be mounted remotely.

• Detergent system to be located remotely.• Wash water supply-line strainer.

The impinger section contains impinger panels to collectgrease and liquid particulate, oscillating front and rearwash manifolds and metal mesh pre-filters (and after-filter when specified).

The electronic air cleaner section contains the ionizing-collecting cells to remove very fine particles; oscillatingfront and rear wash manifolds and metal mesh pre-filters and after-filters.

When a factory installed fire suppression system isspecified, both the impinger and electronic air cleanersections include spray nozzles. Fire control is usuallyrequired in kitchen exhaust and similar applications.

The media section contains bag type filters providingsafety filtration for the electronic air cleaner in the eventof any accumulated blow-off or contaminant penetrationin the event of an electrical outage.

For odor control, the adsorber section contains theactivated carbon panels in a vee bank configuration.

With the exception of the wash manifolds and theblower/motor, all the major components slide in and outof the housing for ease of service.

To provide access to the system components (exceptthe blower section), gasketed doors with push-buttonlatches and lift-off hinges are located 90 degrees to thedirection of airflow on one side of the cabinet. Accesspreference should be noted when unit is ordered.Access to the blower section is obtained by removingthe bolts retaining the discharge end panel.

The power supplies providing the necessary highvoltage for the electronic air cleaner and the controlsinitiating and sequencing the wash cycle are housed ina NEMA 12 enclosure designed for remote mounting. Inaddition, the enclosure is a central junction for theprimary wiring.

The standard 16-gallon detergent system is furnishedas a completely assembled unit to be piped directly tothe wash water supply, into the wash manifold headers.

Note: 30 or 55-gallon detergent tanks are available asan option.

Note: Trion Tridex Detergent is specially formulated foruse with Trion electronic air cleaners. Use of othercleaners and detergents, not specifically approved byTrion, can cause possible failures in the unit and will voidany warranties on our equipment.

The strainer is to be installed in the wash water supplyline. Factory installed solenoid valves are located in thepiping inside the impinger and the electronic air cleanersections.

An optional chemical fire suppression system may bespecified to be included with the ATS unit if it is arequirement of the application. The system availablefrom the factory must be completed at theinstallation site by a qualified and authorized firecontrol contractor. In addition to final hook-up, he willcomplete tie-in with other existing systems, test, finalinspect and if necessary, coordinate his work with localor other designated fire inspectors. The fire suppressionsystem includes strategically located, spray nozzles andan electrical fire detection device to signal a controlhead that opens a valve to discharge a chemicalcylinder. An auxiliary mechanical “Pull” is also suppliedto be installed at a remote location to manually activatethe system. The general contractor should coordinatehis work with that required by the fire control contractor.Refer to fire control system outline drawing, Figure 7.

The following are standard options that may bespecified on the basic systems:

1. Without carbon section2. Without media section*3. Without carbon and media sections4. Without blower section5. Additional electronic air cleaner section (double

pass unit)6. 30 or 55 gallon detergent system7. Perforated plate in lieu of the metal mesh filters8. Fire suppression system

2

*A carbon section without a media section is notrecommended by TRION.

3. System Design and Layout(Refer to, or request, submittal drawings for dimensionsand data pertaining to a specific unit that is not includedin this manual).

The arrangement of the supplied components and thegeneral layout of the system will vary according toapplication, adjoining equipment and available space.However, there are several basic factors pertaining toall installations that must be considered:

To maintain the selected cleaning efficiency, it isimportant to assure that the total air volume (capacity inCFM) is uniformly distributed across the entire face areaof the unit. The metal mesh filters, perforated plate ormist suppressors, provide some resistance to effecteven air distribution. However, since most air ducts aredesigned to handle air velocities greater than the ratedvelocity of the air cleaner, it is necessary to properlytransition any attached ducting. If possible, a contractionratio of 1 in 3 (approximately 20°) should be maintained.If space prohibits, turning vanes, air baffles or othermeans may be utilized. Ducting – where attached to thecabinet collars – should be gasketed, caulked orotherwise made watertight. The bottom of the air-entering duct should be reasonably flat and slopedtoward the impinger drain pan for a length of 18 inches.This will assure that any wash water splashback isreturned to the drain basin. The ducting and ductconnections should be designed in accordance withapplicable code requirements.

When there is a danger of rain, snow or debris beingdrawn into the system with outside air, the make-up airintake should be protected with rain louvers, hoodingand hardware cloth to prevent the rain, snow or debrisfrom entering the electronic air cleaner.

Some contaminants to be collected, such as oils invaporous state, must be condensed into particulate formprior to entering the ionizing-collecting cells in order tomaintain the anticipated efficiency. Gases, vapors orany non-particulate cannot be precipitated and willtherefore pass through the collecting elements. Anycondensing that takes place downstream from the aircleaner defeats the purpose. By the same token, heavyconcentrations of water vapor, or other matter thatbecomes highly conductive when condensed, must beprevented from entering and/or condensing in theelectronic air cleaner to prevent electrical arc over andshorting. The impinger module aids in this process andwill adequately handle light concentrations, however, itis recommended to insulate upstream ductingconveying warm air that is subjected to coldtemperatures on applications such as kitchen exhaust.

SAFETY NOTE:Factory designed access to all electrically chargedhigh voltage components contain electrical interlocks

for the safety of operating personnel. Any additionalaccess that may be provided in the system, wherethere is access to high voltage, must be equipped withsuch interlocks. Interlocks are readily available fromthe factory.

Water wash drain lines from the cabinet drain basinshould be trapped or otherwise sealed against thesystem pressure (in accordance with local codes).Wash water to the unit must meet the volume requiredfor the specific unit involved, and between 35 PSIG Min.– 50 PSIG Max. at full flow to provide proper spraypatterns from the wash nozzles. The wash water MUSTbe Hot water (1400F recommended) and installed asclose as possible to the unit and detergent system.

NOTE: THE HOT WATER TANK IS NOT PROVIDED BYTRION.

When applicable, the detergent system, the wash waterinlet piping and the drain lines must be protected fromfreezing temperatures.

Each installation varies according to needs, but thewater wash control must be located indoors, out of theweather, and as closed to the air cleaner as practical.Ideal mounting height is at eye level for ease in readingthe instrumentation, and to facilitate service. Theinstructions furnished for manually operating the fireextinguishing system shall be posted conspicuouslynear the control in the kitchen or well-occupied workarea.

For ease in maintenance and component removal,adequate space, 39” Minimum Required, must beprovided in front of all access doors, motors, pump andaccessory equipment. Special consideration should begiven in this respect for installations where the unit issuspended overhead. Catwalks or platforms should beprovided.

CAUTIONIn addition to the above space requirement, installationof the Model ATS in NFPA applications shall have aclearance of at least 18 inches to a combustiblematerial, 3 inches to limited combustible material, and0 inches to noncombustible material. Any reduction inclearance or exceptions must be in compliance withNFPA and acceptable to the Authority HavingJurisdiction.

****WARNING****Fire Suppression Systems

Extreme caution should be exercised when this unit isinstalled in applications that are collecting volatile orpotentially flammable contaminates such as cookinggrease and petroleum based oils.Trion strongly recommends a fire suppression systembe installed in the ductwork and on the Model ATS incases where these contaminates are collected on thecell plates and collect on the attached ductwork.Contact the factory for questions or concernsregarding a fire suppression system.

3

To enable the factory to respond efficiently tomanufacturing requests, the equipment purchase ordermust contain the following information in addition to themodel and options.

1. The application and as much contaminate load dataas possible. This will enable the wash control to bepreset and adjusted to the optimum setting.

2. The high-voltage lead length required if longer thanthe standard length of 50 feet.

3. The side of the blower section the blower motorstarter is to be installed. Left or right as determinedwhen standing in the direction of air flow with the airstriking your back.

4. The external static pressure that the blower/motorwill handle due to ducting, hooding or otherequipment.

Contact the local Trion Sales Office or the factory ifquestions arise, or if any additional information isrequired.

SECTION II INSTALLATION

FOR THE INSTALLING CONTRACTOR

1. Unpack and InspectAt the time the unit is received, all shipping containersand their contents should be examined for damage. Anydamage occurring in shipment must be immediatelyreported to the carrier, an inspection report completedand a claim filed at the receiving point.

The unit modular sections are shipped completelyassembled and joined and, where size permits, theelectronic air cleaner ionizing-collecting cells areshipped inside the cabinet. On large units, the upper tierof cells may be shipped in separate containers. Thewash control, detergent feeder and other separateaccessories are shipped in the containers as noted onthe packing list.

2. Position Air Cleaner CabinetIf advantageous, to remove weight for ease in handling,the filtration elements can be removed from theirrespective cabinets. Position the unit in the designatedlocation giving consideration to the following points:

(a) Excluding the blower section, there are accessdoors on one side of the section modules. Providesufficient clearance in front of the doors on at leastone side for service and element removal. Normallythe side on which the factory installed blower motorstarter is mounted is the pre-planned side for singleside access.

(b) Level the unit to assure proper drainage from thedrain pans.

After the cabinet has been properly located, it may besecured into place by bolting or welding. Reinstall anysection elements removed during installation making

directional arrows concur with the designed airflowthrough the cabinet.

3. Connect Adjoining Duct WorkWhen the adjoining ducting is installed on the airentering side, the bottom of the horizontal duct runshould be relatively flat and sloped toward the sectionhousing drain pan for an 18-inch length. This will enableany wash water splashback occurring during thewashing operation to run back into the drain pan.

Secure the adjoining ducting to the section housingutilizing the .375-inch clearance holes provided. Theseams should be made air and watertight by caulking orgasketing.

Upstream ducting conveying warm air and subjected tocold temperatures must be insulted to preventexcessive condensation.

4. Mount Detergent SystemRefer to Figures 1 and 4. The detergent system shouldbe located as close to the unit as practical in a levelposition. Service space must be provided for periodicalmanual filling of the detergent tank, and to gain accessto the pump and motor assembly. When positioned, theassembly may be secured in place at the predrilledfactory mounting pads, either by bolting or welding.

5. Connect DrainConnect a drain line to the 2” NPT couplings provided inthe drain basins of the impinger and electronic aircleaner sections in accordance with the governingplumbing codes. The drain line must be sealed with atrap or other means to prevent air by pass. If a trap isused, it should hold sufficient water column to overcomethe system air pressure and to assure that loss of liquidfrom evaporation between cleaning periods will notbreak the seal. The drain line should not be smaller thanthe drainpipe coupling, or it will otherwise restrict theflow of water. Refer to Figure 5.

6. Connect Water Wash SupplyThe items furnished for field installation in the waterwash supply are a strainer, a back flow preventer (notsupplied) and a detergent system. Refer to the PipingSchematic Figure 5.

Unless otherwise specified, the water wash supplyshould be hot (1400F recommended-WATER HEATERNOT SUPPLIED BY TRION) at the volume specified forthe given unit, and at a full flow pressure between 40and 50 PSIG.WARNING: Adequate precautions should be takenin the event the water supply, detergent system anddrains are subjected to freezing temperatures.

Although not required, a pressure gage and a manualservice valve are recommended as shown in thediagram. The components should be located within thesystem to provide for service access.

4

7. Mount ControlMount the wash control, also containing the high voltagepower supplies, in the selected location. It must bemounted indoors out of the weather and should be ateye level to ease in monitoring unit operation and asclose to the ATS unit as practical. Allow sufficient spacein front of the access door for service. Refer to Figure 3for mounting hole layout and dimensions.

8. Complete Wiring(a). High Voltage Wiring

WARNING:EXERCISE ALL THE NORMAL PRECAUTIONSWHEN WORKING WITH HIGH VOLTAGE ANDCOMPLY WITH NEC AND ALL APPROPRIATELOCAL CODES.

The high voltage wiring entails interconnecting thepower supply(s) with the ionizing-collecting cell(s)located in the electronic air cleaner section cabinet.On multicell units, the wiring between the cellswithin a tier is automatically made with intercellspring contacts.

Refer to the Field Wiring Diagram Figure 6. Two 50ft., (or the length specified) high voltage leads, onefor the ionizer and one for the collector, are factoryfurnished. When the installation requires more thanone power supply, a set on leads is furnished foreach supply. Ring type connectors have beenfactory installed at the cell termination of the leads.After the leads have been run and cut to the properlength, the slip-on connectors, shipped on theirrespective power supply terminals, should besecured by both crimping and soldering. Forworking ease, the power supply(s) may beremoved from their retaining slide channels byremoving the single bolt in the top corner of thecircuit board. Each lead is to be run in separaterigid conduit and must be of continuous run. (Donot splice.) Knockouts are provided in the sectionhousing pilasters for conduit connection.

(b). Primary WiringRefer to the Field Wiring Diagram - Figure 6. Theprimary wiring should be completed using rigidconduit in accordance with prevailing electricalcodes.

The wash control is the main distribution point for allprimary wiring. The wiring includes the input supplyto the control and the interconnections between thecontrol and the following components:1. Detergent feeder2. Manifold drive motors*3. Solenoid valves*4. Door interlocks*5. Blower motor starter/disconnect6. Temperature sensor (when specified)7. Fire suppression control (when specified)

*One each for impinger and electronic air cleaner

9. Fire Suppression System (when specified to befactory supplied)

The installation of the fire suppression nozzles, firesensor device, the components within the chemicalcylinder housing and the interconnections of thecomponents has been completed at the factory. Theauthorized fire control contractor must complete theremote mechanical “Pull,” any other hookup or tie-in,final test and inspection. Refer to fire control systemoutline drawing, Figure 7.

Mount the fire extinguishing system instructions in thedesignated area that is conspicuously located. Thisshould be in the kitchen or a well occupied work areaand is normally near the control.

10. Check Out for System Start-upWhen the installation has been completed, assure thatthe equipment is ready for start-up by checking thefollowing:

A. All construction debris is removed from the modularsection cabinets and the adjoining ductwork.

B. The inside of the power supply/control housing andthe detergent feeder tank is clear of any foreignmaterials.

C. The drain lines from the section drain basin areclear and that the line is completely connected to itspoint of termination.

D. All supply line piping is completed and wash wateris available.

E. When required, assurance that the fire suppressionsystem has been inspected and tagged into serviceby an authorized person.

F. Supply line power is available and electrical wiringis completed to the following components:

1. ATS Control2. Blower motor starter3. Manifold drive motors4. Solenoid valve5. Door interlock6. Temperature sensor (when specified)7. Ionizing-collecting dells8. Fire suppression system, as applicable

G. NOTE: Do not put the initial supply of detergentinto the detergent tank. This is to be done aftervolume settings are made at start-up.

5

SECTION III OPERATION

WARNINGRISK OF ELECTRIC SHOCK

These servicing instructions are for use by qualifiedpersonnel only. To reduce the risk of electric shock,do not perform any servicing other than thatcontained in the operating instructions unless youare qualified to do so.

FOR THE MAINTENANCE ENGINEER

1. Description and Principles of Operation

The basic ATS units are made up of five modularsections. Each of the first three sections employsdifferent mechanisms to remove and capture particulatematter from the air.

The first section, an impinger, is primarily designed for,and is especially effective in, capturing relatively largegreasy liquid particulate. The impinger is constructed oftwo equally spaced layers of roll formed baffles. Thespacing creates and air flow pattern which causes thecontaminate to collect and flow down the baffles. Holesin the frame permit the liquid to drip into the drain basinbelow. Periodically, at a predetermined setting aremotely located control automatically activatesoscillating wash manifolds located on both sides of theimpinger to flush away any remaining tenacious matter.(Refer to the electronic air cleaner section below foradditional description on the integral washer. It isidentical to the impinger washer.)

The second section houses an electronic air cleaner,technically known as an electrostatic precipitator. In thistype of equipment, all airborne particles, even ofmicroscopic size, are electrically charged (positively) asthey pass through a high voltage ionizer. These chargedparticles are then attracted and adhere to a series ofparallel collecting plates, which form the negativeelements of an electrostatic field.

The ionizer consists of charged stainless steel spikedblades spaced between grounded electrodes. Thecollecting section consists of parallel plates arranged sothat each alternate plate is charged while theintermediate plates are electrically grounded.

The ionizing-collecting cells (contaminate collectingelements) are housed in the cabinet on slide rails. Theycan be removed from the cabinet as required, throughthe end access door, by sliding them out like drawers.On multicell units, all of the electrical connectionsbetween cells in a given tier are automatically madethrough spring connectors. On the access end, the highvoltage from the power pack(s) is made with cables.When installing cells into the cabinet, observe thedirectional arrows on the cell end plates. The side of thecell containing the spiked ionizer blades always must belocated on the air entering side.

The power supply(s) convert the 115-volt, 60Hz, single-phase AC supply to the high voltage DC needed topower the cell(s). The power supplies are solid state,pulse width modulated (PWM), line and load regulated.Potential output voltages of 12.5 KVDC are required forthe ionizer and 6.25 KVDC for the collector at amaximum current of 6 MA. Each supply is retained inthe control in slide channels and secured with one boltlocated in the top corner of the circuit board.

At a predetermined frequency the remotely locatedcontrol automatically activates an integral wash systemto flush away the collected contaminant. Whenactivated, the duration of the washing cycle isapproximately 80 minutes.

The wash system consists of a series of spray nozzlessoldered into oscillating water wash manifolds. Themanifolds are located in the front and rear of each celltier. They are mechanically interconnected with a drive-belt and driven through direct linkage by a fractional HPmotor. A detergent feeder is also incorporated into thewash system. The amount of detergent needed for eachwash is readily field adjustable and that amount isdependent upon wash water temperature, the type andamount of contaminant collected.

In addition to the preset automatic wash cycle, thewashing operation may be initiated manually whenrequired. The events in a wash cycle are:

A. Power pack(s) and system blower ”OFF”

B. Washer and detergent “ON” (each module)

C. Washer and detergent “OFF” (each module)

D. Pause for detergent to react

E. Washer “ON” for rinse (each module)

F. Washer “OFF” (each module)

G. Blower “ON” for forced dry

H. Power pack(s) “ON”

When a fire control system is specified, both theimpinger and electronic air cleaner sections containchemical spray nozzles.

The third section houses a bag filter(s). In the event ofan electrical outage in the electronic air cleaner, the bagfilter acts as a safety backup collector.

Also, in some applications, the bag filter will collect anyprecipitated agglomerates that may tend to “blow-off”the electronic air cleaner.

When the bags become saturated with contaminantthey must be removed and replaced. However, thisrequirement is relatively infrequent due to the pre-filtration upstream from the bag.

6

A series of long deep pockets arranged side-by-sideform the configuration of each bag. The ultra fine fibersused in the makeup of the filtering media offer to trapthe contaminant.

The fourth section is employed in the ATS unit for odorcontrol. Panels, filled with activated carbon granules,are arranged in a vee bank configuration to provideadequate surface area. The surface of each granule isextremely porous and absorbs materials that are in agaseous or vaporized state that cannot be removed bythe particulate filters. Using the carbon filters without thepre-filtration by the bag filters is not recommended.When the panels have become saturated or fully loadedthey may be replaced with new or reactivated carbon.

The fifth section, the blower/motor section, has beenrated to handle the air movement requirements for thesystems and the adjoining ducting.

When the fire suppression system has been specified tobe factory furnished it consists of strategically locatedchemical spray nozzles located in the impinger andelectronic air cleaner modules. The fire suppressionchemical is stored in a cylinder housed in aweatherproof enclosure mounted on one side of theblower module. An electrical detection device, mounteddownstream from the impinger module in the electronicair cleaner module, activates the system by sending asignal to a control head discharging the chemicalcylinder.

In addition to the electrical detection device, a remotelylocated pull station is provided for mechanical activationof the system manually.

Depending on the installation and any local, or othergoverning requirements, the ATS unit fire suppressionsystem may be tied-in with other fire suppressiondevices. When the fire suppression system is activated,the unit electrical input power is disconnected to theATS unit blower and the high voltage required for theelectric air cleaner is disconnected. After the firesuppression system has been activated, theauthorized fire suppression contractor must put itback into service. For a system supplied, with the ATSunit, refer to Figure 7.

2. Initial Start-up

Prior to equipment start-up, the fire extinguishingsystem employed in the ATS unit (and possiblyadjoining equipment) must be inspected by properlytrained and qualified personnel. This includes allactuation components including remote manual pullstations, mechanical or electrical devices, detectors,fire-actuated dampers, etc. These items shall bechecked for proper operation during the inspection inaccordance with the manufactures listed procedures. Inaddition to these requirements, the specific inspectionrequirements of the applicable NFPA standard shallalso be followed. If required, certificates of inspection

shall be forwarded to the authority having jurisdiction.For a fire suppression system supplied with the ATSunit refer to Figure 7.

A. Inspect the inside of the adjoining ductwork andTrion cabinet to be sure it is clean and free of anydebris or construction materials. Especially note theopening in the drain basin for any restrictions. Theducting, where secured to the cabinet collars,should be sealed watertight with either gasketing orcaulking.

B. Inspect the ionizing-collecting cells to see that all ofthe ionizing blades are intact and that no largepieces of foreign material are lodged between theplates. Also verify that the cells are properlyinstalled in the cabinet with the spiked ionizingblades located on the air entering side (Follow theair flow directional arrows).

C. Check the high voltage leads to see that they areconnected to the proper terminals, both at theionizing-collecting cells and inside the power pack.Refer to Figures 6.

D. Be sure that the drain lines from the drain basinsare completely connected and properly terminated.A trap or seal of some type should be incorporatedin the line to prevent air bypass.

E. Check the water supply line to be sure water isavailable and that the strainer, back flow preventer(by others) and detergent system are properlyinstalled and connected. Refer to piping diagramFigure 5.

F. Be sure that electrical power is available, that thewiring is completed, and that the system blower isready to energize. Refer to field wiring diagramFigure 6.

G. Be sure that all access doors are closed.

H. Close the system electrical supply switches, makingpower available to the control and blower motorstarter. Check to verify blower rotation is as shownon the rotation indicator arrow.

I. Turn the “ON-OFF” selector switch to the control“ON”. The blower should run (if installed) and thepower supply(s) should be energized. Electrical arc-over within the ionizing-collecting cells may occur. Itis a normal occurrence caused by accumulationdust from constructions or other sources in thecell(s) and should soon subside. If the arc-over incontinuous and does not subside, recheck therouting of the high voltage leads between the powersupply(s) and the cell(s). Refer to field wiringdiagram Figure 6. The ionizer lead must beconnected to the ionizer and the connector lead tothe collector. If arc-over still occurs, or difficulty

7

other than that outlined above, refer to the TroubleShooting reference chart Section IV.

J. Be sure the detergent tank is clean, and then fill thetank 1/8 full with clean water. Do not fill with thedetergent until start-up adjustments have beencompleted.

K. (Review this paragraph in its entirety before initiatingthe wash start button.)

Next, set the detergent volume setting per wash atthe detergent feeder. Manually initiate the washcycle by pushing the "Wash Start" button on thecontrol. The wash control duration is 80 minutesand by means of a factory preset programmablelogic controller (PLC) will sequence the washingevents as previously outlined. When the detergentpump is energized, note the amount that is used byobserving the reduction in the liquid level in thetank. The usage should be approximately 1 part ofdetergent to 20 parts of water. The water anddetergent requirements for each unit model arelisted in Table 1 on the Piping Schematic, Figure 5.To adjust the volume output from the pump, refer tothe Detergent System Outline, Figure 4. The pumpis a constant displacement type and the amount ofdetergent forced into the water supply to wash theunit is dependent upon the setting of the controlvalve in the bypass return line to the reservoir. Theside of the translucent reservoir is marked withvolume markers. Adjust the control valve to obtainthe correct usage for the given unit model, thensecure the setting with the Allen head set screwlocated in the valve adjustment knob. When thecorrect adjustment has been made, remove theremaining water from the reservoir and fill the tankwith initial supply of detergent furnished.

L. When the wash control has cycled out, manually setthe programmable timer relay (TR), or initiator clock,located in the control for automatic initiation of thewashing operation. This setting can be tailored to thewashing frequency best suited for the specificapplication and may be best explained by example.

Suppose the application of the equipment is to cleanrestaurant kitchen exhaust air. The collectedcontaminant to be washed away is of greasy nature,containing particulate such as smoke and fume fromthe grill, mist and vapors from the French Fryer, flourdust and other various matter that is created bynormal kitchen operation.

In our example, the restaurant operates Mondaythrough Saturday (closed Sunday) and opens daily at6:00 a.m. and closes daily at 11:30 p.m. This busyschedule presents a relatively heavy dirt loading andbeing of greasy nature should be washed away daily.The best time being shortly after closing when theatmosphere has settled but before the greasycontaminant collected has had a chance to hardenand setup.

From the above, a wash schedule of every dayexcept Sunday at 1:00 a.m. can be established. Asthe duration of events preset at the factory isapproximately 80 minutes, the cycle will end atapproximately 2:20 a.m.

Prior to setting the initiator clock it will be necessaryto charge the battery located inside the clock. This isaccomplished by turning the selector switch on thefront of the control to the "ON" position. A light insidethe switch will glow. If it does not glow, check to besure there is supply line power to the control. DONOT PUSH THE WASH BUTTON. Allow the controlto remain in the "ON" position for 24 to 36 hours

while the battery is charging.

To set the initiator clock, it is first necessary to set theexisting time, then the program times that are to beinitiated.

To set existing time:

1. Depress the reset (R) button to cancel out anyprevious settings.

2. Slide the P-Run switch to the clock position.Monday (MO) will be indicated.

3. Push the (1 ... 7) button until the present day ofthe week is indicated.

8

4. Push the hour (h) button to the present hour ofthe day.

5. Push the minute (m) button to the minutes pastthe hour of the day.

6. Slide the P-Run switch to the run position. Thecolon will blink indicating the clock has been set.

To set the programs (wash times) according to thetimes in the example outlined above.

1. Slide the auto-manual switch to the auto position.

2. Slide the P-Run switch to the program (P)position. The word "ON" and the number 1 willappear on the display. This indicates the time thefirst program is to be turned "ON."

3. Push the day (1 ... 7) button until only the dayMonday (MO) appears on the display.

4. Push the hour (h) button until the designate hour(01:00) appears on the display.

5. It is not necessary to set the minute (m), as 1:00o'clock on the hour was the selected wash initiation"ON" time. The "ON" time has now been set.

6. Next, set the program "OFF" time. This will be 1minute after the "ON" time. A 1-minute duration isadequate program time as the initiation signal issent to the wash control logic timer instantaneously.

Push the I/0 (P) button. The word "OFF" and thenumber 1 will appear on the display. This indicatesthe set time the first program is to be turned "OFF."

7. Push the day (1 ... 7) button until only the dayMonday (MO) appears on the display.

8. Push the hour (h) button until the hour 01:00appears on the display.

9. Push the minute (m) button until the time 01:01appears on the display. Program 1, wash time "ON"and "OFF," for Monday has now been set.

10. Next set the second program which will be theTuesday (TU) washing. Push the program I/0 (P)button. The word "ON" and the number "2" willappear on the display.

11. Repeat the setting process for TU as outlinedabove in steps 3 through 9 for MO "ON" - "OFF"time.

12. After the wash program has been set for TU,repeat the same setting procedure for WE, TH, FRand SA. Omit SU.

13. Slide the P-Run switch to the run position. Theexisting time of day will show on the display. The sixselected washdays established in the example havebeen set.

NOTE: Using the above procedures, different washingdays and "ON - OFF" times may be established andset into the initiator clock to best serve a specificapplication.

NOTICE: Once the reset key (R) is pressed, theprevious time and program will be cleared to theinitial state.

Kitchen Exhaust ApplicationsM. For safe and proper operation adhere to the following

instructions and procedures:

1. Exhaust systems shall be operated during allperiods of cooking in restaurant applications.

2. Filter-equipped exhaust systems shall not beoperated with filters removed.

3.The posted instructions for manually operating thefire extinguishing system shall be kept conspicuouslyposted in the kitchen and reviewed periodically withemployees by the management.

4. Listed exhaust hoods shall be operated inaccordance with the terms of their listings and themanufacture instructions.

5. Cooking equipment shall not be operated while itsfire-extinguishing system or exhaust system is notoperating or otherwise impaired.

3. Wash Control and Detergent System Settings

The total time required for the complete wash cycle isapproximately 80 minutes. Four main events take placeduring the wash cycle: Wash, Soak, Rinse and Dry.Once the Wash Control has been initiated, either bymanually pushing the washer start button, or throughthe means of the automatic time clock, the wash eventswill take place automatically. The time for each eventhas been preset at the factory in the programmablelogic control (PLC).

9

Some dirt is more tenacious than others to remove andmay require a stronger detergent solution. Averagesettings have been factory set. Best possible settingsfor any given installation, however, are determinedthrough experience. Determination can be made byvisually examining the collecting elements after the firstfew washings.

To adjust the volume of detergent used within the giventime setting, loosen the knurled knob with an Allenwrench on the control valve located in the by-pass line.Refer to the Detergent System Outline, Figure 4.Turning the knob clockwise increases the volume andcounter clockwise decreases the volume. Whenadjustment has been made, be sure to retighten thesetscrew.

4. Routine Maintenance

A. Washing FrequencyThe frequency that the collected dirt is to be washedfrom the unit depends upon the type and amount ofdirt in the air to be cleaned. Dirt, which is greasy innature, tends to harden after collection and shouldbe washed away often. Likewise, units operatingunder extremely heavy dirt loads should be washedmore often as a large build-up of collected materialwill have a tendency to “blow-off” if permitted toremain on the collecting elements for long periodsof time. In that the type and amount of dirt variesgeographically (and from one location to another inany given area) it is recommended to start operationwith a washing frequency of at least once a week,for most applications except kitchen exhaust.Kitchen exhaust applications should be washeddaily. Schedules may then be altered as neededafter visual examinations of the collected materialcontained on the ionizing-collecting cells. Also, dailywashing is not unusual for units operating on heavywelding fume, kitchen exhaust hoods or similarapplications.

B. DetergentEffective washing is dependent upon detergent. Thedetergent reservoir should be examined on aroutine basis; a minimum tank level established andnever permitted to empty. An empty tank not onlymeans poor washing, but can also be detrimental tothe pump. The inside of the tank should be keptclean, free from dirt and foreign objects. Thedetergent as supplied by Trion, Inc., is formulatedspecifically for electronic air cleaners and should notbe diluted when charging the tank. If substitutes areused, they must be approved by Trion, so as to notvoid the warranty and should be safe for use inventilation systems and non-caustic, as 95% of theionizing-collecting cells are constructed of aluminumand special high voltage insulation and gasketseals.

C. Electrical Operation

The front panel of the control contains indicatinglights for the power supplies, one or two dependingon the size of the ATS unit. The lights should beobserved on a daily basis to ensure that theelectronic air cleaners are operating.

5. Preventative Maintenance

A. Washing frequency – as required.The washing schedule and detergent reservoir levelas outlined under routine maintenance is againreferenced here as excessively large contaminantbuildup on the collecting elements invites downtime. Established routine washing is a preventativemaintenance requirement. The frequenciessuggested below should be altered if necessary.

B. Fire control system - Every 4 to 6 months or asrequired.Inspection, cleaning and servicing of the fireextinguishing system and all listed exhaust hoodsshall be completed by properly trained and qualifiedpersonnel. For a fire control system supplied withthe ATS unit refer to Figure 7.

All actuation components, including remote manualpull stations, mechanical or electrical devices,detectors, fire-actuated dampers, etc., shall bechecked for proper operation in accordance with themanufacturers listed procedures. In addition tothese requirements, the specific inspectionrequirements of the applicable NFPA standard shallalso be followed. If required, certificates ofinspection and maintenance shall be forwarded tothe authority having jurisdiction.

C. Grease removal devices and components – every 4to 6 monthsHoods, impingers, metal mesh filters, ionizing-collecting cell(s) fan, ducts and other appurtenancesshall be cleaned to bare metal at frequent intervalsprior to surfaces becoming heavily contaminatedwith grease or oily sludge. It may be advantageousto clean readily removable items, such asimpingers, metal mesh filters, ionizing-collectingcell(s) or other grease removal devices in a soaktank, with a pressure hose or pressure cleaner.After cleaning to the bare metal, components shallnot be coated with powder, oils or other substance.

When a cleaning service is used, a certificateshowing date of inspection and/or cleaning shouldbe maintained on the premises. Areas not cleanedwill be noted.

Flammable solvents or other flammable cleaningaids shall not be used.

At start of cleaning process, electrical switches thatcould be accidentally activated shall be locked out.Components of the fire suppression system shall

10

not be rendered inoperable during the cleaningprocess.

Care shall be taken not to apply cleaning chemicalson fusible links or other detection devices of theautomatic extinguishing system.

When cleaning procedures are completed, allelectrical switches and system components shall bereturned to an operable state. All access panelsand/or doors and cover plates shall be replaced.Dampers and diffusers shall be positioned forproper airflow.

D. Water Wash System – every 4 to 6 monthsThe water wash spray pattern should be checkedon each nozzle to ensure that a full spray pattern isdeveloped. Distorted patterns are usually caused bydirt in the nozzle orifice, which can be cleaned byinserting a small gage, soft copper wire into theorifice. If any one manifold contains several nozzlesthat are restricted, the drain plug at the idler end ofthe manifold should be removed, after the nozzleshave been cleaned, and the manifold flushed withclean water. The main supply line strainer and thestrainer in the detergent system should be checkedand cleaned. Check the wash manifold drive beltand linkage connections and replace or tighten asrequired.

WARNING:DO NOT USE HIGH PRESSURE STEAM CLEANINGEQUIPMENT TO CLEAN CELLS. THE EXCESSIVEHEAT AND PRESSURE WILL CAUSE THE PLATESTO WARP AND IN TURN POSSIBLY CAUSEEXCESSIVE ARCING.

E. Power Supply(s) and Control every 12 monthsExamine the electrical components located insidethe control housing for any accumulated dirt or dust.If necessary, clean with a good brand of electricalcontact cleaner.

F. Blower Bearings - every 4 to 6 monthsGrease the two blower bearings at the grease fittingprovided with Shell Alvania #2, Texaco Multifac #2or Mobilux #2. At this time, examine the blower forany accumulated dirt and clean as required.

G. Motors – every 24 monthsAs the operation of detergent pump motor is limited,frequent oiling is not required. Lubricate with severaldrops of SAE 10 motor oil every two years. DO NOTOVER OIL. The manifold drive, detergent pump andblower motors have sealed bearings, are factorylubricated for life and require no oiling.

11

SECTION IV TROUBLE SHOOTING

1. Trouble Shooting

WARNING:EXERCISE THE USUAL PRECAUTIONS WHEN WORKINGWITH HIGH VOLTAGE. THE MAXIMUM OPERATINGOUTPUT FROM THE POWER SUPPLY IS 15,000 VDC AND5.5 MA. to 11.0 MA. WHEN IN PARALLEL.

IF SAFETY SWITCHES ARE CLOSED AND CIRCUIT ISENERGIZED, DO NOT TOUCH HIGH VOLTAGE. WHENTHE CIRCUIT IS DE-ENERGIZED, ALWAYS BLEED OFFREMAINING STATIC CHARGE WITH AN INSULATEDHANDLED SCREW DRIVER BY SHORTING GROUNDTHE POINTS OF HIGH VOLTAGE DC POTENTIAL.

WARNINGRisk of Electrical Shock

The servicing Instructions are for use by qualifiedpersonnel only. To reduce the risk of electric shock, donot perform any servicing other than that contained inthe service instructions unless you are qualified to doso.

A. IntroductionThis section on trouble shooting provides a descriptionof potential malfunctions, their cause, location andcorrection. A Trouble Reference Chart listing the mostprobable causes and corrections follows the generaltext.

NOTE: All repair to the fire suppression system (Ifsupplied), must be completed by the authorized fire controlcontractor. For a system supplied with the ATS unit refer toFigure 7.

The electronic air cleaner is the unit within the systemthat has the highest efficiency collection rating and isalso the one with the highest potential for malfunction.When a malfunction does occur, the outage is usuallyfound in the electrical secondary circuit in theionizing-collecting cell(s).

Indicating lights are installed in the face panel of thecontrol to monitor the electrical operation of eachpower supply and the ionizing-collecting cell(s) theyenergize. The quantity of power supplies per unit isdependent upon unit size with one supply to eachionizing-collecting cell tier in height. Other than thebasic hand tools, it is advantageous to have a volt-meter with a 20 KVDC high voltage probe. Theseinstruments are standard catalog items by severalmanufactures.

B. Secondary Short CircuitThe most common outage is a short in the secondarycircuit and is best located through the process ofelimination. Symptoms are a flickering indicating lightaccompanied by an arcing noise in theionizing-collecting cell(s) or an indicating light that isnot glowing.

A flickering light with an arcing noise is an indication ofa high resistance short circuit and a light that is notglowing is an indication of a dead short. (A light that isnot glowing can also be an indication of an open circuitin the primary circuit. Refer to the paragraph on opencircuits.) The short may be in the power supply, thehigh voltage cables or the ionizing-collecting cell(s). Toisolate the short to any one of these threecomponents, proceed as follows:

WARNING

When safety interlock switches are closed, do notcome in contact with high voltage components. Theoperating output from the high voltage powersupply(s) is 12,500 VDC and 6 MA.

When the power supply(s) is de-energized there is a 20 second delay for the voltage to decay. Alwaysshort from ground to a point of high voltage with a Well-insulated jumper wire or an insulated handledscrewdriver to bleed-off any remaining residualcharge.

1. Disconnect both high voltage leads from theirrespective terminals in the power supply and supportthem away from any point of contact.

2. Energize the power supply:

a. If the light still flickers or does not glow; the troubleis indicated to be in the power supply. First, Replacethe power supply in its entirety.

b. If the light glows steady with the leads disconnectedthe power supply is indicated to be normal.

3. Next reconnect both high voltage leads to theirrespective terminals inside the power supply anddisconnect them at the ionizing-collecting cell(s).Support them away from any point of contact andenergize the power supply.

NOTE: It will be necessary to close the access doorelectrical interlock switch operated by the access doorand affix the junction box lid with hardware supplied toclose the electrical interlock switch on the box, tocomplete the primary circuit to the power supply.

a. If either high voltage lead is defective, the light willindicate the trouble. Each lead may then be checkedseparately by disconnecting them, one at a time, fromtheir respective terminals at the power supply. When alead is found to be defective, replace it in its entirety. Donot repair or splice.

b. If the light glows steady with the leads disconnected atthe ionizing-collecting cell(s) the trouble is then indicatedto be in the ionizing-collecting cell(s).

The trouble can then be isolated to a single cell orionizing or collector section of a given cell as follows:

12

(1) First determine if the short is in the ionizing sectionor the collecting section by connecting each highvoltage lead to its respective section, one at a time,and energizing the power pack. (The lead not con-nected must be supported away from any point ofcontact.) The short symptoms will still exist for thesection in which the short is located. If the troublecausing the short is bridging both sections, then theshort will be indicated in both sections when theyare individually connected.

(2) When the short is isolated to a cell tier, remove allthe cells within the tier and visually check the sec-tions indicated to contain the short.(a). If the short is in the ionizer section look for abroken or defective insulator.(b). If the short is in the collector section look for alarge piece of foreign material bridging thecollector plates or a defective insulator.(c). If the short is indicated to be in both sections, itwill probably be a foreign object bridging the air gapbetween the ionizer and the collector.

c. Open Circuits

Although open circuits can occur in the secondary theyusually take place in the primary. If the unit containsonly one power supply and the indicating light does notglow the outage is probably one of the following. (1)Supply line power to the control disconnected.Reconnect.(2) Open access door interlock in control of electronicair cleaner. Be sure all access doors are properly closedand secured.(3) Outage in the power supply. Look for charred orburned components or a loose wiring connection.Replace power supply or reconnect wiring.(4) Defective indicating light. Replace light.

d. Malfunctions other than short or open circuits. Referto trouble reference chart in this section.

8. Spare PartsRecommended spare part quantities are usually basedon the unit size and the amount of units per installation.For specific recommendations, consult the Trion factoryor nearest Sales Office. Consideration, however, shouldbe given to stocking the following components;

DESCRIPTION QTY.Complete Power Supply 1Power Supply Indicating Light 1Ionizing-Collect Cell Insulator 6Trion Detergent 55 gal.

Part Numbers are not listed as they are subject tochange. Always state Unit Model and Serial Numberswhen ordering parts.

13

Troubleshooting Reference Chart

PROBLEM/SYMPTOM

PROBABLECAUSE

LOCATION REASON - CORRECTION

Ionizing Section of Cell 1. Dirty insulator(s) – Clean2. Defective insulator(s) – Replace3. Foreign Object Between Ionizing Bar

and Ground electrode - Remove

Collecting Section of Cell 1. Dirty insulator(s) - Clean2. Defective insulator(s) – Replace3. Foreign Material Bridging Plates -

Remove4. Bent Plates – Straighten or Replace

High Voltage Leads 1. Disconnected High Voltage LeadContacting Ground - Reconnect

2. Defective Lead/Insulation Breakdown– Replace Entire Lead

Indicating Light NotGlowing

Short Circuit

Power Supply Charred/Over Heated Components –Replace Power Supply

Control 1. Disconnected Supply Line Power –Reconnect

2. Faulty indicting Light - Replace

Power Supply 1. Disconnected Wire – Resolder2. Charred/Over Heated Components –

Replace Power Supply

Indicating Light NotGlowing

Open Circuit

Electronic Air Cleaner Housing 1. Electrical Interlock Switch Not Closed– Close Access Door

2. Junction Box interlock switch notclosed – Secure Cover

3. Faulty Electrical Interlock Switch -Replace

Indicating LightFlickering

High Resistance Short High Voltage Circuit

1. Ionizer High Voltage Lead Connectedto Plate Section and Plate Lead toIonizer – Reconnect Leads

2. Loose or Disconnect high VoltageLead-Tighten or Reconnect

3. Loose or Defective IntercellConnection (on Multicell Units) –Tighten or Replace

4. Foreign Object Adrift in Ionizer orPlate Section of Cell – Remove

5. Clean cells and replace in unit.

Loss In CapturingVelocity

Restriction In AirFlow

Modular Sections 1. Metal Mesh Filters Dirty – Clean2. Bag Filter Saturated - Replace

Loss in CollectingEfficiency

DisconnectedComponents

Electronic Air Cleaner 1. Disconnected high Voltage Lead -Reconnect

2. Cell(s) in Multicell Unit Not Connected– Repair or Replace Intercell HighVoltage Connectors

Loss in Odor Control Decrease InAdsorption Ability

Adsorber Module 1. Saturated Activated Carbon –Replace with New or RefurbishedPanels