Trion Air Boss ATS Info for Maintenance Engineer

OPERATION & SERVICE - FOR THE MAINTENANCE ENGINEER
also see Troubleshooting for ATS

1.Description and Principles of Operation
The basic ATS units are made up of five modular sections. Each of the first three sections employs different mechanisms to remove and capture particulate matter from the air.
The first section, an impinger, is primarily designed for, and is especially effective in, capturing relatively large greasy liquid particulate. The impinger is constructed of two equally spaced layers of roll formed baffles. The spacing creates an air flow pattern which causes the contaminate to collect and flow down the baffles. Holes in the frame permit the liquid to drip into the drain basin below. Periodically, at a predetermined setting, a remotely located control automatically activates oscillating wash manifolds located on both sides of the impinger to flush away any remaining tenacious matter. (Refer to the electronic air cleaner section below for addition description on the integral washer. It is identical to the impinger washer.)

The second section houses an electronic air cleaner, technically known as an electrostatic precipitator. In this type of equipment, all airborne particles, even of microscopic size, are electrically charged (positively) as they pass through a high voltage ionizer. These charged particles are then attracted and adhere to a series of parallel collecting plates, which form the negative elements of an electrostatic field.

The ionizing-collecting cells (contaminate collecting elements) are housed in the cabinet on slide rails. They can be removed from the cabinet as required, through the end access door, by sliding them out like drawers. On multicell units, all of the electrical connections between cells in a given tier are automatically made through spring connectors. On the access end, the high voltage from the power packs is made with cables. When installing cells into the cabinet, observe the directional arrows on the cell end plates. The side of the cell containing the spiked ionizer blades always must be locked on the air entering side.

The power supplies convert the 115 volt 60 Hz single phase AC supply to the high voltage DC needed to power the cells. The power supplies are solid state, pulse width modulated (PWM), line and load regulated. Potential output voltages of 12.5 KVDC are required for the ionizer and 6.25 KVDC for the collector at a maximum current of 6 MA. Each supply is retained in the control in slide channels and secured with one bolt located in the top corner of the circuit board.
At a predetermined frequency the remotely located control automatically activates an integral wash system to flush away the collected contaminant. When activated, the duration of the washing cycle is approximately 80 minutes.

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

a. Power packs 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 packs “on”

When a fire control system is specified, both the impinger and electronic air cleaner sections contain chemical spray nozzles.

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

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

When the bags become saturated with contaminant, they must be removed and replaced. However, this requirement is relatively infrequent due to the pre-filtration upstream from the bag.
A series of long deep pockets arranged side by side form the configuration of each bag. The ultra fine fibers used in the makeup of the filtering media offer to trap the contaminant.
The fourth section is employed in the ATS unit for odor control. Panels filled with activated carbon granules are arranged in a vee bank configuration to provide adequate surface area. The surface of each granule is extremely porous and absorbs materials that are in a gaseous or vaporized state that cannot be removed by the particulate filters. Using the carbon filters without the pre-filtration by the bag filters is not recommended. When the panels have become saturated or fully loaded they may be replaced with new or reactivated carbon.
The fifth section, the blower/motor section, has been rated to handle the air movement requirements for the systems and the adjoining ducting.

When the fire suppression system has been specified to be factory furnished it consists of strategically located chemical spray nozzles located in the impinger and electronic air cleaner modules. The fire suppression chemical is stored in a cylinder housed in a weatherproof enclosure mounted on one side of the blower module. An electrical detection device, mounted down stream from the impinger module in the electronic air cleaner module, activates the system by sending a signal to a control head discharging the chemical cylinder.
In addition to the electrical detection device, a remotely located pull station is provided for mechanical activation of the system manually.

Depending on the installation and any local, or other governing requirements, the ATS unit fire suppression system may be tied in with other fire suppression devices. When the fire suppression system is activated the unit electrical input power is disconnected to the ATS unit blower and the high voltage required for the electric air cleaner is disconnected. After the fire suppression system has been activated, the authorized fire suppression contractor must put it back into service. For a system supplied with the ATS unit see fig 7.
 

2. Initial Start-Up
Prior to equipment start up, the fire extinguishing system employed in the ATS unit (and possibly adjoining equipment) must be inspected by properly trained and qualified personnel. This includes all actuation components including remote manual pull stations, mechanical or electrical devices, detectors, fire-actuated dampers, etc. These items shall be checked for proper operation during the inspection in accordance with the manufactures listed procedures. In addition to these requirements, the specific inspection requirements of the applicable NFPA standard shall also be followed. If required, certificates of inspection shall be forwarded to the authority having jurisdiction. For a fire suppression system supplied with the ATS unit see fig 7.

A. Inspect the inside of the adjoining ductwork and Trion cabinet to be sure it is clean and free of any debris or construction materials. Especially note the opening in the drain basin for any restrictions. The ducting, where secured to the cabinet collars, should be sealed watertight with either gasketing or caulking.

B. Inspect the ionizing collecting cells to see that all of the ionizing blades are intact and that no large pieces of foreign material are lodged between the plates. Also, verify that the cells are properly installed in the cabinet with the spiked ionizing blades located on the air entering side (follow the air flow directional arrows)

C. Check the high voltage leads to see that they are connected to the proper terminals, both at the ionizing-collecting cells and inside the power pack. See fig 6

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

E. Check the water supply line to be sure water is available and that the strainer, back flow preventer (by others) and detergent system are properly installed and connected. Refer to piping diagram fig 5.

F. Be sure that electrical power is available, that the wiring is completed, and that the system blower is ready to energize. Refer to field wiring diagram fig 6.

G. Be sure that all access doors are closed.

H. Close the system electrical supply switches, making power available to the control and blower motor starter. Check to verify blower rotation is as shown on the rotation indicator arrow.

I. Turn the “on-off” selector switch to the control “on”. The blower should run (if installed) and the power supplies should be energized. Electrical arc-over within the ionizing-collecting cells may occur. It is a normal occurrence caused by accumulation dust from the constructions or other sources in the cells and should soon subside. If the arc-over is continuous and does not subside, recheck the routing of the high voltage leads between the power supplies and the cells. Refer to field wiring diagram fig 6. the ionizer lead must be connected to the ionizer and the connector lead to the collector. If arc-over still occurs, or difficulty other than that outlined above, refer to the trouble shooting reference chart.

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

K. (Review this paragraph in its entirety before initiating the wash start button.)
Next, set the detergent volume setting per wash at the detergent feeder. Manually initiate the wash cycle by pushing the wash start button on the control. The wash control duration is 80 minutes and by means of a factory preset programmable logic controller (PLC) will sequence the washing events as previously outlined. When the detergent pump is energized, note the amount that is used by observing the reduction in the liquid level in the tank. The usage should be approximately 1 part of detergent and 20 parts of water. The water and detergent requirements for each unit model are listed in Table 1 on the piping schematic, fig 5. To adjust the volume output from the pump, refer to the detergent system outline, fig 4. The pump is a constant displacement type and the amount of detergent forced into the water supply to wash the unit is dependent upon the setting of the control valve in the bypass return line to the reservoir. The side of the translucent reservoir is marked with volume markers. Adjust the control valve to obtain the correct usage for the given unit model, then secure the setting with the Allen head set screw located in the valve adjustment knob. When the correct adjustment has been made, remove the remaining water from the reservoir and fill the tank with initial supply of detergent furnished.

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

Suppose the application of the equipment is to clean restaurant kitchen exhaust air. The collected contaminant to be washed away is of greasy nature, containing particulates such as smoke and fume from the grill, mist and vapors from the French fryer, flour dust and other various matter that is created by normal kitchen operation.

In our example, the restaurant operates Monday through Saturday (closed Sunday) and opens daily at 6:00 am and closes daily at 11:30 pm. This busy schedule presents a relatively heavy dirt loading and being of greasy nature should be washed away daily. The best time being shortly after closing when the atmosphere has settled but before the greasy contaminant collected has had a chance to harden and set.

From the above, a wash schedule of everyday except Sunday at 1:00 am can be established. As the duration of events preset at the factory is approximately 80 minutes, the cycle will end at approximately 2:20 am.

Prior to setting the initiator clock it will be necessary to charge the battery located inside the clock. This is accomplished by turning the selector switch on the front of the control to the “on” position. A light inside the switch will glow. If it does not glow, check to be sure there is supply line power to the control. DO NOT PUSH THE WASH BUTTON. Allow the control to 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 the existing time, then the program times that are to be initiated.

To set existing time:
1. Depress the rest (R) button to cancel out any previous 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 of the week is indicated.
4. Push the hour (h) button to the present hour of the day.
5. Push the minute (m) button to the minutes past the hour of the day.
6. Slide the P-Run switch to the run position. The colon will blink indicating the clock has been set.
To set the programs (wash times) according to the times 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 will appear on the display. This indicates the time the first program is to be turned “on”.
3. Push the day (1…7) button until only the day Monday (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 1:00 o’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 1 minute after the “on” time. A 1-minute duration is adequate program time, as the initiation signal is sent to the wash control logic instantaneously.
7. Push the day (1…7) button until only the day Monday (MO) appears on the display.
8. Push the hour (h) button until the hour 01:00 appears on the display.
9. Push the minute (m) button until the time 01:01 appears 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 the Tuesday (TU) washing. Push the program I/O (P) button. The word “on” and the number 2 will appear on the display.
11. Repeat the setting process for TU as outlined above in steps 3 thru 9 for MO “on”-“off” time.
12. After the wash program has been set for TU, repeat the same setting procedure for WE, TH, FR and SA. Omit SU.
13. Slide the P-Run switch to the run position. The existing time of day will show on the display. The six selected washdays established in the example have been set.

Note: using the above procedures, different washing day s and “on-off” times may be established and set into the initiator clock to best serve a specific application.

Notice: once the reset key (R) is pressed, the previous time and program will be cleared to the initial state.

M. Kitchen Exhaust Applications

For safe and proper operation, adhere to the following instructions and procedures:
1. Exhaust systems shall be operated during all periods of cooking in restaurant applications.
2. Filter-equipped exhaust systems shall not be operated with filters removed.
3. The posted instructions for manually operating the fire extinguishing system shall be kept conspicuously posted in the kitchen and reviewed periodically with employees by the management.
4. Listed exhaust hoods shall be operated in accordance with the terms of their listings and the manufacture instructions.
5. Cooking equipment shall not be operated while its fire extinguishing system or exhaust system is not operating or otherwise impaired.
 

3. Wash Control and Detergent System Settings
Total time required for the complete wash cycle is approximately 80 minutes. Four main events take place during the wash cycle : wash, soak, rinse and dry. Once the wash control has been initiated, either by manually pushing the washer start button, or through the means of the automatic time clock, the wash events will take place automatically. The time for each event has been preset at the factory in the programmable logic control (PLC).

Some dirt is more tenacious than others to remove and may require a stronger detergent solution. Average settings have been factory set. Best possible settings for any given installation, however, are determined though experience. Determination can be made by visually examining the collecting elements after the first few washings.

To adjust the volume of detergent used within the given time setting, loosen the knurled knob with an Allen wrench on the control valve located in the by-pass line. Refer to the detergent system outline fig 4. Turning knob clockwise increases the volume and counter clockwise decreases the volume. When adjustment has been made, be sure to retighten the setscrew.
 

4. Routine Maintenance
A. Washing Frequency
The frequency that the collected dirt is to be washed from the unit depends upon the type and amount of dirt in the air to be cleaned. Dirt, which is greasy in nature, tends to harden after collection and should be washed away often. Likewise, units operating under extremely heavy dirt loads should be washed more often as a large build-up of collected material will have a tendency to “blow-off” if permitted to remain on the collecting elements for long periods of time. In that the type and amount of dirt varies geographically (and from one location to another in any given area) it is recommended to start operation with a washing frequency of at least once a week, for most applications except kitchen exhaust. Kitchen exhaust applications should be washed daily. Schedules may then be altered as needed after visual examinations of the collected material contained on the ionizing collecting cells. Also, daily washing is not unusual for units operating on heavy welding fume, kitchen exhaust hoods or similar applications.

B. Detergent
Effective washing is dependent upon detergent. The detergent reservoir should be examined on a routine basis; a minimum tank level established and never permitted to empty. An empty tank not only means poor washing, but can also be detrimental to the pump. The inside of the tank should be kept clean, free from dirt and foreign objects. The detergent as supplied by Trion, Inc. is formulated specifically for electronic air cleaners and SHOULD NOT be diluted when charging the tank. If substitutes are used, they must be approved by Trion, so as not to void the warranty and should be safe for use in ventilation systems and non –caustic, as 95% of the ionizing collecting cells are constructed of aluminum and special high voltage insulation and gasket seals.
The front panel of the control contains indicating lights for the power supplies, one or two depending on the size of the ATS unit. The lights should be observed on a daily basis to ensure that the electronic air cleaners are operating.
 

5. Preventative Maintenance
A. Washing Frequency - As Required
The washing schedule and detergent reservoir level as outlined under routine maintenance is again referenced here as excessively large contaminant buildup on the collecting elements invites down time. Established routine washing is a preventative maintenance requirement. The frequencies suggested below should be altered if necessary.

B. Fire control system – every 4 to 6 months or as required.
Inspection, cleaning and servicing of the fire extinguishing system and all listed exhaust hoods shall be completed by properly trained and qualified personnel. For a fire control system supplied with the ATS unit see fig 7.
All actuation components, including remote manual pull stations, mechanical or electrical devices, detectors, fire-actuated dampers, etc., shall be checked for proper operation in accordance with the manufacturers listed procedures. In addition to these requirements, the specific inspection requirements of the applicable NFPA standards shall also be followed. If required, certificates of inspection and maintenance shall be forwarded to the authority having jurisdiction.

C. Grease removal devices and components – every 4 to 6 months.
Hoods, impingers, metal mesh filters, ionizing-collecting cells fan, ducts and other appurtenances shall be cleaned to bare metal at frequent intervals prior to surfaces becoming heavily contaminated with grease or oily sludge. It may be advantageous to clean readily removable items, such as impingers, metal mesh filters, ionizing collecting cells or other grease removal devices in a soak tank, with a pressure hose or pressure cleaner. After cleaning to the bare meta, components shall not be coated with powder, oils or other substance.

When a cleaning service is used, a certificate showing date of inspection and/ or cleaning should be maintained on the premises. Areas not cleaned will be noted.

Flammable solvents or other flammable cleaning aids shall not be used.

At start of cleaning process, electrical switches that could be accidentally activated shall be locked out. Components of the fire suppression system shall not be rendered inoperable during the cleaning process.

Care shall be taken not to apply cleaning chemicals on fusible links or other detection devices of the automatic extinguishing system.

When cleaning procedures are completed, all electrical switches and system components shall be returned to an operable state. All access panels and/or doors and cover plates shall be replaced. Dampers and diffusers shall be positioned for proper air flow.

D. Water wash system – every 4 to 6 months
The water wash spray pattern should be checked on each nozzle to ensure that a full spray pattern is developed. Distorted patterns are usually caused by dirt in the nozzle orifice, which can be cleaned by inserting a small gauge, soft copper wire into the orifice. If any one manifold contains several nozzles that are restricted, the drain plug at the idler end of the manifold should be removed, after the nozzles have been cleaned, and the manifold flushed with clean water. The main supply line strainer and the strainer in the detergent system should be checked and cleaned. Check the wash manifold drive belt and linkage connections and replace or tighten as required.
 

E. Power supplies and control – every 12 months
Examine the electrical components located inside the control housing for any accumulated dirt or dust. If necessary, clean with a good brand of electrical contact cleaner.

F. Blower bearings – every 4 to 6 months
Grease the two blower bearings at the grease fitting provided with Shell Alvania #2, Texaco Multifac #2 or Mobilux #2. At this time, examine the blower for any accumulated dirt and clean as required.

G. Motors – every 24 months
As the operation of detergent pump motor is limited, frequent oiling is not required. Lubricate with several drops of SAE 10 motor oil every two years. DO NOT OVER OIL. The manifold drive, detergent pump and blower motors have sealed bearings, are factory lubricated for life and require no oiling.
 

6. Troubleshooting

A. Introduction
This section on trouble shooting provides a description of potential malfunctions, their cause, location and correction. A trouble reference chart listing the most probable causes and corrections follows the general text.

NOTE: All repair to the fire suppression system (if supplied) must be completed by the authorized fire control contractor. For a system supplied with ATS unit, refer to fig 7.
The electronic air cleaner is the unit within the system that has the highest efficiency collection rating and is also the one with the highest potential for malfunction. When a malfunction does occur, the outage is usually found in the electrical secondary circuit in the ionizing collecting cells.

Indicating lights are installed in the face panel of the control to monitor the electrical operation of each power supply and the ionizing collecting cells they energize. The quantity of power supplies per unit is dependent upon unit size with one supply to each ionizing collecting cell tier in height. Other than the basic hand tools, it is advantageous to have a volt meter with a 20 KVDC high voltage probe. These instruments are standard catalog items by several manufactures.
 

B. Secondary Short Circuit
The most common outage is a short in the secondary circuit and is best located through the process of elimination. Symptoms are a flickering indicating light accompanied by an arcing noise in the ionizing collecting cells or an indicating light that is not glowing.
A flickering light with an arcing noise is an indication of a high resistance short circuit and a light that is not glowing is an indication of a dead short. (A light that is not glowing can also be an indication of an open circuit in the primary circuit. Refer to the paragraph on open circuits.) The short may be in the power supply, the high voltage cables or the ionizing collecting cells. To isolate the short to any one of these three components, proceed as follows.
 

1. Disconnect both high voltage leads from their respective terminals in the power supply and support them away from any point of contact


2. Energize the power supply:
a. If the light still flickers or does not glow; the trouble is indicated to be in the power supply. First, replace the power supply on its entirety.
b. If the light glows steady with the leads disconnected the power supply is indicated to be normal.

3. Next reconnect both high voltage leads to their respective terminals inside the power supply and disconnect them at the ionizing collecting cells. Support them away from any point of contact and energize the power supply.
Note: It will be necessary to close the access door electrical interlock switch operated by the access door and affix the junction box lid with hardware supplied to close the electrical interlock switch on the box, to complete the primary circuit to the power supply.
    a. If either high voltage lead is defective, the light will indicate the trouble. Each lead may then be checked separately by disconnecting them one at a time from their respective terminals at the power supply. When a lead is found to be defective, replace it in its entirety. Do not repair or splice.

    b. If the light glows steady with the leads disconnected at the ionizing collecting cells, the trouble is then indicated to be in the ionizing collecting cell. The trouble can then be isolated to the ionizer section or collector cell section and then to an individual ionizer or collector cell as follows:
         1. First determine if the short is in the ionizer section or the collecting section by connecting each high voltage lead to its respective section, one at a time, and energizing the power pack. (the lead not connected must be supported away from any point of contact). The short symptoms will still exist for the section in which the short is located. If the trouble causing the short is bridging both sections, then the short will be indicated in both sections when they are individually connected.
         2. When the short is isolated to either the ionizer or collector cell section, remove all the ionizers or collectors cells in that section and visually check each for the following.
a) If the short is in the ionizer section look for a broken or defective insulator or a broken ionizer wire
b) If the short is in the collector section look for a large piece of foreign material bridging the collector plates or a defective insulator.
c) If the short is indicated to be in both sections, it will probably be a foreign object bridging the air gap between the ionizer and the collector.

c. Open Circuits
Although open circuits can occur in the secondary, they usually take place in the primary. If the unit contains only one power supply and the indicating light does not glow, 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 electronic air cleaner. Be sure all access doors are properly closed and secured.
3. Outage in the power supply. Look for charred or burned 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. Refer to trouble reference chart.

7. Spare Parts
Recommended spare part quantities are usually based on the unit size and the amount of units per installation. For specific recommendations, consult the Trion factory or nearest sales office. Consideration, however, should be given to stocking the following components:

Part numbers are not listed as they are subject to change. Always state the unit model and serial numbers when ordering parts.  

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