Trion Air Boss KES Info for Maintenance Engineer

OPERATION & SERVICE - FOR THE MAINTENANCE ENGINEER
also see Troubleshooting for KES 2 & KES 4

1. Introduction and Principle of Operation
The electronic air cleaner is 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. Theses charged particles are then attracted and adhere to a series of parallel collecting plates, which form the negative elements of an electrostatic field.

The ionizer consists of charged Tungsten wire spaced between grounded electrodes. The collecting section consists of parallel plates arranged so that each alternate plate is charged while the intermediate plates are electrically grounded.

Periodically, depending on the type and concentration of contamination in the air, contaminate is washed from the plates by manually removing the cells and cleaning them (item 4, a & b routine maintenance).

Two major functional components comprise the air cleaner:

(1) Ionizer and collecting cells to ionize and collect airborne particulate matter
(2) Power supply-s to supply high voltage direct current to the ionizing-collecting cells.

Normally, systems are designed for collection efficiencies in the range of 90% or more. Collecting a contaminate at these efficiencies, especially when there are high concentrations, can result in large accumulations in a relatively short period. Therefore, maintenance must encompass two areas: the operation of the equipment for efficient collection, and the systematic removal of the collected contaminate.

2. General Description
The ionizer-s & collecting cells (contaminate collecting elements) are housed in the cabinet on slide rails. They can be removed from the cabinet as required, through the access door, by sliding them out like drawers.
Ionizer to ionizer and collector cell to collector cell electrical connections are automatically made through spring plunger connectors. Power supply-s on the ionizer/ collector cell access door make contact with ionizer and collector cell spring plungers through an insulated high voltage contact

IMPORTANT NOTE: Ionizer and collector cells are designed with a keyed slot permitting one directional installation into the cabinet. When properly installed, the brass contact plungers on the ionizer and cell should be pointed toward the access door.

Installation of the perforated plate pre-filter and either a perforated plate after-filter or metal mesh after-filter is required for all installation of the pre/afterfilters, ionizer and collector cells, the filter clip should be installed.

The power supply-s convert the 120/220 volt, 50/60HZ, single phase AC supply to the high voltage DC needed to power the ionizing-collecting cells. Potential of 12.5 – 13.0 kVDC are required for the ionizer sections and 6.0 – 6.5 kVDC for the collector sections of the cells.

3. Initial Start-up
A. Inspect the inside of the adjoining ductwork and KES cabinet to be sure it is clean and free of any debris or construction materials. Ensure the openings in the drain basin are free of any restrictions. The ducting, where secured to the cabinet collars should be sealed liquid tight in accordance with NFPA.

B. Inspect the ionizer and collecting cells to see that all of the ionizing wires are intact, no large pieces of foreign material are lodged between the plates, high voltage insulators are not cracked, and the ionizer and collecting cells are properly installed in the cabinet.

C. Check the primary wiring to see that it is connected to the proper terminal in both the KES junction box and the remote mounted control box. (fig 3 and fig 6).

D. Be sure the drain lines from the KES cabinet drain coupling are completely connected and properly terminated. A trap or seal should be incorporated in the line to prevent air bypass.

E. Be sure that electrical power is available, the wiring is completed, and the system blower is ready to energize.

F. Be sure the flex cable connector (main power disconnect/ safety interlock) is aligned, pushed down and screwed securely into the mating flange mount connector on the access door. To help with alignment, marks have been placed on the flex cable connector body and the flange mount connector.

G. Close the system electrical supply switches, making power available to the remote mounted control box and the system fan.

H. Turn the control box selector switch to the “on” position. The exhaust fan should run (if installed) and the power supply-s should be energized. Electrical arcing within the collecting cells may occur. It is a normal occurrence caused by accumulation of dusts from construction or other sources in the cell-s and should subside quickly. If the arcing is continuous and does not subside, recheck the cell for trash, damaged plates or cracked insulators.

IMPORTANT NOTE:  Kitchen exhaust fan control and operation will vary with each installation. The optional Trion remote mounted control box contains a 120/ 220 VAC relay for connection to the exhaust fan starter coil. When the control box selector switch is placed in the on position, the relay will energize the fan starter coil.

For safe and proper Kitchen Exhaust operations, 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 manufacturer instructions.

5. Cooking equipment shall not be operated while its fire-extinguishing system or exhaust system is not operating or otherwise impaired.

4. Routine Maintenance
A. Washing Frequency
The frequency the collected dirty must be manually 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. Trion recommends starting with a manual washing frequency of at least once a week. This schedule may then be altered as needed after visual examinations of the collected material contained on the ionizing collecting cells. Daily manual washing is not unusual for units operating on heavy kitchen exhaust hoods or similar contaminants.

Manual washing to clean the perforated plate prefilter, ionizer-s, collecting cells, and metal mesh or perforated plate after-filters can be performed in a soak tank, commercial carwash, or with a pressure hose or pressure cleaner using a low pressure setting. Particular care should be taken in cleaning each of the insulators.

When a cleaning service is used, a certificate showing dates of inspection and/ or cleaning shall be maintained on the premises.

B. Detergent
Effective washing is dependent upon the detergent. The detergent as supplied by Trion, Inc. is formulated specifically for electronic air cleaners. If substitutes are used, Trion must approve them in order not to void the warranty. Please contact Trion for this approval. Alternate detergents should be safe for use in ventilation systems and non-caustic, as 95% of the ionizer and collecting cells are constructed of aluminum and special high voltage insulation and gasket seals.

C. Media filter and odor adsorption module replacement (IF INSTALLED) – Every 3 to 6 Months
Units equipped with this option may experience different loading conditions and scheduled replacement may then be altered as needed after visual examination.

D.  Electrical Operation
The KES and optional remote mounted control box both have LED indicating lights to show power to the PWM power supply-s and output voltage present ( 12.5 – 13.0 kVDC ionizer and 6.0-6.5 kVDC collector). Flickering or failed LEDs indicate electrical arcing, electrical short and/or power failure.

5. Periodic Maintenance
A. Fire Suppression System (IF INSTALLED) – Every 6 Months
Properly trained and qualified personnel shall complete inspection, cleaning and servicing of the fire suppression system.

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 instructions in this manual. In addition to these requirements, the specific inspection 5requirements of the applicable NFPA standard shall also be followed. If required, certificates of inspection and maintenance shall be forwarded to the authority having jurisdiction.

B. KES power supply enclosure – Every 12 Months
The KES power supply enclosure located on the ionizer/ collector cell access door should be examined for accumulated dirt and dust. If required, the components should be cleaned using a good electrical contact cleaner. All terminal connections should be checked for securement and tightened or reworked as required.

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

6. Troubleshooting

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

IMPORTANT NOTE: All repairs to the fire suppression system (if supplied) must be completed by the authorized fire control contractor.

The electronic air cleaner is the unit within the system that has the highest efficiency collection rating. When a malfunction occurs, the outage is usually found in the electrical secondary circuit in the ionizing/ collecting cell(s).

Indicating lights (LEDs) are installed in the face of the power supply enclosure on the KES ionizer/ collector cell access door and provided with the Trion optional remote mounted control box. These lights monitor the electrical operation of each power supply and the ionizer-s and collecting cell-s they energize. The KES-2 requires (1) power supply to energize (1) ionizer and (2) collector cells. The 4000CFM KES-4 requires (2) power supplies to energize (2) ionizers and (4) collector cells.

Other than the basic hand tools, it is advantageous to have a volt meter with a 20 KVDC high voltage probe.

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 ionizer-s and collecting cell-s, 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, insulated high voltage contact on the access door, ionizer-s or collecting cell-s. to isolate the short to any one of these three components, proceed as follows:

IMPORTANT NOTE:  To perform this troubleshooting step, it will be necessary to close the ionizer/ collector cell access door and re-connect the flex cable connector to the flange-mounted connector on the access door. This will re-energize the power supply-s. The panel on the ionizer/ collector cell access door enclosure will also need to be removed.

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:

   1. If the light still flickers or does not glow the trouble is indicated to be in the power supply. Replace the power supply in its entirety.

   2. If the light glows steady with the leads disconnected, the power supply is indicted to be normal.

3. Next reconnect both high voltage leads to their respective terminals inside the power supply and disconnect them at the insulated door contacts for the ionizer-s and collecting cell-s. Support them away from any point of contact and energize the power supply.

   1. If either high voltage lead is defective the light will indicate the trouble. Each 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 the splice

   2. If the light glows steady with the leads disconnected from the insulated door contact for the ionizer-s and collecting cell-s, the trouble is then indicated to be in the ionizer and 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:

4. 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

5. 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.

   1. If the short is in the ionizer section look for a broken or defective insulator or a broken ionizer wire

   2. 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. 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 power supply-s disconnected. Reconnect.

2. Main disconnect/ access door interlock on KES unscrewed. Close access door and insert flex cable connector from junction box into flange mounted connector on access door. Screw connectors together

3. Blown in-line fuse located on the power supply circuit board. Replace power supply.

4. Outage in the power supply. Look for charred or burned components or a loose wiring connection. Replace power supply or reconnect wiring.

5. Defective indicating light. Replace the light.

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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