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Issue Date: 11-20-2013

Demand Control Ventilation System

MODEL “DCV-F” Series

Technical Manual For

Factory-installed Application

GAYLORD INDUSTRIES 10900 SW Avery Street – Tualatin, Oregon 97062 USA

Email: [email protected] Toll Free 800-547-9696 – Fax 503-692-6048

www.gaylordventilation.com

All rights reserved. No part of this book may be reproduced, stored in a retrieval

system, or transmitted in any form by an electronic, mechanical, photocopying,

recording means or otherwise without prior written permission of Gaylord

Industries.

©Copyright 2012, Gaylord Industries

The manufacturer reserves the right to modify the materials and

specifications resulting from a continuing program of product

improvement or the availability of new materials

______________________________________ Page iii

Table of Contents

Chapter 1 – Introduction

About the Manual ……………………………………………………………………………………………………………….. 1-1

List of Abbreviations and Acronyms …………………………………………………………………………………….. 1-1

DCV System Overview …………………………..…………………………………………………………………………….. 1-2

Features and Benefits ……………………………………….…………………………………………………………………. 1-2

Chapter 2 – System Components

Overview …………………………………………………………………………………………………………………………….. 2-1

DCV Command Center ………………………………………………………………………………………………………… 2-2

Resistance Temperature Detectors (RTDs)…………………………………………………………………………… 2-5

Variable Frequency Drive ……………………………..……………………………………………………………………… 2-6

Hub Box ………………………………………………………….……………………………………………………………………. 2-8

Chapter 3 – Designing the System

How the DCV System Works ………………………………………………………………………….…………………….. 3-1

Designing the System ………………………………………………………………………………….……………………….. 3-1

Determining the DCV Command Center Model Number ……………………………………………………… 3-7

DCV Command Center Model Number Sequence Chart …………………………….………………………… 3-7

Determining the Drive Back Board Model Number ………………………………………………………………. 3-9

Drive Back Board Model Number Sequence Chart ……………………………………………………………….. 3-9

DCV Command Center and Drive Back Boards Sample Name Plates …………………………………….. 3-11

Chapter 4 – Installation of the System

Installing the DCV Command Center ….………………………………………………………………………………… 4-1

Installing the Drive Back Board ………………………….…………………………………………………………………. 4-1

Installing Low Voltage Cables

Overview …………………………………………………………………………………………………………………………. 4-2

Installing Hub Box Control Cable ……………………………………………………………………………………… 4-2

Installing Remote Exhaust Fan Start/Stop Switch Cable……………………………………………………. 4-4

Installing Drive Back Board Control Cable ………………………………………………………………………… 4-4

Connecting High Voltage Wiring

DCV Command Center ……………………………………………………………………………………………………… 4-6

Drive Back Board ……………………………………………………………………………………………………………… 4-6

Chapter 5 – Programming the System

Quick Guide Programming Flow Charts…………………………………………………………………………………. 5-1

Overview ……………………………………………………………………………………………………………………………… 5-4

Step 1: Pre-programming Check-out ……………………………………………………………………………………. 5-4

Step 2: Calibrating the RTDs ………………………………………………………………………………………………... 5-5

Step 3: Programming the Exhaust and Makeup Air Fan Variable Frequency Drives (VFDs) ….. 5-9

Step 4: Programming the RTD Constants ……………………………………………………………………………… 5-16

Step 5: Programming the Custom Performance Settings ……………………………………………………… 5-19

Page iv________________________________________________________________________________

Table of Contents – Cont.

Chapter 6 – Additional Control Board & Programming Details

Overview ……………………………………………………………………………………………………………………………… 6-1

Control Board Details …………………………………………………………………………………………………………… 6-1

Programming Details ……………………………………………………………………………………………………………. 6-3

Chapter 7 – Parts

Miscellaneous Parts ……………………………………………………………………………………………………………… 7-1

DCV Command Center Parts …………………………………………………………………………………………………. 7-2

Chapter 8 – Wiring Diagrams

Three different diagrams beginning on page…………………………………………………………………………. 8-1

Appendix A

DCV Startup Workbook – Sample …..…………………………………………………………………………………….. A-1

Appendix B

Frequently Asked Questions …………………………………………………………………………………………………. B-1

Appendix C

Project Example …………………..……………………………………………………………………………………………….. C-1

Limited Warranty ……………………………………………………………………………………………. Inside Back Cover

Chapter 1: Introduction, Page 1-1

About this Manual

The purpose of this manual is to provide guidance for pre-installation assessment, installation,

programming, and commissioning information for the Gaylord Demand Control Ventilation System Model

DCV-F Series for factory-installed application. The manual also includes detailed information on

adjustments to the system and a complete list of replacement parts.

The manual is divided into chapters for easy reference to a particular subject. The pages in the chapters

are numbered with the Chapter number, then a dash, and then the Page number. So for example pages in

Chapter 2 are numbered 2-1, 2-2, 2-3 etc. Figures and Tables are numbered in a similar manner. For

example Figure 5-3-2 is on -3 and is the second figure. Please keep your manual in a convenient

location for so it can be accessed easily.

If you have any questions or concerns with the installation of the Gaylord Demand Control Ventilation

System, please contact Gaylord Industries.

Web: www.gaylordventilation.com

E-Mail: [email protected]

Main Phone: 503-691-2010

Toll Free: 800-547-9696

This manual and other Gaylord product manuals may be downloaded from the Gaylord website:

www.gaylordventilation.com or be obtained by calling Gaylord Industries.

List of Abbreviations and Acronyms

BMS Building Management System

CFM Cubic Feet per Minute (Air Volume)

DBB Drive Back Board

DCV Demand Control Ventilation

DCV-F Demand Control Ventilation – Factory installed RTDs

DCV-R Demand Control Ventilation – Retrofit application

EF Exhaust Fan

FP Fire Protection (System)

FPM Feet Per Minute (Air Speed- Velocity)

HVAC Heating Ventilating Air Conditioning (unit)

HZ Hertz

MUA Makeup Air (unit)

PID Proportional Integral Derivative Value

RTD Resistance Temperature Detector

TD Temperature Difference (Delta T)

TH Temperature High (The temperature at which the system calls for maximum fan speed)

TL Temperature Low (The temperature at which the system calls for minimum fan speed)

VAV Variable Air Volume box

VFD Variable Frequency Drive

WG Water Gauge

Chapter 1: Introduction, Page 1-2____________________________________________________________

DCV System Overview

The Exhaust Fans of traditional kitchen exhaust systems are sized to exhaust the effluent produced by the

cooking appliances running at full load with the fan running at a constant speed throughout the cooking

day. Air removed from the kitchen space must be replaced by the use of a dedicated Makeup Air system,

and this air must be heated and cooled as required to maintain a comfortable kitchen. The energy to

operate the Exhaust and Makeup Air Fans and also heat and cool the Makeup Air for 10 to 18 hours a day

at 100% capacity, wastes a tremendous amount of energy. Just a 20% reduction in airflow volume can

yield approximately 45-50% in annual fan energy savings and a 20% reduction on heating and cooling

costs.

The Gaylord DCV Demand Control Ventilation System is intended for installation in new Gaylord

Ventilators or any existing aftermarket Hood system. It has been designed to reduce overall ventilation

rates by tying the cooking appliance’s sensible heat output to the required airflow rates. It monitors the

sensible heat produced by the cooking appliances, using Resistance Temperature Detectors (RTDs)

mounted in the Hood, to automatically increase or decrease the Exhaust Fan and Makeup Air Fan speeds,

saving a substantial amount of money each year on energy costs. If for example all the cooking appliances

are not in use, or they are turned down, the RTDs sense the lower temperature and the system

automatically decreases the Exhaust Fan speed, and reduces the amount of Makeup Air proportionally to a

level required to maintain optimum capture performance. As the appliance temperatures go up and

cooking increases, the Exhaust Fan and Makeup Air fan increase to a point as required to maintain

optimum capture to remove the smoke, grease, and heat.

Features and Benefits

The Gaylord Demand Control Ventilation System, Model DCV-F Series, is engineered to operate the Hood

Exhaust Fan and Makeup Air Fan at various speeds, based on the cooking activity, and provide the

optimum in hood performance, in terms of smoke, grease, and heat removal, while providing the

maximum in energy savings. The following are just some of the features and benefits of the DCV System:

• Control up to 4 Exhaust Fans each with independent Demand Ventilation and up to 6 Hood

sections.

• Increases or decreases exhaust and makeup air fan speeds based on two or more strategically

placed RTDs in the Hood and one in the exhaust duct that respond to actual cooking activity. This

assures optimum smoke capture performance while providing maximum energy savings. Most

systems use just one detector in the exhaust duct which averages the temperatures under the

hood resulting in possible smoke loss and lower energy savings.

• DCV Command Center includes a 100% Fan button which allows the operator to increase the fan to

its maximum speed if needed.

• All controller components are housed in a stainless steel cabinet, called the DCV Command Center.

• The system may be programmed for Custom Performance to react to specific cooking situations,

maximizing energy savings.

• 24 volt control system reduces wiring and energy costs.

Chapter 2: System Components, Page 2-1

System Components

The Gaylord DCV-F System is made up of several primary components. Figure 2-1-1 illustrates a typical

installation with the primary components identified.

Figure 2-1-1

Typical Installation

Showing Major Components of Gaylord DCV-F System

The following, page 2-2, is a detailed explanation of each component.

4 5

1

3

2

1. Command Center.

2. Optional Wall Mounted Utility

Cabinet containing Drive Back Board.

3. Canopy Mounted RTDs.

4. Duct Mounted RTD.

5. Hub Box.

Chapter 2: System Components, Page 2-2_____________________________________________________

DCV Command Center

The DCV Command Center, Figure 2-2-1, is a stainless steel cabinet that houses the Start/Stop Fan button

(if specified), 100% Fan button, 12 volt output power supply unit, relays, control boards, room ambient

RTD(s), and wiring terminal blocks. The DCV Command Center is the heart of the system and interfaces

with RTDs on the Hood, the Variable Frequency Drives (VFDs) controlling the Exhaust and Makeup Air fans,

and the Building Management System (BMS), if equipped. The DCV Command Center is typically located in

the kitchen area in a convenient location, within 50 feet of the Hood, to operate the Start/Stop Fan and

100% Fan buttons. The DCV Command Center comes in three standard sizes based on the number of

Hood sections involved. Six Hood sections is the maximum number one DCV Command Center can

operate. Refer to Table T-2-2-1 below for cabinet sizes.

Height of Cabinet Cart

Number of

Hood Sections

Height

in Inches

1-2 25

3-4 36

5-6 40

Cabinet Depth is 7”

Figure 2-2-1

Standard DCV Command Center

Height

8”

Note: If the DCV Command Center is

recess-mounted, a 1-1/2” Stainless

steel trim ring (not illustrated) is

supplied.

Ex Fan Start / Stop

Button

100% Fan Button

Table T-2-2-1

Warning: 120 volt circuit. This

equipment can only be serviced by a

Gaylord Certified Service Agency.

Access and working on this

equipment may result in electrical

shock.

_____________________________________________________Chapter 2: System Components, Page 2-3

DCV Command Center – Cont.

A Combo Cabinet, as shown below, is available as an option. It houses the DCV Controls, the Drive Back

Board and the VFDs. The cabinet is constructed of stainless steel.

Important Note: The Combo Cabinet is open on the top to allow heat generated by the VFDs to dissipate

and therefore it cannot be recess mounted.

Height of Cabinet Cart

Number of

Hood Sections

Height

in Inches

1-4 36

5-6 40

Cabinet Depth is 9”

34”

”

Height

Figure 2-3-1

Combo Cabinet

DCV Control / Drive Back Board Table T-2-3-1

Warning: 208-460 volt circuit. This equipment

can only be serviced by a Gaylord Certified

Service Agency. Access and working on this

equipment may result in electrical shock.


DCV Command Center – Cont.

Figure 2-4-1

DCV Command Center

Interior Exploded View

Reset Button

Hi Voltage Box

12 Volt DC

power supply

board

RTD J-Box

RTD – Ambient

Temp.

100% Fan

Button

Control

Boards

Start / Stop Button

Pressure

Transducer

Fuse

VFD Fan

Relay


Resistance Temperature Detectors (RTD)

Resistance Temperature Detectors (RTDs) are a high quality and very accurate temperature sensor (Refer

to Figure 2-5-1 and 2-5-2). The Gaylord RTDs are Listed for mounting in Commercial Kitchen Exhaust

Hoods. One RTD is mounted in the DCV Command Center for each exhaust fan involved to measure the

ambient temperature in the kitchen and one or more RTDs are factory-installed in the canopy of the Hood.

The Temperature Detectors mounted on the Hood are wired with 12 Volt cable to the Hub Box mounted

on the top of the hood. The Hub Box is wired to the DCV Command Center with 12 volt cable provided by

Gaylord.

Variable Frequency Drive (VFD)

A Variable Frequency Drive (VFD) is a motor controller that can decrease or increase the speed of an

electric 3 phase motor based on an input into the VFD (Refer to Figure 2-6-1). The VFD replaces the

Magnetic Starter used to start the motors of exhaust and supply fans. The Gaylord DCV System sends the

VFDs an input to automatically increase or decrease the Exhaust and Makeup Air fans by a programmed

percentage. There is one VFD for each Exhaust Fan if each fan is independently controlled, or one VFD for

a group of fans if all the fans ramp up and down simultaneously. There is typically one VFD for each

Makeup Air unit. The VFDs are mounted on a Drive Back Board (Refer to Figure 2-7-1). As an option the

Drive Back Board can be mounted in a NEMA enclosure (Refer to Figure 2-7-2) or in a Stainless Steel Utility

Cabinet mounted on the end of a Hood. A Combo Cabinet containing the DCV Command Center and the

Drive Back Board is also available as an option (Refer to Figure 2-3-1).

Figure 2-5-1

Resistance Temperature Detector

(Front Side)

Figure 2-5-2

Resistance Temperature Detector

(Back Side)


Variable Frequency Drive (VFD) – Cont.

Drive Back Board

The Drive Back Board includes all the Variable Frequency Drives (VFDs), power supply for the 24 volt

controls, relays and a terminal strip all mounted on a common board as shown in the example on Page 2-7,

Figure 2-7-1. The Drive Back Board replaces the existing Magnetic Starter switches for the exhaust and

MAU fans, and is typically mounted near the Magnetic Starters to keep the wiring to a minimum.

The Drive Back Board typically comes as shown in Figure 2-7-1, and may be ordered mounted in a NEMA

enclosure, such as shown in Figure 2-7-2, in a Stainless steel Utility Cabinet that can be mounted to the

end of a Hood, or a Combo Cabinet that includes the DCV Command Center (Refer to Figure 2-3-1). The

size of the Drive Back Board is dictated by the number and size of VFDs needed, which also determines the

size of the NEMA and stainless steel enclosures. The standard sizes for the Drive Back Board and the

related NEMA Enclosures are shown in Table T-2-7-1 on Page 2-7. The required size is dependent upon the

number and size of the VFDs. The Stainless steel Utility Cabinet is customized to fit both the Hood and size

of the Drive Back Board. This size of the Combo Cabinet is shown on Figure 2-3-1.

Figure 2-6-1

Variable Frequency Drive (VFD)

Warning: 208-460 volt

circuit. This equipment

can only be serviced by

a Gaylord Certified

Service Agency. Access

and working on this

equipment may result

in electrical shock.


Drive Back Board – Cont.

Drive Back Board and NEMA Enclosure

Size Chart in Inches

Drive Back Board NEMA

Enclosure

Height Width Height Width

14-3/16 14-3/16 16 16

18-3/16 14-3/16 20 16

22-3/16 18-3/16 24 20

22-3/16 22-3/16 24 24

28-3/16 22-3/16 30 24

Table T- 2-7-1

Back Board

Variable Frequency

Drives (VFDs)

Relays

Terminal Strip

Power Supply

Figure 2-7-1

Typical Drive Back Board

Mounting Slots

Figure 2-7-2

Typical NEMA Enclosure

Gaylord Nameplate

Model and Serial #

Note: The size of the Drive Back

Board is dependent upon the

number and sizes of the VFDs

Warning: 208-460

volt circuit. This

equipment can

only be serviced by

a Gaylord Certified

Service Agency.

Access and

working on this

equipment may

result in electrical

shock.


Hub Box

The Hub Box is an electrical junction box mounted on the top of each Hood section that is the connection

point for the Hood’s 12 volt Control Cabling.

Figure 2-8-1

Hub Box

Chapter 3: Designing the System, Page 3-1

How the DCV System Works – The Basics

The DCV System is made up of three major components. They are the DCV Command Center, the

Resistance Temperature Detectors (RTDs), and the Variable Frequency Drives (VFDs). The DCV Command

Center is mounted in the kitchen area. The front of the cabinet includes a 100% Fan button and may also

include an optional Start/Stop Fan button. The Hood is fitted with up to four RTDs - one in the exhaust

duct collar and up to three in the canopy. There is one VFD for each Exhaust Fan and one for each Makeup

Air fan. The Hood RTDs and the VFDs are connected to the DCV Command Center with low-voltage cables.

The VFDs are programmed to operate between a minimum and maximum speed based on a Low Cooking

Load and a Full Cooking Load. The Control Board within the DCV Command Center is programmed to

correlate the temperature at each individual RTD to the heat generated by the cooking appliance(s) with a

Full Cooking Load. During a cooking day, as the temperature of the cooking appliances increases or

decreases, the RTDs change. That change is then interpreted at the Control Board. A signal is then sent to

the VFDs to modulate the Exhaust and Makeup Air fan speeds up or down. Typically the Exhaust and

Makeup Air fans will modulate up and down throughout the day based on the use of the cooking

appliances. If ever needed, the 100% Fan button can be pushed to ramp the fans up to maximum speed.

The fans will run on maximum speed for five minutes and then revert back to the signal from the DCV

Command Center. To reduce the risk of a hood spill, the system will respond to temperature changes of

five degrees or more, up or down, in any 40 second period by going to 100% for a five minute period.

The Control Board has many programming features including “Custom Performance” which allows

programming the system to very specific cooking situations resulting in additional energy savings.

Designing the System The DCV System design is based on several key site conditions such as the number of Hoods, the number

of Exhaust Fans, the number of Makeup Air Units, voltages of the fan motors, and many other factors as

described in this manual. If there are modifications to air balance or cooking equipment after DCV System

Startup is complete, contact Gaylord Industries regarding additional components and commissioning.

One piece of information needed to design the system is how the Makeup Air Unit(s) is controlled by the

DCV System. There are two methods of Makeup Air control and choosing the correct one is dependent

upon the number of Exhaust Fans, number of Makeup Air fans, and the desired air balance between the

kitchen and dining areas. First it is necessary to understand basic kitchen air balancing and therefore the

following is presented.

Basic Kitchen Air Balance

Kitchen air balance is a simple strategy. Air that is exhausted by the Hood must be replaced. How this is

done relies on a few basic measurements.

1. For every CFM removed by the exhaust Hood, an equal amount must be brought back into the

kitchen. This is accomplished by bringing the air into the kitchen in a combination of two or

sometimes three ways.

a) Dedicated kitchen Makeup Air system.

b) Transfer Air entering the kitchen through pass windows and doorways from the dining

space.

c) In some cases, usually in very large kitchens, there is also a dedicated HVAC system.

The total CFM of a), b), and c) if used, must equal the total Hood exhaust CFM.

Chapter 3: Designing the System, Page 3-2____________________________________________________

Designing the System – Cont.

2. The kitchen space must be slightly negative to the dinning, or adjacent spaces. This creates a slight

movement of air from the dining area, through pass windows and doorways, to the kitchen area.

This guarantees that smoke, grease and odor do not migrate into the dining area. Typically systems

are designed for the kitchen to have a 10% to 20% negative air volume. National Codes specify a

negative pressure of no more than -0.02” WG (Water Gauge).

3. The entire building, including the kitchen needs to be slightly positive to the outside. This prevents

hot or cold outside air, dust, and bugs from coming into the building when a door or window is

opened.

These pressure measurements can be taken easily with a Digital manometer and some tubing

stretched from one area to another. Gaylord recommends the use of the Dwyer 475 Mark III, shown in

Figure 3-2-1.

The most basic function of any kitchen Hood is to remove smoke and odor generated by the cooking

process. Having proper Hood airflow rates at any point from a Low Cooking Load to a Full Cooking Load,

and proper kitchen pressurization are the two critical items needed to accomplish the goal of keeping

smoke and odor contained and controlled. In a negative kitchen, the air that comes from the dining area

to the kitchen is called “Transfer Air”. If the kitchen is positive air moves from the kitchen to the dining

room, and any escaped smoke or odors from the hoods will be forced out to the customers in the dining

room.

Methods of Interfacing the Makeup Air System

There are two methods of interfacing the Makeup Air System with the DCV Command Center. A

description and example of each follows:

Method 1, Constant Transfer Air:

With this method the amount of Transfer Air coming from the dining area remains constant. As the

Exhaust Fan ramps up or down, the Makeup Air Fan modulates up and down to maintain a constant rate of

Transfer Air from the dining room to the kitchen. This may be accomplished by maintaining the

Figure 3-2-1

Dwyer Manometer

Chapter 3: Designing the System, Page 3-3


differential pressure between the kitchen and dining space as measured by a Pressure Transducer (rare) or

by calculating the required fan speeds to maintain air balance in the kitchen (most common). Refer to

Figure 3-3-1 below for an example.

The Constant Transfer Air Method targets a constant flow of air from the dining or adjacent spaces into

the kitchen. This means for every CFM removed from the Exhaust airflow there will be an equal CFM

removed from the Makeup Air unit.

The benefits of using the Constant Transfer Air Method are kitchens will not gradually become more

positive, and systems with a wide available turndown on the Makeup Air will have the maximum in energy

savings potential for the customer. There are some situations where the Constant Transfer Air Indirect

Method is not appropriate. Refer to the Type of MUA Interface Matrix, Table T-3-6-2 for guidance.

Typical Air Balance Sheet for Constant

Transfer Air Method

100% Exhaust High Speed for Full Cooking Load

EX MUA SA RA TA

3000 2400 1200 1000 400

30% Exhaust Low Speed for Low Cooking Load

900 300 1200 1000 400

MUA Unit HVAC Unit

TA

SA

OA

Hood

EX

MUA RA

Figure 3-3-1

Example Constant Transfer Air Method

In this example, at high speed the exhaust is 3000

CFM and at low speed the exhaust slows down to

900 CFM. The SA – RA = 200 CFM net SA to the

Hood. MUA + Net SA + TA = EX. Note that the

Transfer Air (TA) stays constant at 400 CFM. The

SA and RA remains the same while MUA

decreases from 2400 CFM to 300 CFM.

EX = Exhaust

MUA = Makeup Air

HVAC = Heating Ventilating and AC Unit

OA = Outside Air

SA = Supply Air

RA = Return Air

TA = Transfer Air



The following Table T-3-4-1 shows the Constant Transfer Air Method with a 10,000 CFM Hood(s) exhaust

at 100%, and as the exhaust decreases from 100% to 30%, the volume of Makeup Air decreases at to

maintain a Constant Transfer Air rate of 2,000 CFM. Note that the speed of the MUA decreases

dramatically as the amount of Makeup Air is reduced.

Table T-3-4-1

Constant Transfer Air Method

Percent

Exhaust Exhaust

Volume

Transfer

Air

Volume

Make

up Air

Volume

Percent

Make

up

100% 10,000 2,000 8,000 100%

90% 9,000 2,000 7,000 88%

80% 8,000 2,000 6,000 75%

70% 7,000 2,000 5,000 63%

60% 6,000 2,000 4,000 50%

50% 5,000 2,000 3,000 38%

40% 4,000 2,000 2,000 25%

30% 3,000 2,000 1,000 13%

____________________________________________________Chapter 3: Designing the System, Page 3-5

Designing the System – Cont. Method 2, Proportional Makeup Air:

With this method the amount of Transfer Air coming from the dining area is not consistent. A Pressure

Transducer is not used in this method, and the DCV System ramps the exhaust and Makeup Air fans up

down at the same rate. Refer to Figure 3-5-1 below for an example.

Typical Air Balance Sheet for Proportional

Makeup Air Method

100% High Speed for Full Cooking Load

EX MUA SA RA TA

3000 2400 1200 1000 400

30% of Exhaust Low Speed for Low Cooking Load

900 720 1200 1000 20 +

40% of Exhaust Low Speed for Low Cooking Load

1200 960 1200 1000 40

EX

Hood MUA

HVAC Unit MUA Unit

SA TA

Figure 3-5-1

Example: Proportional Makeup Air Method

OA

RA

In this example, at high speed the exhaust is 3000

CFM and at low speed the exhaust slows down to

30%, 900 CFM. The MUA decreases 30% to 720

CFM resulting in the Transfer Air going from 400

to + 20 CFM, meaning the kitchen is positive as 20

CFM is going from the kitchen out into the dining

room. This balance would be unacceptable, so to

maintain a negative kitchen, the exhaust could

only be turned down 40% to 960 CFM resulting in

40 CFM Transfer Air.

EX = Exhaust

MUA = Makeup Air

HVAC = Heating Ventilating and AC Unit

OA = Outside Air

SA = Supply Air

RA = Return Air

TA = Transfer Air



The Proportional Makeup Air Method is the simpler of the two methods, however it allows systems with

low turndowns to gradually unbalance the kitchen, and if the kitchen becomes positive to the dining area,

smoke and odor could escape from the kitchen. Other than simplicity, the benefit of the Proportional

Transfer Air Method is it will optimize energy savings on systems where the Makeup Air will only allow for

a 20% turndown. Using the Constant Transfer Air Method would force your Exhaust fan to speed up which

mean less energy savings. The Proportional method is acceptable to use as long as the kitchen stays

between 0 and -0.02 in WG throughout its entire modulation span. Use on systems where there is only

20% turndown or less. There are some situations where the Proportional Makeup Air Direct Method is not

appropriate. Refer to the Type of MUA Interface Matrix, Table T-3-6-2 for guidance.

Table T-3-6-1 shows a Proportional Transfer Air Method with a 10,000 CFM Hood. As the exhaust fan slows

from 100% to 30%, the Makeup Air fan slows from 100% to 30%. Note that the volume of Makeup Air

decreases at the same percentage, and the Transfer Air does not stay constant.

Proportional Transfer Air Method

Percent

Exhaust Exhaust

Volume

Transfer

Air

Volume

Make

up Air

Volume

Percent

Make

up

100% 10,000 2,000 8,000 100%

90% 9,000 1,800 7,200 90%

80% 8,000 1,600 6,400 80%

70% 7,000 1,400 5,600 70%

60% 6,000 1,200 4,800 60%

50% 5,000 1,000 4,000 50%

40% 4,000 800 3,200 40%

30% 3,000 600 2,400 30%

Type of MUA Interface Matrix

1 MUA

2 or more

MUA

1 Ex Fan Direct

Proportional

Direct

Proportional

2 or

more Ex

Fans

*Constant

Transfer

*Constant

Transfer

2 or

more Ex

Fans

Direct

Proportional

OK But Not

as Efficient

* To use the Constant Transfer Air

Method, you must be able to measure

a pressure differential between the

kitchen and the dining area.

Table T-3-6-2 Table T-3-6-1


Explanation of the DCV Command Center Model Number

The DCV Command Center model number is made up of a series of alpha/numeric suffixes that indicate

specific conditions of the kitchen ventilation system. The model number sequence is shown on Table T-3-

7-1.

Table T-3-7-1

DCV Command Center Model Number Sequence

1 2 3 4 5 6 7

DCV - - - - - - -

Standard

Model

Prefix

App

Start/

Stop

Button

Req'd.

# of EXH

& MUA

Fans

# of

Hood

Sections

to EXH

Fan 1

# of

Hood

Sections

to EXH

Fan 2

# of

Hood

Sections

to EXH

Fan 3

8 9 10 11

- - -

# of

Hood

Sections

to EXH

Fan 4

Makeup

Air

Control

Method

Optional

Trim

Ring

VFDs

Provided

Space 1

Model Prefix

DCV – Standard prefix for Demand Control Ventilation.

Space 2

Application

F – “F” stands for Factory installed RTDs on Gaylord Ventilators.

R –“R” stands for Retrofit, and means the DCV System is installed into an existing Hood.

Space 3

Start/Stop Fan Button

S – This indicates that an Exhaust Fan Start/Stop button is required on the DCV Command Center. In

cases where there is an existing Start/Stop button, or a Stop/Start switch is incorporated into an

existing DCV Command Center, such as a Gaylord C-100, C-200 through C-7000, then a button on the

DCV Command Center is not required and this space in the model number is left blank.

Space 4

Number of Exhaust and Makeup Air Fans

E_M_ - This indicates the number of Exhaust and Makeup Air fans on the system, and therefore

determines the number of Variable Frequency Drives (VFD) required. The first letter “E” stands for

Exhaust Fan followed by a number indicating the number of Exhaust Fans. The second letter “M”

stands for Makeup Air fan followed by a number indicating the number of Makeup Air fans. So for

example, if there are three Exhaust Fans and one Makeup Air fan the suffix would be E3M1.


Determining the DCV Command Center Model Number – Cont.

Space 5

Number of Hood Sections to Fan #1

1E_ - This suffix stands for the number of Hood Sections connected to Exhaust Fan #1. The first

number indicates the Exhaust Fan number, the letter E stands for Exhaust Fan, and the following

number indicates the number of Hood sections connected to Exhaust Fan #1. If for example there are

three Hood sections connected to Exhaust Fan #1, then the suffix would be 1E3.

Spaces 6 through 8

Number of Hood Sections to Fan #2 through #4

Suffixes for spaces 6 through 8 indicate the remaining number of Hood sections on each additional

Exhaust Fan. If for example there were two additional Hood sections on Exhaust Fan #2, and there

were no more fans, then the suffix for space 6 would be 2E2, and spaces 7 and 8 would be left blank.

Space 9

Makeup Air Control Method

There are three typical methods of controlling the Makeup Air unit(s). The suffixes for each are as

follows:

P – The “P” stands for Pressure Transducer.

B – The “B” stands for BMS, Building Management System.

V – The “V” stands for voltage from the Exhaust Fan VFD.

C – The “C” stands for PLC that combines several Exhaust Fan VFD outputs for one MUA VFD.

Space 10

Trim Ring

TR - This suffix indicates that a stainless steel Trim Ring for the DCV Command Center is required. If no

Trim Ring is required leave this space blank.

Space 11

Variable Frequency Drives

DBB - VFD drives are provided by Gaylord mounted on a Drive Back Board. If the VFDs are not

provided by Gaylord, leave this space blank.

Example: Existing installation will use existing fan Start/Stop switch, 5 Hood sections with 2 Exhaust Fans,

and a single Makeup Air system. 3 Hood sections are on EF1, and 2 Hood sections are on EF2. The

Makeup Air will be controlled by a Pressure Transducer and the DCV Command Center requires a Trim

Ring. The Variable Frequency Drives are provided by Gaylord. The DCV Model number would be as

follows:

Example Model Number

DCV Command Center Nameplate:

The model number is stamped on the nameplate (Refer to Figure 3-11-1)

DCV-R-E2M1-1E3-2E2-P-TR-DBB


Determining the Drive Back Board Model Number

If the Variable Frequency Drives (VFD) are provided by Gaylord and not managed by a Building

Management System (BMS), then a Drive Back Board (DBB) is required. The model number is made up of

a series of alpha/numeric suffixes that indicate specific information about the Exhaust and the Makeup Air

Fan VFDs. The Model Number sequence is described in the Model Number Sequence Table, Table T-3-9-1

and in the explanation that follows.

Table T-3-9-1

Drive Back Board Model Number Sequence

1

2

3

4

5

6

7

DBB - - - - - - -

Model

Prefix

EXH &

MUA

Fan

Volts

EXH

Fan #1

HP

EXH

Fan #2

HP

EXH

Fan #3

HP

EXH

Fan #4

HP

MUA

#1 HP

8 9 10 11

- - -

MUA

#2 HP

MUA

#3 HP

MUA

#4 HP

DBB

Enclosure

Explanation of Suffixes

Space 1

Model Prefix

DBB – Standard prefix for a Drive Back Board.

Space 2

Exhaust and Makeup Air Fan Voltage

This suffix is the voltage for the Exhaust Fan and Makeup Air fan motors. Enter the voltage, 208 or 460.

Space 3

Exhaust Fan #1 HP

1E_ - This indicates the horsepower (hp) of Exhaust Fan #1. The 1 stands for Exhaust Fan #1 and the

letter “E” stands for Exhaust Fan. The number after the E is the hp of the fan motor. So for example, if

Exhaust Fan #1 has a 10 hp motor the suffix would be 1E10. Enter 1E and then the hp. Important

Note: If the hp is fractional, enter a “0” then a decimal point followed by the hp. Example: A 3/4 hp

motor = 0.75 hp.

Space 4 through 6

Exhaust Fan #2 through #4 HP

2E_, 3E_, 4E_ - Suffixes for spaces 4 through 6 indicate the hp for the remaining Exhaust Fans, #2

through #4. Enter the prefix 2E, 3E, and 4E followed by the hp. Leave the space(s) blank if there are no

additional Exhaust Fans.

Chapter 3: Designing the System, Page 3-10___________________________________________________

Drive Back Board Model Number Sequence Chart – Cont.

Space 7

Makeup Air #1 Fan HP

1M_ - This indicates the hp of MUA #1 fan. The 1 stands for MUA #1 and the letter “M” stands for

Makeup Air unit. The number after the M is the hp of the MUA fan motor. So for example, if MUA #1

has a 5 hp motor the suffix would be 1M5.

Space 8 through 10

Makeup Air #2 through #4 Fan HP

2M_, 3M_, 4M_ - Suffixes for spaces 4 through 6 indicate the hp for the remaining MUA unit fans, #2

through #4. Enter the prefix 2M, 3M, and 4M followed by the hp. Leave the space(s) blank if there are

no additional MUA fans.

Space 11

Drive Back Board Enclosure Options

All Gaylord supplied Variable Frequency Drives are mounted on a Drive Back Board (DBB). The DBB is

typically mounted near the existing Magnetic Starters or any convenient location. As an option the

Drive Back Board can be mounted in a stainless steel Utility Cabinet designed to fit on the end of a new

Gaylord Ventilator, the end of an existing Hood or in a wall mounted stainless steel cabinet. A NEMA

enclosure is also an option. The following are the suffixes for each of the three options:

FC___ - FC stands for Factory Hood Mounted stainless steel Utility Cabinet. The Factory Mounted

Cabinet is typically 12” deep, and is the size and profile of the end of the Hood. Following the letters

FC enter the cabinet height, and then the width in inches. For example, if the Utility Cabinet needs to

be 30” high x 54” wide, to fit on the end of a hood, the suffix would be FC3054.

HC___ – HC stands for Hood Mounted stainless steel Utility Cabinet site installed on the end of an

existing Hood. The Hood Mounted Cabinet is typically 12” deep, and is typically the size of the end of

the Hood. Following the letters HC enter the cabinet height, and then the width in inches. For

example, if the Utility Cabinet needs to be 24” high x 48” wide, to fit on the end of a hood, the suffix

would be HC2448.

WC___ - WC stands foe Wall Mounted stainless steel Utility Cabinet site installed. The Wall Mounted

Cabinet houses both the DVC Control and the Drive Back Board and is referred to as a Combo Cabinet

(Refer to Figure 2-3-1) The Cabinet is always 34” wide and either 36” or 40” high. It is always 9” deep.

Following the letters WC enter the cabinet height, and then the width in inches. For example, if the

Wall Mounted Utility Cabinet to be 40” high x 34”, the suffix would be WC4034.

N – N stands for NEMA enclosure. The Size of the NEMA enclosure is always determined by a Gaylord

Engineer. If a NEMA enclosure is desired enter “N”.

Note: If no enclosure is desired leave the space blank.

Example: The Exhaust and MUA fan motors are 208 volt, and there are two Exhaust Fans. Exhaust Fan # 1

is 10 hp, Exhaust Fan #2 is 5 hp, and there is one MUA with a 10 hp motor. A Hood Mounted Utility

Cabinet 30" high x 54" wide is required.

Example Model Number

Drive Back Board Nameplate:

The model number is stamped on the nameplate (Refer to Figure 3-11-2)

DBB-208-1E10-2E5-1M10-HC3054

___________________________________________________Chapter 3: Designing the System, Page 3-11

Sample Nameplate for DCV Command Center

Figure 3-11-1

DCV Command Center Nameplate

Figure 3-11-2

Drive Back Board Nameplate

Chapter 3: Designing the System, Page 3-12___________________________________________________

This Page Intentionally Left Blank

Chapter 4: Installing the System, Page 4-1

Field Installation of the System

Installing the DCV Command Center

The DCV Command Center or Combo Cabinet should be located in the kitchen, within 50 ft. of the Hood in

an area that is easily accessible. It cannot be mounted on the Hood. One factor in determining the

location is the length of the Control Cables running to the Hub Box and the Drive Back Board and the ease

of routing them.

The DCV Command Center comes in three different heights (Refer to Figure 2-2-1), and the Combo Cabinet

in two different heights depending on the number of Exhaust Fans involved (Refer to Figure 2-3-1). The

recommended mounting height from the finished floor to the bottom of the Cabinet is between 25” and

40”. If the DCV Command Center is interfacing with an existing Gaylord Command Center, it is

recommended that the DCV Command Center be mounted at the same distance from the floor.

Surface Mounting

Position the DCV Command Center, or Combo Cabinet, in the determined location, open the door(s), and

mark the wall through the four mounting holes provided in the back of the Cabinet. Drill a pilot hole in the

wall with the appropriate drill for the lag bolt or screw being used. Mount the cabinet. (Note: Mounting

fasteners are not provided)

Recessed Mounting (Standard DCV Command Center only)

A 1-1/2” Trim Ring that slides over the DCV Command Center is available as an option when the DCV

Command Center is to be recessed. To mount the cabinet, cut a hole in the wall approximately 1/2” larger

in both directions than the DCV Command Center. Slide the DCV Command Center into the hole, and

while holding it centered, mark the wall through the four mounting holes in the back of the cabinet. Drill a

pilot hole in the structure with the appropriate drill for the lag bolt or screw being used. Mount the

cabinet. (Note: Mounting fasteners are not provided). If a Trim Ring is provided, slip the trim ring over the

cabinet, push tight to the wall surface, and seal to the cabinet on all four sides with clear or silver silicone.

Important Note: The Combo Cabinet is open on the top to allow heat generated by the VFDs to dissipate

and therefore it cannot be recess-mounted.

Installing the DCV Command Center is now complete

Installing the Drive Back Board

The Drive Back Board includes all the Gaylord-supplied Variable Frequency Drives (VFDs), a 24 volt power

supply, relays and a terminal strip all mounted on a common board as shown in the example below, Figure

4-7-1. The Drive Back Board replaces the existing Magnetic Starter Switches for the exhaust and MUA

fans. The existing Magnetic Starters are abandoned and the electrical power is re-routed to the Drive Back

Board. Therefore, it is recommended that the Drive Back Board be mounted near the existing Magnetic

Starters to keep the wiring to a minimum. Caution: The VFDs must be installed in an area that has no less

than 40% relative humidity and no more the 90% relative humidity, and temperatures from 32° F. to 122°

F.

The Drive Back Board may come mounted in a Stainless Steel Utility Cabinet designed to be mounted to

the end of a Hood, in a Combo Cabinet that houses the DCV Command Center and the Drive Back Board

(Refer to Figure 2-3-1), or in a Listed NEMA enclosure (Refer to Figure 2-7-2).

Chapter 4: Installing the System, Page 4-2_____________________________________________________

Installing the Drive Back Board – Cont.

Installing the NEMA Enclosure Drive Back Board

Mount the NEMA Enclosure to a suitable building structure in accordance with the instructions that come

with the Enclosure.

Installing the Wall-mounted Combo Cabinet

Secure to the wall with lag bolts or screws using the four holes in the back of the cabinet. Important Note:

The Combo Cabinet is open on the top to allow heat to dissipate and therefore cannot be recess-

mounted.

Installing the Drive Back Board is now complete

Connecting the Low Voltage Control Cables

Overview

Typically most municipalities do not require a licensed electrician to install and connect low voltage cables.

However always check with local authorities. It is a best practice to secure low voltage cables with wire

ties or other devices used in the industry.

Before routing any Low Voltage Control Cables, it is first necessary to install a 1-1/2” EMT conduit, from

the conduit hole in the top of the DCV Command Center, to above the ceiling line. All Hub Box 8-

Conductor Control Cables and the Drive Back Board 12-Conductor Control Cable are pulled through this

conduit.

Hub Box Control Cable

There is one Hub Box for each Hood Section. Each Hub Box comes with the 8-Conductor Control Cable

already connected to the terminal strip inside the box. The wires are connected to a Control Board located

inside the DCV Command Center. There is one Control Board for each Exhaust Fan and first Hood section

on that fan, and one Control Board for each additional Hood section. Each Control Board is factory labeled

with a number and letter to uniquely identify the board within the system (Refer to Figure 4-3-1). The

number part of the label will be 1, 2, 3, or 4 corresponding to a specific Exhaust Fan. The letter part of the

label will be A, B, C, D, E, or F to correspond to a specific Hood Section. A Primary Control Board label has

a prefix indicating the Exhaust Fan number (1, 2, 3, etc.) and the suffix “A” indicating that it is a Primary

Control Board. Secondary Control Boards have a prefix that is the same number as the Primary Control

Board to which it is connected and the suffix will be a letter in sequence after “A”. As an example, if the

project consists of two Hood Sections with one Exhaust Fan and three Hood Sections with another Exhaust

Fan, then the DCV Command Center would have five Control Boards Labeled “1A”, “1B”, “2A”, “2B”, and

“2C”. Boards 1A and 1B are the Primary and Secondary Control Boards for the first two hood sections and

boards 2A, 2B, And 2C are the Primary and two Secondary Boards for the other three Hood Sections.

To connect the Hub Box Control Cable(s) to the Control Boards located inside the DCV Command Center

proceed as follows.

1. Approximately 12” up from end of each Hub Box Control Cable mark the cable with the Exhaust Fan

number and the Hood Section number as described above. Example; The 8-Conductor from Hood

#1 Exhaust Fan #1 label “1A” and a second Hood section on Exhaust Fan #1 label “1B”, etc.

2. Route the Hub Box Control Cable(s) from the Hub Box(s) over to the area above the DCV Command

Center and then into the 1-1/2” conduit and down into the DCV Command Center. Pull the cable

Chapter 4: Installing the System, Page 4-3

Hub Box Control Cable – Cont.

down to approximately the bottom of the DCV Command Center. Note: if the DCV Command

Center is surface mounted, it is recommended that the conduit be covered with an enclosure.

3. Coil excess cable in the ceiling area.

4. Cut each cable the appropriate length for the wires to land on the correct Control Board.

5. Remove the outer shield from the Cable(s) as required.

6. The wires from each cable will land on the Control Board with the same Exhaust Fan number and

Hood Section letter. Example: The Control Cable marked “1A”, will connect to the Control Board

factory-labeled “1A”. Important Note: Primary Control Boards always have the suffix “A” and

Secondary Control Boards have the suffix “B”, “C”, “D”, etc.

7. Remove approximately 1/4” of insulation from each wire.

8. Using Table T-4-4-1 for the Primary Control Board and T-4-4-2 for the Secondary Control Board as a

guide. Starting at the left (facing the hood) the RTDs are numbered in sequence with the final RTD

in the duct collar.

9. Using the Terminal Connections Wire Colors shown on Table T-4-4-1 as a guide, insert each set of

wires into the 2 Wire Female Connectors. This is a friction connection. If a wire is inserted

incorrectly, it may be removed by pushing a push pin down the friction release hole in the top of

the Connector.

10. Repeat Steps 4 through 6 for each Hub Box Control Cable.

Terminal J10

Terminal J12

Terminal J9

Terminal J13

Terminal J11

Figure 4-3-1

DCV Control Board

Chapter 4: Installing the System, Page 4-4____________________________________________________

Hub Box Control Cable – Cont.

Wiring the Hub Box Control Cable is now complete.

Remote Exhaust Fan Start / Stop Switch Cable

In the event that the Exhaust Fan is controlled by a Remote Start/Stop Switch or by a Building

Management System (BMS), then a 2-conductor low voltage cable must interconnect the DCV Command

Center with the Remote Switch or BMS. The normally open contacts on the Remote Switch or BMS must

be connected to terminals BS1 (24 VDC) and BS2 at the DCV Command Center.

Drive Back Board Control Cable

A 12-conductor Control Cable is used to connect the Drive Back Board to the DCV Command Center. To

connect the Control Cable proceed as follows.

1. Route the Drive Back Board Control Cable from the Drive Back Board over to the area above the

DCV Command Center and then into the 1-1/2” conduit and down into the DCV Command Center.

Pull the cable down to approximately the bottom of the DCV Command Center. Note: if the DCV

Command Center is surface mounted, it is recommended that the conduit be covered with an

enclosure.

2. Coil excess cable in the ceiling area.

3. At each end of the cable proceed as follows:

a) Remove the outer shield from the Cable as required.

b) Cut the wires to the appropriate length to land on the 12-conductor Terminal Strips (Refer to

Figures 4-5-1 and 4-5-3).

c) Remove approximately 1/4” of insulation from each wire.

d) Using the Terminal Connections Wire Colors shown on Table T-4-5-1 as a guide, insert each wire

into the appropriate terminal and tighten.

e) Wire-tie the wires as required for a professional appearing installation.

Table T-4-4-2

Secondary Control Board Terminal Connections

from 8 Conductor Hub Box Control Cable

Terminal

# Description of Use Wire Color

J9 RTD-1 Black / White

J10 RTD-2 Red / Green

J11 RTD-3 Brown / Blue

J12 RTD-4 Orange / Yellow

J13 Not Used

Table T-4-4-1

Primary Control Board Terminal Connections

from 8 Conductor Hub Box Control Cable

Terminal

# Description of Use Wire Color

J9 Ambient RTD Factory Wired

J10 RTD-1 Black / White

J11 RTD-2 Red / Green

J12 RTD-3 Brown / Blue

J13 RTD-4 Orange / Yellow

____________________________________________________Chapter 4: Installing the System, Page 4-5

Drive Back Board Control Cable – Cont.

Wiring the 12 Conductor Drive Back Board Cable is now complete.

Table T-4-5-1

DCV Command Center to

Drive Back Board 12-

conductor Cable Terminal

Connections

Terminal #

on DBB and

DCV Control

Board

Wire Color

AC4 Yellow

DS4 Tan

AC3 Pink

DS3 Red

AC2 Purple

DS2 Orange

AC1 Gray

DS1 Green

TS Brown

AR Blue

+24 Black

ES White

Figure 4-5-1


Figure 4-5-2

Typical DCV Command Center

Terminal

Strip

Figure 4-5-3

Terminal Strip inside DCV

Command Center

Terminal

Strip

Chapter 4: Installing the System, Page 4-6____________________________________________________

Connecting High Voltage Wiring

Warning: All high voltage wiring (120, 208, 380 volt etc.) must be performed by a licensed electrician.

An electrical permit may be required. Access and working on this equipment may result in electrical

shock.

DCV Command Center

Wire the DCV Command Center as follows:

1. Wire a 120-volt, 20-amp, non-interruptible service through the conduit opening provided in the top

of the DCV Command Center. Note: This service must be fused separately. Land the wires on

terminals L, N, and Ground. Refer to the project wiring diagrams.

Connecting the high voltage wiring to the DCV Command Center is now complete.

Drive Back Board

The VFDs mounted on the Drive Back Board replace the existing Magnetic Starter(s). The existing

Magnetic Starters will be abandoned. To wire the Drive Back Board proceed as follows:

1. Reroute the incoming power wires from each existing Exhaust and Makeup Air Fan’s Magnetic

Starter to the appropriate VFD(s) on the Drive Back Board.

2. Reroute the outgoing power wires going from each existing Magnetic Starter to the Exhaust Fan

and Makeup Air Fans to the appropriate VFD on the Drive Back Board.

3. Run two low voltage wires from Terminals FS1 and FS2 to N.O. contacts the Hood Fire System.

4. If the MUA is Direct-fired, or it has a DX coil that cannot be turned down, run two wires from the

MUA unit to Terminals MO1 and MO2 to power a 24 VDC override relay.

Connecting the high voltage wiring to the Drive Back Board is now complete.

Figure 4-6-1


Terminal Strip

_________________________________________________Chapter 5: Programming the System, Page 5-1

Quick Guide Programming Flow Chart

The Quick Guide Programming Flow Chart provides a quick glance at the basic steps of Programming the

DCV System. Detailed instructions for programming begin on Page 5-5.

Step 1

Pre-Programming

Checkout

Exhaust

Fan Check

Check fan for

proper

rotation.

Verify that Hood

exhaust volume is

within 5% of design.

recorded volume

No

Yes

Do No Proceed until corrective action

brings volume to within 5% ±.

Makeup

Air/HVAC

Check

No Each unit

comes on

with exhaust

fan. Yes

Do not proceed –

Take corrective

action.

Proceed to

Step 2

Important – before proceeding with Step 1 open the Gaylord

DCV Startup Workbook for the project and use the Pre-

programming Checkout Sheet for Step 1.

Chapter 5: Programming the System, Page 5-2_________________________________________________

Quick Guide Programming Flow Chart – Cont.

Step 2

Calibrating the

RTDs

Verify RTD location

and function.

Map locations and fix

wiring if necessary.

Place Control Board(s) into

Program Mode and go to

Calibration Menu.

Place Control Board in

Runtime Mode and check

response.

Measure temperature at each RTD

and enter value into matching

Parameter in Calibration Menu.

RTD Calibration

complete.

Proceed to Step 3

Step 3

Programming the Exhaust

& Makeup Air Fan VFDs

Confirm there is

power to all VFDs

Start the Hood Capture

Performance Test.

Add 5% to required

speed and program

into VFD.

Observe Hood capture

and adjust speed as

required to capture.

Repeat process

for each

Exhaust Fan.

Programming the Exhaust & Makeup

Air Fan VFDs is now complete.

Proceed to Step 4

Enter values into

Motor Speed

Calculator.

Program

calculated values

into each VFD.


Quick Guide Programming Flow Chart – Cont.

Step 4

Programming the

RTD Constants

Display the value of each

RTD and record in the RTD

Constants Programming

Worksheet.

Turn on all cooking

appliances to simulate peak

cooking conditions and

allow temp to stabilize.

Run all

Fans at

100%

Program tL

and tH into

each Control

Board.

Program the

RTD Constants

into each

Control Board.

Programming the

RTD Constants is

now complete.

Proceed to Step 5

Step 5

Programming the

Custom Performance

Settings

Perform Hood

Capture Test for

different cooking

scenarios.

Custom

Performance

Setting is factory

set for “D”.

Programming the

Custom Performance

Setting is now

complete.

Programming

the entire

system is now

complete.

Adjust Custom Performance

Setting and retest until Hood

Capture and economy are

balanced..


Programming and Setting Up the System

Overview

Once all the hardware has been installed and wired the system needs to be calibrated, programmed, and

set up. There are seven primary steps in programming and setting up the system. They are:

Step 1: Pre-programming Check-out.

Step 2: Calibrating the RTDs.

Step 3: Programming the Exhaust and Makeup Air Fan VFDs.

Step 4: Programming the RTD Constants.

Step 5: Programming the Custom Performance function.

Prior to programming and setting up the system a Pre-programming Check-out must be performed.

Step 1: Pre-programming Check-out The Pre-programming Check-out verifies proper operation of the Exhaust Fan(s) and confirms the exhaust

volume. It also checks the operation of the Makeup Air Fan(s) and any HVAC units. To perform the Pre-

programming Check-out, first open the DCV Startup Workbook for the project and open the Pre-

programming Check-out Sheet (Refer to Appendix “A” for a sample). Complete this sheet while

performing the Check-out. With the cooking appliances off, perform the Pre-programming Check-out as

follows:

1. Exhaust Fan Check.

a) Push the Start/Stop Fan button. Check each Exhaust Fan VFD to ensure that its minimum

speed is set to 30 Hz, ± 2 Hz.

b) Push the 100% Fan button. Check the Exhaust Fan(s) VFD to ensure that its maximum speed is

set to 60 Hz, 58 to 60 nominal.

c) Visually check each Exhaust Fan and verify that the fan wheel rotation is correct.

d) With the Exhaust Fan running at 100%, using an anemometer, verify that the Hood(s) exhaust

volume (CFM) is within 5%, plus or minus, of the volume recorded on the Site Survey Form.

Important Note: If the volume is not within 5% Stop. Do not proceed until corrective action

brings the volume to within 5%.

2. Makeup Air / HVAC Check.

a) Check the Makeup Air Fan to ensure that it is on.

b) If the kitchen is also served by an HVAC system, check to ensure it is on.

c) Check the dining room HVAC unit to ensure that it is on.

d) Check fan rotation.

The Pre-programming Check-out in now complete. Proceed to Step 2.

_____________________________ Chapter 5: Programming the System, Page 5-5

Step 2: Calibrating the RTDs

Overview

Calibrating the RTDs is a critical activity in the commissioning process. Failure to properly set the RTDs will

render them either useless or a liability for the system. The RTDs are calibrated using the Control Boards

located inside the DCV Command Center (Refer to Figure 5-6-1). There is one Control Board for each Hood

Section and since the DCV Command Center can support a maximum of six Hood Sections, there could be

up to six Control Boards. There is also at least one RTD located in the DCV Command Center to measure

the ambient temperature in the kitchen. Each Ambient RTD located in the DCV Command Center is wired

to a Primary Control Board, while the Secondary Control Boards are not connected to an Ambient RTD.

The Primary Control Board is required for each Exhaust Fan the DCV Command Center is supporting. The

Maximum number of Exhaust Fans that can be supported by one system is four, so there could be up to

four Primary Control Boards in one DCV Command Center.

Each Control Board is factory labeled with a number and letter to uniquely identify the board within the

system. The number part of the label will be 1, 2, 3, or 4 corresponding to a specific Exhaust Fan. The

letter part of the label will be A, B, C, D, E, or F to correspond to a specific Hood Section. A Primary Control

Board label has a prefix indicating the Exhaust Fan number (1, 2, 3, etc.) and the suffix “A” indicating that it

is a Primary Control Board. Secondary Control Boards have a prefix that is the same number as the

Primary Control Board to which it is connected and the suffix will be a letter in sequence after “A”. As an

example, if the project consists of two Hood Sections with one Exhaust Fan and three Hood Sections with

another Exhaust Fan, then the DCV Command Center would have five Control Boards Labeled “1A”, “1B”,

“2A”, “2B”, and “2C”. Boards 1A and 1B are the Primary and Secondary Control Boards for the first two

hood sections and boards 2A, 2B, And 2C are the Primary and two Secondary Boards for the other three

Hood Sections.

Figure 5-5-1

DCV Command Center

Showing Control Board

Pressure Transducer

Control Boards


Calibrating the RTDs – Cont.

Before calibrating the RTDs it is first necessary to verify the identity of each RTD. RTDs should be installed

from left to right (facing the cookline) starting with RTD1 and ending with the last RTD in the duct collar.

When installed using this schema the control board will read the RTDs in the same sequence. If during this

verification step it is found that the RTDs are not in the correct order disconnect each improperly located

2-wire cable from the RTDs and move to the proper RTD. In order to complete this procedure it is

necessary to understand how the Control Board display functions.

Each Control Board has two modes: Runtime and Programming. The board has four DIP switches to the left

of the 3-digit display. As shown in figure 5-6-1 the switch nearest to the display controls the mode. When

the switch is in the “up” position the board is in the Runtime mode. When the switch is in the “down”

position the board is in the Program mode. When in Program mode the display will light without user

intervention. While in Runtime mode, the display will light only after holding down all three buttons below

the display for 3 seconds and will go dark after a period of inactivity.

To verify the identity of an RTD you will need access to the RTD, the powered DCV Command Center, and a

method of inducing a discernible temperature change at the RTD such as a hot rag or cup of ice. It will be

helpful to also sketch a map of the RTDs and their locations in the Hood. The procedure is slightly different

depending on whether the RTD is connected to a Primary board (labeled with 1A, 2A, 3A, or 4A) or a

Secondary board (labeled with a letter other than “A”). Use Table 5-7-1 to determine the correspondence

of RTD to Control Board, Terminal, and Parameters. While the parameters are consistent the location of

the RTDs are different. This is due to the first terminal (J9) on the Primary Board connecting to an Ambient

RTD in the DCV Command Center.

Up Button

Set Button

Mode Dip Switch

nearest the Display

Down Button

Display

Figure 5-6-1

Control Board



The procedure for verifying the identity of each RTD is as follows:

1. Put the Control Board into Runtime mode (if not already). Using a small tool, like the end of a

paperclip, slide the mode DIP switch (nearest the display) to the Up position (Refer to Figure 5-5-1).

2. Push and hold the three white buttons below the display, (Set, Up and Down Buttons) until the display

is lit (about 3 seconds).

3. Press the Up or Down Button until “t0” is displayed.

4. Push the Set button once and the temperature reading for RTD “t0” is displayed.

a. If this value is for the Ambient RTD at the Command Center, only verify the temperature

displayed is “reasonable”.

i. If the value is reasonable, proceed to press the Step button to display “t0” then push

the Up button once to display “t0”, and then push the Set button once to display the

temperature at the first hood-mounted RTD. Proceed to Step 5

ii. If the value is “0”, check the connections at J9 on the board and at terminals BS1 and

BS2 on the DIN rail-mounted terminal blocks. Press the reset button on the power

supply cover at the top of the cabinet. After the board momentarily displays the

software version (e.g., r2.3), return to Step 2.

b. If this value is not for the Ambient RTD proceed with the Step 5.

5. If the value is “0” check the wiring, reset the system, and display the value again.

6. Record the value.

7. Place a hot rag on the left-most canopy-mounted RTD for 5-10 seconds.

8. Observe the temperature displayed at the Control Board. If the display has timed out, hold down the

three buttons to light the Display and then press the Set button to display the temperature value.

9. If the temperature reflects the change, record the temperature display parameter (e.g., “t1”) next to

the RTD1 on the hood sketch, then repeat the test with each of the remaining RTDs in the system.

10. If the temperature does not change, press the Set button to display the parameter (e.g. “t0”) then

cycle through “t1”, “t2”, “t3”, and “t4” until the high temperature is found. If necessary reapply the hot

rag to confirm.

11. Once the RTD has been identified record the “t-number” next to the RTD on the sketch and check the

rest of the RTDs in the hood section.

12. If the RTDs in the hood do not correctly correspond to the Control Board switch the 2-wire cables on

top of the hood so that the RTDs and Control Board do correspond correctly.

Primary

Board RTDs

Secondary

Board RTDs

Board

Terminal

Temperature

Display

RTD

Calibration

RTD

Constant

Ambient 1 J9 t0 S_0 CA

1 2 J10 t1 S_1 C2

2 3 J11 t2 S_2 C3

3 4 J12 t3 S_3 C4

4 N/A J13 t4 S_4 C5

Table 5-7-1

Corresponding RTDs and Control Board Parameters

Chapter 5: Programming the System, Page 5-8________________________________________________


Repeat the preceding steps for each Hood Section and associated Control Boards. Note: There is no

ambient RTD used on Secondary Control Boards. Secondary Control Boards use t0, t1, t2, and t3; t4 is not

used. Once all of the installed RTDs have been verified for function and location, proceed with the

Calibration procedure.

Calibrating the RTDs involves measuring the temperature at each RTD and programming that value into

the control board. Because the control board is interpreting a detected resistance (which can vary due to

wiring length and other factors) as a temperature, the board needs the present temperature value to

correlate to the present resistance value for a baseline. A Handheld Meter with a Thermocouple is

required for this purpose. The RTDs for each Hood Section must be calibrated independently. In some

case this will need to be done in a working kitchen. However, for safety it is recommended that the

cooking equipment be off and cool when performing this procedure.

To calibrate the RTDs proceed as follows:

1. Place the Control Board for the hood section into Program mode by moving the mode DIP Switch to

the down position. The display will read “Pro”.

2. Press the Set button repeatedly until “CAL” appears (hint: two presses after “C5” appears). Push and

hold the Up and Down buttons together. The display will read “ALL”. Caution: do not press the Set

button when “ALL” is displayed. Doing so will require recalibration of all RTDs.

3. Push the Up or Down button until “S_0” (or “S_1, “S_2”, etc.) is displayed.

4. Press the Set button once. A value of 80 is displayed or the last value entered.

5. Using the Handheld Meter with Thermocouple, measure the temperature at the corresponding RTD by

placing the end of the Thermocouple wire against the tip of the RTD (or as close as practical for the

ambient and duct-mounted RTDs).

6. Enter the temperature value measured into the Control Board by pressing the Up or Down button until

that value is displayed, then press the Set button. The display will return to “Pro”.

7. Repeat Steps 2 through 6 until all of the RTDs for that hood section have been Calibrated.

8. Place the Control Board into Runtime mode by moving the mode DIP Switch to the Up position.

9. For each Control Board in the DCV Command Center and repeat Steps 1 through 7 until all of the

installed RTDs are calibrated.

Calibrating the RTDs by Method 2 is now completed. Proceed to Step 3

Chapter 5: Programming the System, Page 5-9

Step 3: Programming the Exhaust and Makeup Air Fan Variable Frequency Drives (VFDs)

Overview

The basic principle of a VFD is that it can change the speed of an electric motor by varying the frequency

(in Hz) of the power going to the motor. So for example, a motor running at full speed would be operating

at 60 Hz. To run the motor at 3/4 speed, the VFD would be set to 45 Hz, 75% of 60 Hz, or for 1/2 speed the

VFD would be set to 30 Hz, 50% of 60 Hz. The VFDs used for the Gaylord DCV System are capable of

continuous variable frequency outputs, between the minimum and maximum frequencies as programmed

into each VFD. This allows the fans to be ramped up and down based on the temperature of the cooking

appliances as detected by the RTDs.

The VFDs for the Exhaust and Makeup Air Fans are factory-programmed to 30 Hz for a Low Cooking Load,

and 60 Hz (or 100%) for Full Cooking Load. This allows initial operation of the system. However, all of the

VFDs must be programmed on-site to provide optimum performance of the Hood(s) at the greatest energy

savings.

The VFDs are programmed using a Mitsubishi Handheld Programmer, FR-PU07BB. The programmer comes

with a three-meter cable, though for systems where the VFDs are located far from the DCV Command

Center, a longer CAT5 cable is recommended. The Handheld Programmer and CAT5 cable may be

purchased from Gaylord Industries. Refer to Page 1-1.

Programming the VFDs primarily involves entering the desired frequencies for both the low and high

speeds. Determining the desired frequencies is accomplished by first conducting a Hood Capture

Performance Test to determine the maximum Exhaust Fan speed followed by calculating the maximum

Makeup Air Fan speed and the minimum speeds for all fans.

Hood Capture Performance Test

The Hood Capture Performance Test is used to determine the maximum Exhaust Fan speed to capture all

the smoke generated by a Full Cooking Load. Conduct this test while determining the frequency for the

High Speed fan as described on Page 5-10 and 5-11.

Hood Capture Performance Test – Full Cooking Load

1. With the Exhaust and the Makeup Air Fans running at full speed (design airflow), turn on all of the

cooking appliances under the Hood to their normal operating temperatures and allow the

temperatures to stabilize (Alternate burners on open burner ranges rather than turning them all

on with no load).

2. Create smoke by cooking a full load of food at one time on all appliances. Smoke may be

simulated by applying water or oil to the hot surfaces to create steam. Important Note: Do not

use smoke bombs.

3. Observe the capture performance. Using the VFD Programming Instructions below, change the

fan speed until the smoke just begins to spill out into the kitchen, and then increase the fan speed

until it just captures all the smoke. Once satisfied with the capture performance, for a safety

factor, increase the Exhaust Fan VFD frequency by 5%.


Programming the Exhaust and Makeup Fan VFDs – cont.

To connect the Handheld Programmer, proceed as follows:

1. Power off the VFD to be programmed.

2. Pull the front cover off the VFD (Refer to Figure 5-10-2)

3. Plug one end of the cable into the port of the VFD (Refer to Figure 5-10-2).

4. Replace the cover on the VFD.

5. Plug the other end of the CAT5 cable into the Handheld Programmer (Refer to Figure 5-10-1).

6. Once connected slide the On/Off switch on the back of the Handheld Programmer to the ON

position and the POWER indicator will light.

7. Power on the VFD.

Determining the Frequencies for Low Speed and High Speed Fan

Before actually programming the VFDs for low and high fan speeds, it is first necessary to determine the

required frequencies for both settings. The frequencies for both low and high speed are determined by

conducting Hood Capture Performance Test as described on Page 5-9 and by the Makeup Airflow

maximum and minimum. Once determined then the VFDs are programmed.

To determine the high fan speed/frequency proceed as follows:

1. Place the Exhaust Fan into Manual Mode using the following procedure.

a) Turn off power to the Exhaust Fan VFD and wait for its digital display to go dark.

b) Remove the front cover from the VFD.

c) Using a small screwdriver or mechanical pencil to depress the terminal catch, carefully remove

the 24-volt wire from terminal STF on the VFD.

d) Replace the front cover on the VFD.

Figure 5-10-1

Hand Held Programmer

Back Side

Figure 5-10-2

Typical VFD with Cover Off

CAT5 Cable

Connection

On / Off

Switch

________________________________________________Chapter 5: Programming the System, Page 5-11


e) Restore power to the VFD.

f) Press “PrSET” on the Handheld Programmer. The display will look as shown on Figure 5-12-1.

g) Press “79” and then press “READ” once. The display will look as shown on Figure 5-12-2.

h) Press “1” and then press “WRITE”. The “1” will be flashing. The VFD is now in Manual Mode.

2. Start the Hood Capture Performance Test with “Full Cooking Load”.

3. Press “PU”. The display will show the current frequency.

4. Enter the desired frequency and then press “WRITE” once and then press “FWD”. The display will

look as shown in Figure 5-12-3 with 33 Hz entered as an example. The Exhaust Fan speed will

change according to the change in frequency from the previous setting.

5. (Optional) Press “SHIFT” repeatedly to cycle the handheld display through frequency (Hz), the

percentage of maximum frequency (%), and the electrical current draw (A).

6. Observe the Hood’s capture performance. If the Hood is not capturing or if it appears that the fan

is running too fast, the fan speed may be increased or decreased by pressing “PU”, entering the

new frequency and then pressing “WRITE”. Continue this process until the Hood is capturing.

7. Once satisfied with the current fan speed, as a safety factor increase this frequency by 5% and

record this value as the high speed depending on the Hood Capture Performance Test conducted.

This recorded frequency will later be used to program the VFD for this fan.

8. Restore the Exhaust Fan VFD to Automatic Mode using the following procedure:

a) Press “PrSET” on the Handheld Programmer. The display will look as shown on Figure 5-12-1.

b) Press “79”, and then press “READ” once. The display will look as shown on Figure 5-12-2.

c) Press “2”, and then press “WRITE”. The “2” will be flashing. The VFD is now in the Automatic

Mode.

d) Turn off power to the Exhaust Fan VFD and wait for its digital display to go dark.

e) Remove the front cover from the VFD.

f) Replace the 24-volt wire to terminal STF on the VFD.

g) Replace the front cover on the VFD.

h) Restore power to the VFD.



The low fan speed will be 30 Hz for a 50% turndown, unless the airflow requirements of the Makeup Air

Unit prevent the exhaust fan from turning down that low. The Motor Speed Calculator (Figure 5-13-1)

found in the Startup Workbook will calculate the low fan speed given the required exhaust and makeup

airflows and the minimum airflow for running the makeup air unit.

To use the Motor Speed Calculator:

1. Enter the number of Hood sections on each Exhaust Fan.

2. Enter the maximum Exhaust motor speed based on the Hood Capture Performance Test.

3. Enter the measured airflow for each Hood section.

4. Enter the minimum Makeup airflow (if none, leave blank).

5. Enter the Makeup Air Design Airflow.

Figure 5-12-1

Display After Pushing PrSET

Figure 5-12-2

Display After Pushing 79

Figure 5-12-3

Display After Entering the New

Hertz, 33 in this Example



6. The value for maximum exhaust motor speed will be used to program Parameter 905 in the

Exhaust Fan VFD. Parameter 1 must be greater than or equal to this value (Parameter 1 default

value is 60 Hz).

7. The value for the minimum exhaust motor speed will be used to program Parameter 904 in the

Exhaust Fan VFD. Parameter 2 must be less than or equal to this value (Parameter 2 default value is

30 Hz).

8. The value for maximum MUA motor speed will be used to program Parameter 905 in the Makeup

Air Fan VFD. Parameter 1 must be greater than or equal to this value (Parameter 1 default value is

60 Hz).

9. The value for the minimum MUA motor speed will be used to program Parameter 904 in the

Makeup Air Fan VFD. Parameter 2 must be less than or equal to this value (Parameter 2 default

value is 30 Hz).

Enter the number of hood

sections for each exhaust fan

Enter the “high speed”. Default

is 60 Hz.

Enter the actual exhaust airflow

Enter the minimum makeup

airflow (if there is one)

Enter the makeup design airflow

Figure 5-13-1

Motor Speed Calculator



10. The value for the minimum MUA Speed Signal (%) will be used to program Parameter (904) which is

a secondary value for Parameter 904. This value corresponds to the voltage signal that the MUA

VFD will receive at minimum speed. If the minimum speed on the Exhaust is 30 Hz out of a

maximum of 60 Hz, then the MUA VFD will receive a 5-volt signal at minimum speed or 50% of 10

volts.

You have completed determining the frequency for low and high fan speed. Proceed to Programming

the Determined Frequency into the VFDs.

Programming the Determined Frequency into the VFDs.

To program the VFDs for low and high fan speeds proceed as follows:

1. Connect the programmer to the VFD using a CAT5 cable.

2. Press “PrSet”. The display will look as shown in Figure 5-14-1

3. Enter “904” on the key pad, then press “READ” once to access Parameter 904 in the VFD. The

display will look as shown in Figure 5-14-1. The second line on the display designates the current

frequency setting, in this example the 30 Hz that is factory-programmed.

4. On the Programmer keypad, enter the frequency for the low fan speed as calculated in the Startup

Workbook. Press “WRITE”, and the change will be written to the VFD (in this example, 33 Hz). This

may take a few seconds. The minimum fan speed setting is now programmed. The display will look

as shown on Figure 5-14-2 showing Completed. If you wish to change the entry repeat steps 1

through 3.

Figure 5-14-1

Display After Entering 904

Figure 5-14-2

Display After Entering New Low Speed

Frequency, 33 Hz in the Example



5. For the Makeup Air VFD only:

a. Press “PrSet”.

b. Enter “904”.

c. Press “Read” two times. The display will look like Figure 5-15-1.

d. Enter the value for minimum speed in Hz if different than what is displayed.

e. Press “Write” once.

f. Enter the value for minimum MUA Speed Signal in %.

g. Press “Write” once more. The display will look like Figure 5-15-2.

6. Press “PrSET”. The display will look as shown on Figure 5-16-1.

7. Enter “905” on the key pad, then press “READ” once to access Parameter 905 in the VFD. The

display will look as shown in Figure 5-16-1. The second line on the display designates the current

frequency setting, in this example the 60 Hz that is factory-programmed.

8. On the Programmer keypad, enter the frequency for the high fan speed in Hz. Press “WRITE”, and

the change will be written to the VFD (in this example, 33 Hz). This may take a few seconds. The

minimum fan speed setting is now programmed. The display will look as shown on Figure 5-16-2

showing Completed. If you wish to change the entry repeat steps 6 through 8.

9. Repeat this process for all VFDs.

Figure 5-15-2

Display After Step 5.g.

Figure 5-15-1

Display After Step 5.c.



You have completed Programming the Exhaust and Makeup Air Fan VFDs. Proceed to Step 4

Step 4: Programming the RTD Constants

Overview

The RTD constants are used to “normalize” the temperatures measured by each RTD such that the exhaust

fan will respond to the highest relative temperature under the hood. Consider the cooking appliance line

shown in Figure 5-16-3. The highest temperature measured at each RTD is as follows: t1 = 95° F, t2 = 87° F,

and t3 = 115° F. If the temperature at RTD t3 over the broiler increases to 115°, the exhaust fan would

increase to 100%. If the broiler is turned down or off, the griddle and fryer are in use, and t1 reaches 95°,

which is the high temperature for that RTD, then the Exhaust Fan would speed up to 100% fan speed

based on the demand generated by the appliance even though that is 20° less than the high temperature

for t3. Note: Factory-installed RTDs occupy strategic locations based on known hood characteristics.

Figure 5-16-1

Display After Entering 905

Figure 5-16-2

Display After Entering New High Speed

Hertz, 54 Hertz in this Example

Cooking Appliances

Left to Right

1. Griddle

2. Fryer

3. Spacer

4. Broiler

5. Range

6. Oven

t1 t2 t3

Figure 5-16-3

Typical Cooking Appliance Line


Programming the RTD Constants

Before programming the RTD Constants it is necessary to calculate the values using the Constant

Calculator in the DCV Startup Workbook (see Table T-5-18-1). Note: Appendix ”A” shows a sample of the

complete DCV Startup Workbook. Contact Gaylord Industries if you do not have this file. To set the RTD

Constants proceed as follows:

1. The first step is to temporarily ramp all Exhaust Fans to 100%. The 100% Fan Button will not work

for this purpose as the test takes much longer than the five minutes the fan will run. Instead flip up

the override switch on Relay CR5 located on the DBB.

2. Turn on all cooking appliances under the Hood(s) served by the Exhaust Fans to their maximum

setting.

3. Allow the cooking appliances to come up to temperature and stabilize.

4. Record the temperatures measured by each RTD as displayed at each Control Board.

a) Ensure the Control Board is in Runtime mode (the display is dark unless activated by holding the

three white buttons) by using a small tool, like the end of a paperclip, to slide Dip Switch #1 to

the Up position (Refer to Figure 5-17-1).

b) Push and hold the three white buttons, (Set, Up and Down Buttons) until the digital display on

the Control Board lights (about three seconds).

c) Monitor the temperatures of the hood RTDs until they stabilize.

a. Push either the Up or Down button repeatedly, until “t1” is displayed.

b. Press Set to display the current temperature at that RTD

c. Press the Set button again to return the display to “t1”

d. Repeat for other RTDs until all have stabilized

d) Cycle back to “t0”. Push the Set button once and the temperature reading for RTD “t0”,

Ambient Temperature, is displayed. Record this temperature on the RTD Constant Calculator

spreadsheet under “Temperature Displayed” (Refer to Table T-5-26-1 as a sample).

e) Push the set button again and the display will return to “t0”.

f) Push the Up button and the display will advance to “t1”.

g) Push the Set button once and the temperature reading for RTD “t1” is displayed. Record this

temperature in the RTD Constant Calculator.

h) Repeat this process for each RTD on each Hood Section/Control Board.

5. After the temperatures have been recorded on the RTD Constant Calculator spreadsheet in the

previous step, the RTD Constants and values for tL and tH are automatically calculated.

Figure 5-17-1

Control Board

Up Button

Set Button

Dip Switches. From

right to left, Dip

Switch 1, 2, 3 and 4

Down Button


Programming the RTD Constants – Cont.

6. Program tL, tH, and the RTD Constants into each Control Board. To program proceed as follows:

a) Place the Control Board into Program mode by pushing Dip Switch 1 down. The display will

read “Pro”.

b) Push the Set button repeatedly until the display reads “tL”, then push the Set button one more

time.

c) Using the Up and Down Buttons enter the value for tL from the Excel table.

d) Push the Set button again, which displays tH, then press one more time.

e) Using the Up and Down Buttons enter the value for tH from the Excel table.

f) Push the Set button repeatedly until the display reads “CA”.

g) Push the Set button again and the factory default RTD Constant is displayed.

h) Using the Up and Down buttons, enter the RTD Constant for CA from the RTD Constant

Calculator spreadsheet.

i) Push the Set button and the display will be “C2”.

j) Repeat Steps (g) through (i) for the remaining RTD Constants shown in the RTD Constant

Calculator.

7. After programming tL, tH, and the RTD Constants into each Control Board push Dip Switch 1 on the

Control Board back to the Up position and release the override switch on Relay CR5. Turn off any

unnecessary equipment.

Programming the RTD Constants is now complete. Proceed to Step 5.

PurposeRuntime

Item

Temperature

Displayed

Program

Item

RTD

Constant

Ambient Temp t0 CA 1.0

Hood Temp t1 C2 1.0

Hood Temp t2 C3 1.0

Hood Temp t3 C4 1.0

Hood Temp t4 C5 1.0

0 TL 5 TH 13

PurposeRuntime

Item

Temperature

Displayed

Program

Item

RTD

Constant

Hood Temp t0 CA 1.0

Hood Temp t1 C2 1.0

Hood Temp t2 C3 1.0

Hood Temp t3 C4 1.0

0 TL 5 TH 13

RTD Location

RTD Location

RTD-1

RTD-2

RTD-3

RTD-4

Hood Section # For Control Board # 1B

DCV Control Cabinet

RTD-1

RTD-2

RTD-3

RTD-4

Secondary Control Board RTD Constant Calculator

Primary Control Board RTD Constant Calculator

Hood Section # For Control Board # 1A

Table T-5-18-1


Step 5: Programming the Custom Performance Settings

The DCV System has six Custom Performance settings which change the reaction relationship between the

Hood temperature and the Exhaust Airflow resulting in how quickly or slowly the Exhaust Fan ramps up or

down. The six settings are identified as Settings “A” through “F”. Figure 5-19-1, shows the relationship of

the fan speed to the cooking load (based on hood temperature).

Custom Performance Settings allow the DCV System to be customized to change from being very

conservative to very aggressive in regard to energy savings. Performance selection is dependent upon risk.

Risk in this context relates to the ability of the DCV System to respond to a piece of cooking equipment. A

broiler can be considered a low risk, because there is an easily sensible heat load. The sensible heat from

an appliance such as electric fryer may be difficult to detect. Using a more conservative approach such as

ramping to a higher fan speed at the lower end of the sensible heat range can address the risk posed by

equipment with low sensible heat loads. Conversely, less risky equipment such as broilers, open burner

ranges, and other easily sensed equipment can utilize a more economical approach that slowly ramps the

fan at the low end of the sensible heat range, then ramps more quickly at the high end of the sensible heat

range.

Figure 5-19-1 graphically shows the relationship of airflow to sensible heat for each of the custom

performance settings. Curves A and B are more conservative settings that provide more hood exhaust for

small initial increases in heat load. Curves E and F provide low exhaust rates at idle and low cooking rates,

then increase the exhaust rate at the higher end of the sensible heat range. Curves C and D provide a

balanced approach that takes into account a variety of equipment. DCV Systems are factory set at D which

provides a linear exhaust response to the sensible heat load. Curve C provides a middle ground between

the B and E curves to respond to a mix of high and low risk equipment.

Figure 5-19-1

Custom Performance Curves


Programming the Custom Performance Settings - Cont.

There is not a “rule” for utilizing the Custom Performance Settings. In order to determine what

customization will be best requires testing of the system under varying cooking conditions. For example, a

kitchen may have broiler that is only used at certain times of the day. To determine a customization

perform a Hood Capture test with the broiler off and the other equipment under the hood(s) controlled by

the fan cooking with normal load. If the hood fails, then move the setting from D to B and test for capture.

Conversely, if the hood captures fine at D, move the setting to E and test. Once the optimum setting has

been determined, retest with the broiler on.

Each Primary Control Board is factory-programmed for Custom Performance Setting “D”, which is called

the Base Setting. To change to a different setting proceed as follows;

1. Place the Primary Control Board for the Exhaust Fan in Program mode by moving Dip Switch #1 to

the down position (Refer to Figure 5-17-1). The display will read “Pro”.

2. Use the Set button, (leftmost of the three white buttons) to scroll through the menu until “out” is

displayed.

3. Press the Set button one more time and a letter will appear. (“d” is the factory default)

4. Using the Up and Down buttons, (middle and rightmost of the three white buttons) move up and

down to select the Custom Performance Setting desired (refer to Figure 5-19-1).

5. Push the Set button. The Custom Performance Setting for the Exhaust Fan is now programmed.

Repeat steps 1 through 5 for each additional Exhaust Fan.

Programming the Custom Performance Settings is now complete.

You are now finished with Programming the entire DCV System

______________________________Chapter 6: Additional Control Board & Programming Details, Page 6-1

Control Board Details

Overview

This chapter is devoted to providing additional details on the Control Board. It includes a Quick Guide

Programming Chart that can be used for all programs described in previous chapters plus additional

programming that is used for fine tuning the system and troubleshooting.

J9

Dip Switches. From

right to left, Dip

Switch 1, 2, 3, and 4

Set Button

Up Button

Down Button

Figure 6-1-1

DCV Control Board Layout

J11

J10

J12

J13

J21 & J22

Secondary

Board

Communication

12VDC (-, GND)

J3 Relay

Output

100% Fan

Terminals

J19 & J20

DC REF/GND

J8

J5, 4-20 mA

Out

Red LED

indicates “Call

for Fan”

Chapter 6: Additional Control Board & Programming Details, Page 6-2______________________________

Control Board Details – Cont.

DCV Control Board Terminal Connections

Terminal

# Description of Use Comments

J3/J8 Relay Output

12VDC to relay coil when there is a demand

for fan. On when cooking activity is sensed

or when the 100% Fan Button is pressed.

Control Board will indicate with a red LED.

J5 Analog signal to VFDs to

modulate Exhaust Fans 4-20 mA output (positive)

J6 Ground / DC Reference For J5 and J7

J7 N/A Not used (2-10 Volt Option)

J9 Ambient RTD, Primary Board. Located in DCV Command Center.

#1 RTD on Secondary Board

J10 #1 RTD Hood Canopy #2 on Secondary Board

J11 #2 RTD Hood Canopy #3 on Secondary Board

J12 #3 RTD Hood Canopy Not used on Secondary Board

J13 #4 Exhaust Duct RTD

J19/J20

Momentary closure across

terminals results in the analog

output going to 100% for a

period of 5 minutes.

5VDC potential between terminals. Pushing

the Power Supply Reset Button inside the

cabinet will cycle power to the Control

Boards and terminate the 100% override.

J21 RJ25 output for inter-board

communication

Not used on Primary Control Board.

Output on Secondary Control Board.

J22 RJ25 input for inter-board

communication

Input on Control Board from a Secondary

Control Board

Table T-6-2-1


Programming Details

Setting Program & Operational Mode

Set the Dip Switches as indicated below for the desired effect.

Dip Switch 1: ON (Down Position)-> Program Mode

OFF (Up Position) -> Run Mode, set immediately after Program mode is set

Dip Switch 2: ON (Down Position) -> C

OFF (Up Position) -> F (Standard)

Dip Switch 3: ON (Down Position) -> Modbus ON (Only used when interfaced with a PC)

OFF (Up Position) -> Standard Operation (Standard)

How to Navigate the Menus

RUNTIME Data Menu: Simultaneously depress the SET/UP/DOWN buttons until the display activates to

enter the RUNTIME Data Menu. Once in the menu, push the UP or DOWN buttons to cycle through data

options. Pushing the SET button displays data for the selection. Pressing SET again will exit selection. The

RUNTIME Data Menu is shown in Table T-6-3-1.

Program Menu: To program the Control Board place Dip Switch 1 Down into the ON position using a small

device such as a paper clip. After the Display shows “Pro” navigate the menus as shown below in Tables T-

6-4-1 through T-6-6-1.

t0: Temperature (calibrated and scaled by 4) read on sensor 0 (ambient)

t1: Temperature (calibrated and scaled by 4) read on sensor 1




o_S: Output type (t = voltage, c = current) and number of attached sensors

FrL: Fan request local (0-120)

Fr1: Fan request from INPUT (0-120)

Fr2: Fan request from OUTPUT (0-120)

Fr: Maximum requested fan power (0-120)

Fst: Current fan power state (0-120)

Ft: Fan timer (cooldown time or 100% fan power time)

RUNTIME Data Menu

Note: System will

not Change while

in Program Mode

Table T-6-3-1


Programming Details – Cont.

Quick Guide Programming Table

Paramete

r Button Options Factor

y Pre-

Set

Notes Description

Pro Set NA Indicates you are in Program Mode

1 Con Set NA Parameter’s setting defines board as a

Primary or Secondary Control Board.

2 UP/DN ON OFF ON

“ON” sets the board as a Primary Control

Board

“OFF” sets the board as a Secondary Control

Board.

3 AbS Set Parameter determines source of Ambient

Temperature value.

4 UP/DN SEn PrE SEn Select/Set

to Enter

“SEn” sets board to use temperature

measured by Ambient RTD.

“PrE” sets board to use manually entered

constant value for Ambient Temperature.

5 Set Set

This option appears only when “AbS” is set to

"PrE". It is used to define the Ambient

Temperature as a constant.

6 UP/DN 55 104 75 Select/Set

to Enter

Values are in degrees Fahrenheit. If you must

use this parameter, set for the projected

average yearly temperature in the Kitchen.

7 Out Set

Parameter determines the output curve for

Exhaust Fan. Factory-set at "d”. Consult the

factory for the other settings. See Page 5-24.

8 UP/DN A, b, C, d, E, F d Select/Set

to Enter

9 Sdt Set

Shut down timer. This is the time the fan will

continue to run after the RTDs have gone

below their lower set point. The time is in

minutes, and should be set to 15 minutes.


to Enter

Table T-6-4-1




Parameters Button Options Factory

Pre-Set Notes Description

11 tL Set

Parameter establishes the fan activation

threshold for the Hood.

12 UP/DN 0 25 15

13 tH Set

Parameter establishes the peak heat value

for the Hood above which the fan will run at

100%.


to Enter

Consult factory for temperatures that exceed

125° F over ambient conditions.

15 dt Set

Parameter value for temperature change

over a 40 second period. If the temperature

in the hood changes at a greater rate the

Exhaust Fan will ramp to 100% for five

minutes, and then return to modulating

control.


to Enter

A rule of thumb setting for setting this value

is to set it to 7 if tH is less than 45, set it to 10

if tH is 45 or greater. Further refinement can

be made by observing reaction times on the

active cookline.

17 CA Set

Parameter for the RTD Constant for the RTD

connected to J9. On a Primary Control Board

this is the Ambient RTD. On a Secondary

Control Board this is RTD1.

18 Set 1.0 Select/Set

to Enter

On a Primary Control Board this parameter

will not vary, but may change on a Secondary

Control Board.


Table T-6-5-1



Parameters Button Options Factory

Pre-Set Notes Description

19 C2 Set

Hood-mounted RTD.

20 0.2 4.0 1.0 Select/Set

to Enter

21 C3 Set

Hood-mounted RTD.

22

0.2 4.0 1.0 Select/Set

to Enter

23 C4 Set

Hood-mounted RTD.

24


to Enter

25 C5 Set

Hood-mounted RTD on Primary Control

Board. Not-used on Secondary Control

Board.

26


to Enter

27 CAL UP/DN

Press the UP and DOWN buttons at the

same time to enter the Calibration menu.

28 ALL UP &

DN/Hold All, S_0, S_1, S_2,

S_3, or S_4

Select /

Set to

enter

temp

ALL will calibrate all RTDs together to the

temperature to be set in the next field.

"ALL" is only to be used when the RTDs are

all at ambient temperature.

Selecting S_0 to S_4 will allow you to

individually calibrate each RTD one at a

time.

29

UP/DN 50 130 80 Select/Set

to Enter

Enter value measured with a thermocouple.

Once a value is entered, pressing Set will

return to the top of the Programming

menu.

Table T-6-6-1

__________________________________________________________________Chapter 7: Parts, Page 7-1

Parts – Miscellaneous

Table T-7-1-1

Miscellaneous Parts

PC # Description Gaylord Part # Illustration

1 Hub Box 20823 N/A

2 RTD Conductor Cable – 2-

Conductor Cable - 14 ft. long.

Includes 2 pin connector at one

end.

20382 N/A

3 8- Conductor Cable – Hub Box to

DCV Command Center. Sold by

the ft. Specify the length.

20877 N/A

4 Drive Back Board, 12-Conductor

Controller Cable. Sold by the ft.

Specify the length.

20878 N/A

5 Hub Box Kit – Includes the Hub

Box, pre-wired 50’ Eight

Conductor Control Cable and 4

pre-wired RTDs

76099 Refer to Figure

4-2-1

Chapter 7: Parts, Page 7-2__________________________________________________________________

Parts – DCV Command Center

7

11

8

10

5

4

2

1

3

6

9

__________________________________________________________________Chapter 7: Parts, Page 7-3

Parts – DCV Command Center – Cont.

Table T-7-3-1

DCV Command Center Parts

PC

# Description

Gaylord Part

# Illustration

1 Reset Button 20874

2 Fuse Not Illustrated

3

12 Volt DC Power

Supply 25 Watt 20883

12 Volt DC Power

Supply 45 Watt 20884

4

Relay (Optional) 18632

Relay Base 11413

5 Pressure Transducer 20846

Chapter 7: Parts, Page 7-4__________________________________________________________________

Parts – DCV Command Center – Cont.

Table T-7-4-1

DCV Command Center Parts

PC

# Description Gaylord Part # Illustration

6 Control Board 20318

7 Control Relay - 1amp

DCV 20885

8 Start / Stop Button 20284

9 100% Fan Button 20825

10

RTD with Round

Mounting Bracket as

Illustrated

20319

11 Door Latch - (keyed) 16547

__

______________________________________________________Chapter 8: Wiring Diagrams, Page 8-1

Wiring Diagrams

DCV Command Center Sample Internal Wiring Diagram with optional Start/Stop Fan button

Chapter 8: Wiring Diagrams, Page 8-2________________________________________________________

Wiring Diagrams

DCV Command Center Sample Internal Wiring Diagram for Interconnection with a Gaylord Wash

Command Center

________________________________________________________Chapter 8: Wiring Diagrams, Page 8-3

Wiring Diagrams

Drive Back Board Sample Internal Wiring Diagram

Chapter 8: Wiring Diagrams, Page 8-4________________________________________________________


Appendix A: DCV Startup Workbook - Sample, Page A-1

Page A-1 through A-3 show sample tabs from the “DCV Startup Workbook”. Contact Gaylord for the Excel

file.

Figure A-1-1

Configuration Tab

Figure A-1-2

Pre-Program Checkout Tab

Project Name: Sample DCV Project

Board Type

Fan

Name/Number

Hood Section Primary Exhaust Fan EF-1

Hood Section Secondary Exhaust Fan EF-1

Hood Section Exhaust Fan




1 1Number of Makeup Fans Number of Exhaust Fans

Hood

Name/Number Board Number

6.02 1A

6.39 1B

Appendix A: DCV Startup Workbook – Sample, Page A-2________________________________

Figure A-2-1

Motor Speed Calculator Tab

Appendix A: DCV Startup Workbook - Sample, Page A-3

Figure A-3-1

Constant Calculator Tab

Figure A-3-2

Tuning Tab

PurposeRuntime

Item

Temperature

Displayed

Program

Item

RTD

Constant

Ambient Temp t0 CA 1.0

Hood Temp t1 C2 1.0

Hood Temp t2 C3 1.0

Hood Temp t3 C4 1.0

Hood Temp t4 C5 1.0

0 TL 5 TH 13

PurposeRuntime

Item

Temperature

Displayed

Program

Item

RTD

Constant

Hood Temp t0 CA 1.0

Hood Temp t1 C2 1.0

Hood Temp t2 C3 1.0

Hood Temp t3 C4 1.0

0 TL 5 TH 13

Primary Control Board RTD Constant Calculator

Hood Section # For Control Board # 1A

RTD-4

Hood Section # For Control Board # 1B

DCV Control Cabinet

RTD-1

RTD-2

RTD-3

RTD-4

Secondary Control Board RTD Constant Calculator

RTD Location

RTD Location

RTD-1

RTD-2

RTD-3

Appendix A: DCV Startup Workbook Generator - Sample, Page A-4_________________________________

Figure A-4-1

Motor Speed Calculator Tab

Items

Exhaust

Fan 1

Exhaust

Fan 2

Exhaust

Fan 3

Exhaust

Fan 4

Number of Hoods (Maximum of 6 total) 2 3 0 0

Adjusted Maximum Exhaust Motor Speed at

Capture & Contain (see VFD Parameters 905 and 1) 60 55 60 60

enter Tested Total Exhaust (Hood 1) (CFM) 2500 4000

enter Tested Total Exhaust (Hood 2) (CFM) 3000 1500

enter Tested Total Exhaust (Hood 3) (CFM) 2000

enter Tested Total Exhaust (Hood 4) (CFM)



Report Airflow per Exhaust Fan (CFM) 5500 7500 0 0

Report Airflow per EF at Adj. Max Speed (CFM) 5500 6875 0 0

Report Total Exhaust/Total Exhaust at Adj. (CFM)

enter MUA Name Plate Minimum Airflow:

enter MUA Design Airflow:

Report MUA Airflow Adjusted (CFM)

Set Drive

Max. MUA Motor Speed (Hz)

(Parameters 905 and 1)

Set Drive

Min. MUA Motor Speed (Hz)

(Parameters 904 and 2)

Report TurnDownSUPPLY

Report Total Air from Other Sources (CFM)

Report Total System Exhaust, (Minimum)

Report Total TurnDown EXHAUST

Set Drive

Min. Exh. Motor Speed(s), Hz. (Bias)

(Parameters 904 and 2) 30 30

2600

4600

63%

2000

10400

9775

56

30

80%

13000 12375

DCV Series VFD

Motor Speed

Calculator

(1 Supply, 1-4

Exhaust Fans)Enter Value from field

Program into VFD

Information / Report

______ Appendix B: Frequently Asked Questions, Page B-1

Gaylord DCV Control Board FAQ’s

1. How Do I Program the Variable Frequency Drives?

Answer: They are Factory Programmed with only a few parameters needing to be accessed

and possibly adjusted in the field. Refer to the VFD Installation and Programming guide.

2. How does the MUA unit work when it is controlled by pressure?

Answer: The Pressure Transducer provides a 4-20 mA signal that is sent with the other

Exhaust Fan signals to a combined variable frequency drive back Panel. The Setting of the

Pressure Transducer and MUA VFD is beyond the scope of this manual. Contact Gaylord

Industries for more information.

3. How long does the fan run when I push the 100% fan button?

Answer: They System will run at 100% for 5 minutes. You can access a timer on the

RUNTIME Data Menu called “Ft” to see the countdown. Pressing the Reset button will

cancel the override.

4. How do I get the system to run at 100% Fan so I can set the Constants?

Answer: Flip the override switch on Relay CR5 to send the system to 100%. Remember to

release the switch when finished.

5. What is the purpose of the “AR” Terminal?

Answer: AR, meaning Analog Run, can be used to override the Demand Control Ventilation

System for conditions where you have Direct fired Makeup air, or DX coils that cannot be

turned down. A 24 VDC signal can be sent to Relay CR5 to open AR to override the

modulation of the system.

6. Does the DCV System have a way to deal with FP Overrides?

Answer: Yes, the DBB has set of contacts for connection to the FP system. Upon activation

of the FP system relay logic on the DBB will override all Exhaust VFDs to 100%, and stop all

Makeup Air VFDs.

7. How many Fans Can the Control Board Control?

Answer: The DCV Command Center can monitor up to 6 hoods and control up to 4 Exhaust

Fans and 4 MAU Fans.

8. How does a Control Board know when it is a Primary or a Secondary?

Answer: Control Boards are designated using the “Con” Parameter from the Program Menu.

Primary boards are set to “on” and Secondary Control Boards are set to “off”. This

parameter is factory-set.

Appendix B: Frequently Asked Questions, Page B-2______________________________________________


______ Appendix C: Programming - Project Example, Page C-1

Project Example

Getting the most out of the system relies on eliminating any excess exhaust air from the system over a

comfortable Capture and Contain point, (Refer to Hood Capture Performance Tests beginning on Page 5-

17), and getting the system set to the correct minimum and maximum VFD motor speeds. Execution of

these items will allow the installation to be a big success, lowering the cost of to run the kitchen Hoods.

Use the “Motor Speed Calculator” Worksheet, made available through Gaylord to do the calculations for

the project. A Project Example is shown below illustrating the simple math used in the worksheet to

determine minimum and maximum flow rates and corresponding motor speeds. The Result of the

calculations will be entered into each of the Exhaust and Makeup Air drives by using a handheld VFD

programmer. Parameters 904 and 905 are used to set the drives minimum and maximum motor speeds.

Systems using VFDs, or other devices, not provided by Gaylord, consult the manufacturer’s programming

manual for the Frequency Bias, (Low or minimum set point), and Frequency Gain, (High, or 100% motor

speed Set Point). Pre-Engineered Variable Frequency drives systems coming from Gaylord will be set for

the Proportional Makeup Air Method, and have the supply and Exhaust VFDs set to 30 Hz for the lower

minimum motor speed and 60 Hz for the upper motor speed.

Example Project: There are three Hoods and three Exhaust Fans. The exhaust volume is: H1 = 4000 CFM, H2 = 2500 CFM, H3

= 3500 CFM = 10,000 CFM Total. There is one MUA operating at 8000 CFM. Dining Room Transfer Air rate

= 10000 CFM - 8000 CFM = 2000 CFM Transfer Air Rate.

The MUA is a Greenheck Indirect Fired unit with no cooling, and the system can be operated from 14,000

CFM down to 2800 CFM. (If the System cannot run below 80%, use “Constant Transfer Air Method). By

performing the Hood Capture Performance Test, as described on Pages 5-17 and 5-20, the Hoods were

found to be running high on Exhaust air. It was decided that the hoods comfortably capture at 52 Hz. The

DCV installer will set the maximum system Exhaust rate to 52 Hz for each of the 3 VFDs, or can optionally

sheave the fans to the desired motor speed. Prior to sheaving the fans a power measurement would be

made (after sheaving measure airflow for entry into the Motor Speed Calculator).

Complete the Motor Speed Calculator (refer to Figure C-2-1) using the following steps:

1. Enter “1” for the number of hoods under EF-1, EF-2, and EF-3.

2. Change the default value of “60” to “52” for the Adjusted Maximum Exhaust Motor Speed for each

fan.

3. Enter the tested airflows for each hood/fan.

4. Enter the nameplate minimum airflow for the Makeup Air Unit.

5. Enter the Makeup Air design airflow.

This results in the following:

� Maximum Exhaust/Parameter 905: 52 Hz

� Minimum Exhaust/Parameter 904: 30 Hz (the calculator will only allow a maximum of 50%

turndown from design airflow)

� Maximum Makeup Air/Parameter 905: 50 Hz

� Minimum Makeup Air/Parameter 904: 21 Hz (the calculator limits this value to a minimum of 20 Hz

to protect the motor)

� Minimum Makeup Air Speed Signal/Parameter (904): 57.7% (the change in scale of the Exhaust Fan

VFD modulation means that at 30 Hz the output from the VFD will be 5.77 volts rather than 5.0

volts)

Appendix C: Programming - Project Example, Page C-2___________________________________________

Figure C-2-1

Completed Motor Speed Calculator

Limited Warranty

Effective June 1, 2012

The Gaylord DCV Series DCV Command Center and Drive Back Board is warranted to be free from defects of material and workmanship under normal use when installed, operated and serviced in accordance with factory recommendation. The Variable Frequency Drives, if provided by Gaylord Industries, are not covered by this Limited Warranty but are covered by the manufacture of the Variable Frequency Drive under their standard warranty. The Manufacturer’s obligation under this warranty and any warranties implied by law shall be limited to repairing or replacing at its option any part of said equipment when either Gaylord Industries, or the Licensed Gaylord Manufacturer’s examination shall disclose to its satisfaction to be thus defective, for a period of one (1) year from the date of beneficial use, or eighteen months from date of shipment, whichever occurs first, provided proper and acceptable evidence of such is recorded at the factory. GAYLORD INDUSTRIES AND THE LICENSED GAYLORD MANUFACTURER SHALL NOT BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGNETICES RESULTING FROM A BREACH OF THIS WARRANTY. In the United States, the labor required to make repairs and replacements under this warranty shall be furnished by Gaylord Industries or the Licensed Gaylord Manufacturer or its authorized representative. Such labor shall only be provided Mondays through Fridays during the hours between 8 a.m. and 4 p.m. Requests for repairs or replacement parts should be made to GAYLORD INDUSTRIES, 10900 SW AVERY STREET, TUALATIN, OR 97062, USA. Outside the United States, all replacement parts furnished under this warranty shall be F.O.B. Gaylord Industries, Tualatin, Oregon U.S.A. The owner shall pay the necessary freight delivery charges, and necessary labor for removal and installation of parts, and any tariffs, duties or all taxes. Component parts not manufactured by Gaylord Industries such as electrical switches, relays, solenoid coils, etc., shall be warranted under the terms and conditions of the warranty that is published by the manufacturer of said component parts. This warranty does not cover routine maintenance and inspection of the cleaning system as spelled out in The Gaylord Ventilator Technical Manual. This warranty also does not cover malfunctions or improper operation caused by fluctuating electrical power or power surges. This is the sole warranty with respect to the aforesaid items. NEITHER GAYLORD INDUSTRIES OR THE GAYLORD LICENSED MANUFACTURER OR ANY OTHER PARTY MAKES ANY OTHER WARRANTY OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE AFORESAID OBLIGATIONS ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS AGREEMENT. Service and Warranty Policies 1. No warranty work shall be performed on the product without a Purchase Order from Gaylord

Industries, if financial reimbursement is to be requested. 2. No warranty shall be provided on equipment that has been started up and in operation for more the 90

days unless, a product maintenance schedule has been created and performed per the requirements of this technical manual.

3. Any, and all, wearable parts are not to be considered warranty items, regardless of installation date, unless previously authorized by the factory.

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