Britannia Refresh Mini User manual

Refresh Mini, Midi & Maxi
and
Refresh Ultima
Installation, Operation and
Maintenance Manual
Document No. F054
Issue: Final

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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DISCLAIMER
Whilst every care is taken in ensuring the information contained herein is accurate, no responsibility implied,
or otherwise, is accepted for loss or damage incurred due to this information. It is the responsibility of the
reader to ensure the method used is suitable in accordance with relevant health & safety legislation for his
particular application and he should satisfy himself by conducting risk assessments and method statements
before proceeding with a trial or sample component.
The information in this publication may not be regarded as a guarantee for the proprieties of materials or
products dealt with or of their processing.
Copyright
© Britannia Kitchen Ventilation Ltd 2014. All rights reserved.
Any redistribution or reproduction of this manual, in part or entirely in any form is strictly prohibited.
Revision History
Revision No. Section(s) Revised Revision Date By Whom
Draft All 28th January 2014 AST
Final All 26th March 2014 AST
Britannia Kitchen Ventilation Ltd.
10Highdown Road
Sydenham Ind. Estate
Leamington Spa
Warwickshire
CV31 1XT
England
Phone [phone]
Fax [phone]
Email sales@kitchen ventilation.co.uk
Web www.kitchen-ventilation.co.uk
Registered in England 3062962
Registered office Whisby Road, Lincoln, LN6 3QZ

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Contents
1. Overview 5
1.1 Refresh Mini, Midi & Maxi Units 6
1.2 Refresh Ultima Unit 7
1.2.1 Glossary of Terms 9
1.3 System Overview 10
1.3.1 Functional Description 10
2. Assembly, Installation and Commissioning 17
2.1 Introduction 17
2.1.1 Risk Assessment 17
2.1.2 Access and Offloading 17
2.1.3 Warnings and Cautions 17
2.1.4 Receipt 17
2.1.5 Storage and Preservation 18
2.2 Assembly 18
2.2.1 Preparation for Unpacking 18
2.2.2 Unpacking Procedures 18
2.2.3 Preparation for Assembly 18
2.2.4 Refresh Mini, Midi & Maxi Assembly Procedures 19
2.2.5 Refresh Ultima Assembly Procedures 19
2.3 Installation 20
2.3.1 Preparation for Installation 20
2.3.2 Refresh Mini, Midi & Maxi Assembly Procedures 22
2.3.3 Refresh Ultima Installation Procedures 23
2.4 Commissioning 25
2.4.1 Pre-commissioning Procedures 25
2.4.2 Commissioning Procedures 25
2.4.3 Post Commissioning Procedures 26
3. Operation 27
3.1 Introduction 27
3.1.1 Warnings and Cautions 27
3.1.2 Operation Overview 27
3.2 Operating Procedures 28
3.2.1 Starting-up 28
3.2.2 Increasing the Speed of the Fans 28
3.2.3 Decreasing the Speed of the Fans 29
3.2.4 Muting an Active Alarm 29
3.2.5 Accessing the Information Screens 29
3.2.6 Accessing the “Configuration” Screen from the “Date/Time” Screen 29
3.2.7 Filter Status Screen 29
3.2.8 Shutting-down 30
3.3 Resetting the Filter Operational Hours 31
4. Maintenance 33
4.1 Introduction 33
4.1.1 Warnings and Cautions 33
4.1.2 Equipment, Tools, Consumables and PPE 34
4.2 Preventive Maintenance 35
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4.2.1 Preventive Maintenance Overview 35
4.2.2 Preventive Maintenance Schedule 35
4.2.3 Preventive Maintenance Procedures 37
4.3 Fault Finding 44
4.3.1 Fault Finding Procedures 44
4.4 Corrective Maintenance 46
4.4.1 Maintenance Policy 46
4.4.2 Removal Procedures (Refresh Mini, Midi & Maxi) 46
4.4.3 Removal Procedures (Refresh Ultima) 50
4.4.4 Replacement Procedures (Refresh Mini, Midi & Maxi) 55
4.4.5 Replacement Procedures (Refresh Ultima) 60
4.4.6 Maintenance Checks and Visual Inspections 64
4.5 Spares 68
4.5.1 Spares Tables 68
4.5.2 Ordering Information 69
4.6 GA Diagrams 70
4.6.1 Refresh Mini, Midi & Maxi 70
4.6.2 Refresh Ultima 70
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1. Overview
This installation, operation and maintenance manual covers:
Refresh Mini
Refresh Midi
Refresh Maxi
Refresh Ultima
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1.1 Refresh Mini, Midi & Maxi Units
The Refresh Mini, Midi & Maxi units are similar in construction and filtration design as the Refresh
Ultima unit. The Mini, Midi & Maxi units vary in width and therefore the number of filters installed to
allow further items of equipment to be installed.
The following graphic provides a detailed overview of the unit. The Refresh ‘Midi’ is shown below
as a ‘typical’ unit:
Overview of Refresh Midi Unit (Mini & Maxi are similar)
Power Lead Fan Ramp-Up Control Knob on Access Panel
3 Sided Fan Enclosure
and Mounting Frame
with Plug and Socket
for Fan Control Wiring
Removable
Rear Panel
Fan Mounted on
Slide-out Fan Plate
HEPA Filters
Stainless Steel Baffle
Type Grease Filters
G4 Filters
Carbon Filters
Grease Collection
Drawer
Wet Chemical Fire
Suppression
(optional equipment)
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1.2 Refresh Ultima Unit
The following graphic provides a detailed overview of the unit:
Overview of Overview of Refresh Ultima Unit
Canopy
Double
Skinned
Support Leg
Stage 1
Baffle Filters Hinged access door to
filter stages
Four trolley wheels for
manoeuvring
Hinged access doors
to filter stages
Two adjustable feet for
stability
Services Tower
Hinged access door to
fan motor and controls
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Plug for connecting
the Services Tower
to electrical power
supply View of Stage 2
filters behind hinged
access door
View of Stage 5
filters behind hinged
access door
View of Stage 3 & 4
filters behind hinged
access door
Fan motor and
controls behind
hinged access door
Overview of Refresh Ultima Unit Services Tower
Refresh Control
Panel mounted to
the front of the
Services Tower
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1.2.1 Glossary of Terms
This section provides a glossary of terms used in the manual.
Term Definition
Refresh Unit Product name given to a range of stainless steel kitchen canopies
Refresh Control Panel Product name for the twin function intelligent controls package to
control the fan speed via operator buttons and to monitor the life-
time of each filtration stage
Fan A backward curved centrifugal fan housed in the Services Tower
to draw grease laden air through the filter stages
Canopy A rigid, self-supporting stainless steel structure which acts as a
point of extraction for grease laden kitchen air
Baffle Filter A high efficiency filter for removing entrained grease and moisture
from extract air
Grease Drainage Hole Allows drainage of entrained grease droplets and moisture which
fall from the grease filters
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1.3 System Overview
1.3.1 Functional Description
When cooking, hot, humid and grease laden air is extracted by the unit.
1.3.1.1 Refresh Mini, Midi & Maxi
A backward curved centrifugal fan, mounted on a slide-out fan plate at the top of the unit, draws
contaminated grease laden air from cooking appliances through four stages of filtration.
Note: The Refresh Maxi has 2 no fans installed.
The four stages of filtration are:
Stage 1: High efficiency Britstream baffle-type grease filter unit mounted in front of the stage 2
filters
Stage 2: G4 pleated filter panels mounted behind the baffle-type grease filters
Stage 3: HEPA filter panels
Stage 4: Carbon filters; loose granule, re-fillable to reduce odours
Refer to the following process flow which describes the four stages of filtration:
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1.3.1.2 Refresh Ultima
A backward curved centrifugal fan (housed in the Services Tower) draws contaminated grease
laden air from cooking appliances through five stages of filtration.
The five stages of filtration are:
Stage 1: High efficiency Britstream baffle-type grease filters mounted at the front of the
canopy
Stage 2: G4 filter pad, mounted horizontally within the rear section of the Services Tower
Stage 3: F6 filter panels mounted horizontally below the mesh panel, above stage 4 filters
Stage 4: HEPA H10 filter panels mounted horizontally below the stage 3 filters
Stage 5: Carbon filters; loose granule, re-fillable to reduce odours
Refresh Ultima Services Tower Showing the Location of Filter Stages 2 to 5
Stage 2 filters mounted
in pull out drawer
Stage 5 filters fitted
behind removable
panel
Stage 3 and Stage 4 filters
fitted behind removable
panel
Fan motor fitted behind
hinged, locked door
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Refer to the following process flow which describes the five stages of filtration:
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Grease Drainage Hole: Collected grease and moisture drains down and into the grease drainage
hole. Refer to the picture below.
Note: The slot head drain screw has been removed for clarity.
Grease Drainage Hole
Supply Air Diffuser: The fixed supply air diffuser allows filtered air to be reintroduced back into
the kitchen space. Refer to the picture below.
Perforated Diffuser Panel
LED Spot Lights: LED spot lights are fitted to the inside surface of the canopy. Refer to the picture
below:
LED Spot Lights
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1.3.1.3 Refresh Control Panel (Refresh Ultima)
The Refresh Ultima comes complete with a control panel fitted. The control panel is mounted at the
front of the Services Tower.
Refresh Control Panel
This controls package has two functions:
1. To control the fan speed via operator buttons. The motor speed is controlled via inverter drive.
2. To monitor the life-time of each of the 4 main stages of disposable filter media types.
1.3.1.4 Filter Reset Panel (Refresh Ultima)
The filter reset panel allows the operator to set the lifecycle of the filter. The filter reset panel is
mounted behind the Refresh Control panel inside the Services Tower.
Filter Reset Panel
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1.3.1.4.1 Equipment Technical Summary
Note: The following technical summary refers to the Refresh Ultima only.
Down light size, type and wattage:
Lamp Diameter
(mm) Voltage (V) Lamp Wattage (W) Ingress Protection (IP) Rating
87mm Ø 240 9 65
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2. Assembly, Installation and Commissioning
2.1 Introduction
This section refers to all Refresh units.
2.1.1 Risk Assessment
A full risk assessment must be carried out before assembly and installation work commences on
site. The risk assessment should identify all Personal Protective Equipment (PPE) requirements.
This should be undertaken prior to the installation team arriving. Consideration should also be
given to drafting a full method statement for the process.
2.1.2 Access and Offloading
A safe access route must be established into the area in which the Refresh Unit will be installed.
This area is to be free from obstruction
A suitable offloading point must be identified before you begin to unload and it should be as close
to the installation area as possible
2.1.3 Warnings and Cautions
WARNING:
DO NOT INSTALL THIS EQUIPMENT FOR THE VENTILATION OF GAS, OIL OR SOLID
FUELLED EQUIPMENT. RISK TO THE HEALTH OF OPERATIVES CAUSED BY THE ACTUAL
COMBUSTION PROCESS WHICH USES UP AVAILABLE OXYGEN FROM THE COOKING
SPACE AND CREATES TOXIC CARBON BASED GAS EMISSIONS. ONLY ELECTRICALLY
POWERED EQUIPMENT MUST EVER BE VENTILATED BY THIS TYPE OF SYSTEM
WARNING:
COMPETANT PERSONNEL FAMILIAR WITH THE ASSESSMENT OF HAZARDS AND RISKS
ASSOCIATED WITH INDUSTRIAL ELECTRICAL AND VENTILATION EQUIPMENT SUCH AS
FANS AND AIR HANDLING UNITS SHOULD INSTALL THE PRODUCT.
WARNING:
USE LIFTING EQUIPMENT WHICH HAS A SUITABLE SAFE WORKING LOAD FOR THE
EQUIPMENT BEING LIFTED.
WARNING:
ENSURE STEPS, PODIUM STEPS, SCISSOR LIFT OR MOBILE SCAFFOLD TOWER ARE
SECURE AND STABLE BEFORE USE.
WARNING:
MAKE SURE THE CANOPY IS FULLY SECURED BEFORE REMOVING THE SUPPORT
STANDS
Caution:
Supplied packaging provides protection against scratches and scrapes only
2.1.4 Receipt
Step 1: Check the package is complete to the delivery note and that there are no missing
items.
Step 2: Check the package is undamaged.
Step 3: Where items will not be unpacked straight away, check:
Step a) The shrink-wrap is complete and plastic banding is secure.
Step b) There are no edges protruding which can become damaged or cause injury.
Where edges are exposed, cover using suitable protection.
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2.1.5 Storage and Preservation
2.1.5.1 Storage Caution:
Supplied packaging provides protection against scratches and scrapes only.
Items must not be stored in high traffic areas. No impact protection is provided.
2.1.5.2 Preservation
Items must be stored in dry conditions.
2.2 Assembly
2.2.1 Preparation for Unpacking
Step 1: Ensure you place items to be unpacked as near as possible to the site of installation.
Step 2: Ensure you have sufficient free space to work.
2.2.2 Unpacking Procedures
Step 1: Using a suitable tool, remove the plastic banding around the item
Step 2: Remove all packaging as necessary.
2.2.3 Preparation for Assembly
2.2.3.1 Personnel
Skilled site engineers
Senior site installation engineers (site Foreman).
2.2.3.2 Personal Protective Equipment (PPE)
The need for PPE must be identified once a full risk assessment has been carried out. Refer to
Section 2.1.1 Risk Assessment.
Below is a list of PPE that must be worn when assembling BKV equipment:
Safety footwear with steel mid-sole, steel toe caps, padded ankle protection and high grip
soles.
High visibility vest
Kevlar gloves
Carpenter gloves
Safety spectacles
Safety goggles.
Tools Required:
Suitable and approved lifting equipment
Adjustable support stands
Spirit level
Suitable hand tools]
Suitable spanner to tighten M10 fixings.
Drawings:
Refer to
Section 4.6 GA Diagrams for reference.
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2.2.4 Refresh Mini, Midi & Maxi Assembly Procedures
The following procedures cover only the Refresh Midi, Maxi and Ultima units as these units require
assembly. The refresh Mini is supplied a one-piece unit.
Step 1: Prepare a clear & level area around the proposed installation area in accordance with
the drawings with approximately 1 metre clearance all-round the unit for access.
Note: The unit must be installed on a level surface.
Step 2: Install the bottom unit in the proposed installation area.
Step 3: Using the spirit level, make sure the bottom unit is level. Adjust the feet accordingly as
necessary and then recheck the level.
Step 4: Using safe and suitable methods lift and then position the first half of the unit on top of
the base and lock into position.
Step 5: Assemble the filters and cover panels to the unit as necessary.
2.2.5 Refresh Ultima Assembly Procedures
Services Tower:
Step 1: Prepare a clear & level area around the proposed installation area in accordance with
the drawings with approximately 1 metre clearance all-round the unit for access.
Step 2: Safely locate the base of the refresh unit at the correct location and in accordance with
the drawings.
WARNING:
USE LIFTING EQUIPMENT WHICH HAS A SUITABLE SAFE WORKING LOAD FOR
THE EQUIPMENT BEING LIFTED.
Step 3: Using the lifting equipment], lift the first half of the Services Tower unit on top of the
base and lock into position.
Step 4: Slide the second half of the Service Tower unit into position next to the first half
ensuring it is flush.
Step 5: Using the M10 fixings, bolt the two sections of the Service Tower together.
Step 6: Using the spanner, tighten the M10 fixings to secure the two sections.
Canopy: WARNING:
USE LIFTING EQUIPMENT WHICH HAS A SUITABLE SAFE WORKING LOAD FOR THE
EQUIPMENT BEING LIFTED.
Step 1: Using the lifting equipment and height adjustable stands, assembly the canopy on a
level surface.
Step 2: Place the spirit level on the outer edge of the upper valance to level each section.
Step 3: Assemble the unit from its component parts.
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2.3 Installation
2.3.1 Preparation for Installation
WARNING:
DO NOT INSTALL THIS EQUIPMENT FOR THE VENTILATION OF GAS, OIL OR SOLID
FUELLED EQUIPMENT. RISK TO THE HEALTH OF OPERATIVES CAUSED BY THE ACTUAL
COMBUSTION PROCESS WHICH USES UP AVAILABLE OXYGEN FROM THE COOKING
SPACE AND CREATES TOXIC CARBON BASED GAS EMISSIONS. ONLY ELECTRICALLY
POWERED EQUIPMENT MUST EVER BE VENTILATED BY THIS TYPE OF SYSTEM
You must have the following completed documentation before installation of this equipment:
Site installation form
Manufacture and location drawings
Site survey form
Onsite inspection form
Risk assessments
Suitable Method Statements.
2.3.1.1 Personnel
Skilled site engineers
Senior site installation engineers (site Foreman).
2.3.1.2 Personal Protective Equipment (PPE)
The need for PPE must be identified once a full risk assessment has been carried out. Refer to
Section 2.1.1 Risk Assessment.
Below is a list of PPE that must be worn when installing BKV equipment:
Site safety hard hat
Safety footwear with steel mid-sole, steel toe caps, padded ankle protection and high grip
soles.
High visibility vest
High visibility coat
Kevlar gloves
Carpenter gloves
Safety spectacles
Safety goggles
Vented dust masks
Ear Defenders.
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