This guide provides step-by-step instructions for starting up and commissioning an RTT Air Make-Up Unit (AMU) and paint booth. It covers everything from pre-start inspections and initial power-up to booth balancing, burner setup, functional testing, operator training, and final system signoff. The guide also includes troubleshooting tips, answers to frequently asked questions, and component identification to help ensure the equipment is installed, configured, and operating safely and efficiently before being placed into service.
RTT Finishing Solutions 2975 Discovery Blvd. Rockwall,Texas 75032
OVEN START-UP The following instructions are intended for trained personnel to perform proper initial start-up operations on RTT ovens. It is not recommended that untrained personnel perform the start-up as damage to the equipment could result if steps are not properly followed. Text typed in blue indicates information to be filled in by the start-up technician. Recommend tools required for start include but are not limited to: True RMS amp meter/volt meter #2 phillips head screw driver Flash light Small precision flat head screw driver Allan wrench set Small crescent wrench Channel locks Digital manometer (0” to 10”)
RTT Job Number: __________ (located on metal mfg plate attached to main control panel door)
Start-Up Date: ________________
Start-Up Technician Name: _______________________________________________
End User Business Name: ________________________________________________
End User Contact Name: _________________________________________________
End User Contact Phone Number: __________________________________________
Fuel Type Supplied to Oven: ________________ (natural gas or propane)
Model number located on burner: ________________________
Model Number
Example
1. Ensure proper voltage and phase is present on main disconnect switch. Do not energize the disconnect if the incoming voltage is plus or minus 15% from the rated voltage on the mfg name plate.
Oven Disconnect
Check incoming voltage here
Heater Box 1 Control Panel Phase A to ground _________ Phase B to ground _________ Phase C to ground _________ Phase A to Phase B ________ Phase B to Phase C ________
Heater Box 2 Control Panel Phase A to ground _________ Phase B to ground _________ Phase C to ground _________ Phase A to Phase B ________ Phase B to Phase C ________
Phase C to Phase A ________ Phase C to Phase A ________ 2. Open all gas ball valves and ensure proper gas pressure is present on the incoming gas pressure gauge (2psi to 5psi). Ensure gas line has been purged of air before attempting ignition. Incoming gas from building (turn valve on) Incoming gas pressure gauge
Press silver button to get a reading
Gas pressure should read between: 5 P.S.I. Maximum
2 P.S.I. Minimum
Heater Box 1 Valve Train
Heater Box 2 Valve Train
Incoming Gas Pressure_______
Incoming Gas Pressure_______
3. Press red reset button on the high and low gas pressure switches mounted to the front of the gas train. It may be necessary to remove the cover and/or press the buttons a few times.
Reset
Heater Box 1 Valve Train Reset _____ Heater Box 2 Valve Train Reset _____
4. Confirm field wiring connections are tight and that exhaust motor is wired for the correct voltage (230 or 480).
Zone 1 Exhaust Fan Connections OK_____ Zone 2 Exhaust Fan Connections OK_____
5. Confirm thermocouple sensor is mounted in a location where it will receive airflow, but not in ductwork or too close to any support steel. Ensure wire type to thermocouple is type J – no other wire type is allowed to thermocouple.
Zone 1 Thermocouple properly installed and wired _____ Zone 2 Thermocouple properly installed and wired _____
6. Ensure exhaust fan damper (if equipped) is set in approximately the halfway position.
(Example Photo)
Zone 1 Damper installed and properly adjusted _____ Zone 1 Damper installed and properly adjusted _____
7. Ensure all of the H slots in the re-circulation ductwork are open at least 1.5 to 2 inches. Leaving the H slots closed can cause the burner box to overheat and shutdown the oven. This setting is simply a starting point and may need to be adjusted further to achieve even air flow and heat distribution.
(Example Photo)
All H Slots opened at least 1.5 to 2 inches _____ (Technician Initials)
8. Energize the main control panel. The Oven Temp and High Temp controllers should illuminate and display the current ambient temperature. The oven touch screen should boot up and show the home screen.
9. Refer to the oven operation manual for detailed instructions on typical operation. Typically, using batch #1 for the initial start-up is best. The temperature is pre-set to 111F and the time is set to 21 minutes. Use the Batch Setup tab to adjust the temperature and time set points.
10. Press the "Oven Start" button. The fans will begin to sequence on one at a time. Ensure each fan is rotating in the direction of the arrow that is attached to the fan housing.
Recirculation Fan Rotation
Combustion Fan Rotation
Exhaust Fan Rotation
Zone 1 Combustion Fan Rotation matches indicator sticker _____ Zone 1 Exhaust Fan Rotation matches indicator sticker _____ Zone 1 Recirculation Fan 1 Rotation matches indicator sticker ____ Zone 1 Recirculation Fan 2 Rotation matches indicator sticker ____ Zone 2 Combustion Fan Rotation matches indicator sticker _____ Zone 2 Exhaust Fan Rotation matches indicator sticker _____ Zone 2 Recirculation Fan 1 Rotation matches indicator sticker ____ Zone 2 Recirculation Fan 2 Rotation matches indicator sticker ____
11. After all fans are running in the correct direction, use amp meter to measure the amps to each motor. Note amperage below:
Zone 1 Combustion Fan Amps
Zone 2 Combustion Fan Amps
Phase A _________ Phase B _________ Phase C _________
Phase A _________ Phase B _________ Phase C _________
Measure amps on the wires leaving MR1 Contactor while the combustion fan is running correct rotation.
Zone 1 Exhaust Fan Amps
Zone 2 Exhaust Fan Amps
Phase A _________ Phase B _________ Phase C _________
Phase A _________ Phase B _________ Phase C _________
Measure amps on the wires leaving MR2 Contactor or exhaust VFD while the exhaust fan is running correct rotation.
Zone 1 Recirculation Fan 1 Amps
Zone 1 Recirculation Fan 2 Amps
Phase A _________ Phase B _________ Phase C _________
Phase A _________ Phase B _________ Phase C _________
Measure amps on the wires leaving MR3 & 4 Contactor while the Reciculation fan is running correct rotation.
Zone 2 Recirculation Fan 1 Amps
Zone 2 Recirculation Fan 2 Amps
Phase A _________ Phase B _________ Phase C _________
Phase A _________ Phase B _________ Phase C _________
Measure amps on the wires leaving MR3 & 4 Contactor while the Reciculation fan is running correct rotation.
12. After all fans are proven running, and gas pressure is within the correct range, the “Oven Purging” indicator will be shown.
13. If any faults are shown, select the “Status” tab in order to see which fault is causing the problem. To determine why the fault could be occurring, select the “Click Here For Help” button which will start a slide show of the most common items that can cause a fault.
Click help button to begin troubleshooting slide show
14. After the oven purges, the burner will attempt to ignite. An ignition indicator will display on the screen during the trial for ignition period of 15 to 30 seconds. If the burner successfully ignites, the display will read “Burner On”, and the oven will begin coming up to the temp set point. If the ignition fails, an alarm buzzer will sound - press and hold the "RESET" button until the buzzer stops. The oven will re-purge and try again.
15. After the oven ignites, closely monitor the oven and ensure that it reaches the set point temp and does not over-shoot by more than 10 degrees. While the oven is at “high fire” check the downstream gas pressure gauge to ensure it is within the proper pressure range:
NOTE: IT IS CRITICAL THAT THIS MEASUREMENT IS ONLY TAKEN WHILE THE BURNER IS AT HIGH FIRE (GAS ACTUATOR ALL THE WAY TO OPEN POSITION)
Downstream pressure gauge (Burner manifold Pressure) Press button while burner is running
at high fire to check pressure
If Natural Gas: Gas pressure should read between:
11” w.c. Maximum
10” w.c. Minimum
Zone 1 Down Stream NG Pressure ____________ Zone 2 Down Stream NG Pressure ____________
If Propane: Gas pressure should read between:
4.5” w.c. Maximum
3.5” w.c. Minimum
Zone 1 Down Stream LP Pressure ____________ Zone 2 Down Stream LP Pressure ____________
IF GAS PRESSURE IS OUT OF RANGE, CONSULT FACTORY FOR ADJUSTMENT INSTRUCTIONS
16. To shut down the oven: Press the oven stop button. The burner will shut down however the fans will continue to run until the oven cools to the “safe shutdown temperature set point” (usually around 160F). Once the temp falls below the safe shutdown set point, the fans will turn off. The touchscreen will display a prompt to alert the operator of the safe shutdown procedure. NEVER USE THE E-STOP TO SHUT THE OVEN DOWN UNLESS IT IS AN EMERGENCY OR IF THE TOUCHSCREEN IS DAMAGED AND NOT RESPONDING. DAMAGE TO THE FANS WILL RESULT. IF THE FANS STOP WHEN THE OVEN IS HOT (POWER FAILURE), EITHER RE-START THE FANS, OR OPEN THE DOORS TO ALLOW THE OVEN TO QUICKLY COOL. Detailed Sequence of Operation
“Oven Start” button is pressed. Exhaust fan(s) energizes then 4 seconds later the recirculation fan(s) energizes. If fans are running in correct rotation with no issues, proving switches will close.
Control panel checks gas valve train for proper pressure. If pressure is within range, and all air proving switches are made, purge timer begins.
After purge timer expires, and “Burner Enable” toggle switch is set to on position, control panel sends call for heat command to flame controller.
Flame controller confirms gas pressure is correct, blocking valve proof of closure is made, no flame is present, and combustion air is not made.
After all safety checks are complete, flame controller energizes combustion fan(s) and checks the combustion fan air proving switch.
After combustion air proving switch makes, the flame controller energizes the burner igniter.
After the burner igniter is on for approximately 3 seconds, the flame controller energizes the main gas valves.
Gas flows through the blocking valves and through the butterfly valve to the burner where it meets the igniter and air which allow a flame to propagate across the burner.
After approximately 10 seconds, the flame controller turns off the igniter then checks the signal from the UV scanner. If the signal is within range, the flame controller sends the “Burner On” signal to the PLC. After the PLC receives the burner on signal, it allows the gas actuator to modulate based on the signal from the oven temperature controller. At this time, the oven will begin to come up to the temperature set point displayed on the touch screen.
After the oven reaches the temperature set point, the batch timer (if enabled) will begin counting down. After the batch timer expires, the oven will either remain at set point, move to a new temperature set point, or automatically perform safe shutdown procedure. Safe shutdown procedure – when the operator presses the stop button, or the batch timer expires on auto shutdown mode, the burner will turn off and the fans will remain running until the oven temperature falls below the safe shutdown temperature set point (usually about 160F). After the temperature falls below the safe shutdown set point, the fans will turn off and the control panel will wait for further instruction.
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