Oven Assembly by RTT

This section provides installation guidelines for RTT Finishing Solutions ovens, outlining the typical installation process, including equipment placement, utility connections, and any required on-site assembly. It also explains the role of RTT Finishing Solutions in providing installation supervision, emphasizes that installation should only be performed by qualified personnel, and highlights the importance of following proper installation practices to ensure safe and reliable operation.

OVEN ASSEMBLY MANUAL

RTT Finishing Solutions 2975 Discovery Blvd, Rockwall, TX 75032 www.rttsolutions.com 888-452-6684

INDEX

Page

Tools Required

Trim Details

5-6

General Notes

7-11

Section A.

Floor Assembly

12-15

Section B.

Wall Assembly

16-19

Section C.

Door Header & Side Wall Face Channel

20-28

Section D.

Roof Assembly

29-30

Section E.

Flashing – Wall & Roof (Interior & Exterior)

31-35

Section F.

Flashing – Openings

36-37

Section G.

Heater Box Installation - Floor Mounted

38-41

Section H.

Heater Box Installation - Top Mounted (Floor Mount not

42-46

Required)

Section I.

Installation of Duct Work

47-50

Section J.

Installation of Door Opening Support Channel

51-52

Section K.

Installation of Doors

53-54

Section L.

Installation of Door Seals

55-58

Section M.

Installation of Latches & Handles

59-61

Section N.

Installation of Exhaust Fan & Fan Damper

62-66

Section O.

Installation of Screen Over Return Air Opening

67-68

Section P.

Control Panel

69-85

Section Q

Safety Instructions

85-87

Section R

Startup Instructions

88-90

Section S

Operating Instructions

91-92

Section T

Maintenance Instructions

93-94

Section U

OSHA Heat Safety

95-98

Section V

Drawings and Electrical Schematic

TOOLS REQUIRED

1. Welding machine

2. Saw for cutting flashing, floor channel and 2” angle interior trim

3. Screw gun

4. Caulk gun

5. Large knife (for cutting filter insulation)

6. Chalk line

7. 4’ level

8. Tape Measure

9. Hammer drill with bit for 3/8” floor anchors and 3/8” floor anchors (used for

ovens without floors)

10. Clamps

11. Come-a-long

12. Drill

General Notes

Introduction

All Col-Met Spray Booths, Inc. ovens are thoroughly tested during the assembly process. Most installations are therefore relatively simple. Installation typically includes unloading the oven, moving the oven to the desired installation site, attaching gas and electric service, and attaching the exhaust stack. Some installations require the burner box to be installed at the jobsite. Larger ovens may require some mechanical assembly at the jobsite. Col-Met Spray Booths, Inc. does not normally provide installation services. However, supervision services for any or all parts of the installation process are available from Col-Met Spray Booths, Inc. Only qualified personnel should perform the installation. Specifically, qualified personnel typically include equipment riggers, electricians, mechanical contractors and properly trained end user personnel.

Unloading, Handling and Placement

2.1

Unloading and Moving the Oven

Smaller ovens are normally shipped by motor freight. They can usually be unloaded by forklift. Larger ovens are shipped with special carriers. They are typically wrapped in plastic and/or covered with tarps. Larger ovens can be unloaded by lift truck. A spreader bar must be used when lifting burner boxes from overhead. Anytime a lift truck is used in handling an oven, the forks should enter from the sides of the oven and go under the oven frame. Larger ovens that require unloading by lift truck may require two or more trucks. Special care should be taken in using lift trucks to unload ovens. Handling the oven on the floor often includes means such as shuffling pipes, material handling carts, special equipment or dragging. Qualified equipment riggers are all familiar with these methods. All material handling carts and equipment should support the oven frame. Do not place handling carts under the middle of the oven unless the frame is also supported. If the oven has a removable overhead burner box, overhead hoists are necessary for reassembly.

2.2

Oven Location

The oven should be located at or above grade on a level, non-combustible floor. Adequate space should be provided above the oven and on all sides to permit routine maintenance and inspection. A minimum of three feet clearance must be maintained between the oven and any combustible walls or ceiling. The explosion proof relief doors and hatches cannot be obstructed. Per NFPA 86 and OSHA 1910.107 (2), no open flame or spark-producing equipment shall be located in any area where volatiles are sprayed or within 20 feet of such a spray area, unless separated by a partition. This would also include mixing areas, paint storage areas or any flammable materials.

2.3

Leveling the Oven and Proper Door Operation

It is common when installing the oven for the doors to appear to be hinged improperly. It is especially deceiving when an oven has doors on both ends. The oven must be level for proper door operation. If it is not level, place a shim under one corner of the oven frame. If the leveling improves with the shim, continue adding shims until the doors are level. Shims may be required on more than one door for those ovens with doors on both ends. See Section K for more information on leveling the doors.

2.4

Removing Shipping Supports

Occasionally, temporary supports are built into the oven frame to provide reinforcement during shipping and handling if the oven is shipped assembled. Specifically, ovens with steel plate floors or those ovens without any floors usually have angle iron supports across the bottom of the doorways. After the oven has been located at the place of final installation, these supports should be cut out.

2.5

Securing the Oven

Shipping brackets and floor mounts are attached to the sides of the oven at the base of the frame if the oven is shipped assembled. After the oven has been properly located and leveled, it should be anchored to the floor. If the oven has a steel plate floor, it may be desirable to secure the oven floor to the plant floor. A steel plate floor tends to buckle in ovens of larger sizes and higher operating temperatures. Holes in the steel plate floor can be made by drilling or torch-cutting.

Special Requirements

Most ovens are tested at Col-Met Spray Booths, Inc. prior to shipping. However, for shipping and handling purposes some ovens require final assembly at installation. Height restrictions in shipping and handling sometimes require that burner boxes be built removable and the oven cabin be shipped knocked-down flat. Width and depth restrictions s ometimes require that the oven be built in sections. Occasionally, at the customer’s request, the control panel might be built for remote installation. In these cases, the reassembly requirements are minimal. Each of these scenarios are discussed in detail below. Col-Met Spray Booths, Inc. supervision is available for any or all parts of the installation.

1.1 Burner Box

1. The burner box houses the recirculation fans and the burner. The fan motors and air seals are also generally attached. If the oven has the burner box removed from the oven then the following steps are required for reassembly: Pick up the burner box using overhead means. See Section H for more detailed instructions.

2. Verify that the turning vanes for the fans are secured to the blower housings at the bottom of the burner box.

3. Make sure the gasket tape is in place on top of the oven inside the burner box frame.

2. Place the burner box within the frame on the top of the oven. There is a junction box with a terminal strip in it on the burner box. A wire must be run from this terminal strip to the oven control panel. This wire must be enclosed in conduit. Normally, there are three runs of conduit required for a given oven - – one for the motor leads, one for the thermocouples and flame rod, and one for the control wiring.

Weld the burner box to the frame on top of the oven.

4. Connect the wires from the terminal strip box on the burner box to the terminal strip box on the top of the oven. All of the wires are numbered for easy reconnection.

5. On larger ovens, belt guards are shipped separately. Attach the belt guards using the included sheet metal screws.

On the inside of the oven, the top air supply and return plenums should be secured to the sheet metal housing inside the burner box by sheet metal screws.

3.2

Exhaust Fan

The exhaust fan assembly includes the exhaust blower, motor and air seal. If the exhaust fan has been removed from the oven, the following steps are required for reassembly:

Pick up the exhaust fan assembly using a forklift or overhead means.

2. Attach the exhaust kit to the top of the oven using the attached bolts and sheet metal screws. The exhaust kit is located over the large diameter hold in the top of the oven and the orientation will be obvious with the bolt and screw hold patterns.

Reattach the electric wires from the kit to the adjacent junction box.

Reconnect any air tubes that have been disconnected.

3.3

Remote Control Panel

Because of installation or handling limitations, a remote control panel is sometimes necessary. The remote control panel generally includes all controls that the operator must use on a daily basis, such as any temperature controls, start/stop switches, batch timer. The main control panel will contain the motor starters, the flame safety and the electrical service disconnect.

If the oven has a remotely mounted control panel, then the following steps are required for installation:

Mount the control panel and electric disconnect at the desired location.

2. Make three separate runs of conduit as discussed in Section 3.1, paragraph 4 above. Hole-outs have been excluded to let your installing electrician choose where to come into the boxes. The electrical terminal strips require one conduit run for the higher voltage motors and a second run for the lower voltage control circuit wiring. The thermocouple terminal strips require their own conduit run. The control voltage is 120 V AC/1  /60Hz. The thermocouple wires should be “J - type” (two -conductor or four-conductor). These require a wire to be run from the remote control panel to the main control panel. The polarity of the thermocouples should be matched (white – positive and red – negative). A qualified electrician should size the wiring and conduit accordingly.

Connecting Utilities

Installation of the oven requires the connection of utilities. All ovens require electric service for powering the motors and controlling the oven. All gas ovens require the connection of gas service. Almost all ovens require the connection of an exhaust stack. Ovens with a dry chemical fire suppression system require that the end user contact a local fire control specialist for fire control system activation.

4.1 Electric Service

An electric disconnect for the oven has been attached to the control panel. The service line supplying the power to the oven should also be equipped with a disconnecting device with interrupting capability to clear the maximum fault current capacity of the immediate power supply system. A qualified electrician should attach the appropriate power to the disconnect.

1. All electrical installations should be in accordance with the National Electric Code.

Connect a ground wire from the grounding lug to a known ground.

3. Connect the appropriate electric service to the disconnect on the control panel. The wire should be sized per the amperage rating of the circuit breaker and the National Electric Code.

Control voltage provisions are not necessary. They have been addressed by a factory-mounted transformer located inside the control panel.

4.2

Gas Service

In order to operate properly, the oven requires a specific inlet gas pressure. Col-Met Spray Booths, Inc. ovens are designed to operate on a gas supply pressure of 5 PSI. Do not exceed this gas pressure. An additional positive shut-off regulator located prior to the oven gas train is typically required to provide the appropriate gas pressure. A qualified mechanical contractor should be able to size the gas lines and regulators accordingly. See the following note if you will be using propane gas:

NOTE: PROPANE GAS OVENS

If it was not specified at purchase that your installation would be serviced by propane gas, then some modifications to your oven will be necessary. Call Col-Met Spray Booths, Inc. for instructions. If propane gas service was specified at purchase then no special provisions are required. You should follow the instructions above.

4.3 Exhaust Stack Installation

Any oven that is fueled by gas and any oven that is used to process a product that contains flammable volatiles or combustible material must include a powered exhaust fan. Exhaust stack is not normally provided with the oven. You must contact a local mechanical contractor or supplier for the appropriate ductwork.

4.3.1 Exhaust Stack Type

The type of stack required varies with exhaust temperature and the mechanical specifications of the building in which it is installed. Consult your local building and equipment authority for the relevant building code. In order to meet NFPA Standard 211 for Chimneys, Vents and Solid Fuel Burning Appliances a positive pressure stack rated for the applicable temperature is required.

4.3.2 Stack Termination (NFPA 211 – Section 4)

A metal chimney for an oven operating up to 500  F should extend at least three feet above the highest point where it passes through the roof and at least two feet above any portion of the building within ten feet laterally. For those ovens operating at temperatures greater than 500  F but less than 900  F, the chimney should extend at least ten feet above the highest point where it passes through the roof and at least ten feet above any portion of the building within 25 feet laterally.

4.3.3 Stack Clearances (NFPA 211 – Section 4)

A metal chimney should have a clearance of not less than 24” from any wooden construction or combustible material. A metal chimney shall have a clearance not less then 2” from any non -combustible structure. A metal chimney erected on the outside of a building shall not be installed any closer than 24” to any door, window or walkway. Consult NFPA 211, Section 4 for details on installation of a chimney through any story of a building or a combustible roof.

4.3.4 General Requirements

The oven’s rated CFM was calculated using 20 -foot tall, straight vertical exhaust stacks with no bends or turns. Any bends or turns in the exhaust stack may restrict the exhaust, causing a reduction in the maximum gallons of solvent that the oven can safely handle. If it is not practical to run the exhaust in this manner, a pressure drop analysis can be performed on your exhaust ducting by the engineering staff of Col-Met Spray Booths, Inc.

Section A

Floor Assembly

Step 1.

Floor Assembly W ith ¼” Floor Plate (optional).

(A)

Lay two sections of the floor plate down.

(B)

Square corner to corner and weld together.

Weld 2” long

approximately 10” apart. Continue until ba se is completely together per

dimensions on your set of drawings (see Dwg 1-B).

Note : Standard ovens DO NOT have ¼” floor. Step (A) is not required.

Step 2.

Floor Channel (All Dimensions Are On Customer Set of Drawings)

(A) Take chalk line and layout lines for O.D. (outside dimensions) & I.D.

(inside dimensions) of oven side walls and one end wall if oven is single

entry. If oven is double entry you only need side walls.

(B) Cut if necessary T-4 channel, lay between lines and attach channel the

full length of the oven. If it is a single entry you must 45 one end of each side

wall floor channel and both sides of end wall floor channel (see Dwg. 3-B).

no floor, you must drill holes in bottom of channel for anchor bolts. Anchor

with 3/8” floor anchors (not supplied) approximately 12” from each end and

then ever 6 ft. If heater box is floor mounted, you must cut T-4 or T-6 so you

leave an opening for it. You get opening width and location from customer

drawing (see Dwg. 3-C).

Section B

Wall Assembly

Step 4.

Installation of Walls.

(A) Fill male side of oven panel with 1 ½” x 4” strip insulation and pu t

approximately ¼” to ⅜” bead of oven cement on female side of panel (Dwg.

4-A).

(B) Start installation with first panel (see panel layout for panel number) at

door opening (see dwg. on placement of 1 st panel).

Screws in bottom end of panel. This should hold panel in place. Put all Tek

Screws in bottom of panels as you go.

(D) Most panels are standard 26” repeat. You should mark floor channel

for both walls because when you install your panels you may get some tighter

together than others. With base channel marked 26”, you will keep both walls

together and the same length. All panels must have strip insulation and oven

cement bead. Cement bead always goes to inside of oven.

Section B

Wall Assembly

Step 4.

Installation of Walls.

(A) Fill male side of oven panel with 1 ½” x 4” strip insulation and pu t

approximately ¼” to ⅜” bead of oven cement on female side of panel (Dwg.

4-A).

(B) Start installation with first panel (see panel layout for panel number) at

door opening (see dwg. on placement of 1 st panel).

Screws in bottom end of panel. This should hold panel in place. Put all Tek

Screws in bottom of panels as you go.

(D) Most panels are standard 26” repeat. You should mark floor channel

for both walls because when you install your panels you may get some tighter

together than others. With base channel marked 26”, you will keep both walls

together and the same length. All panels must have strip insulation and oven

cement bead. Cement bead always goes to inside of oven.

Step 5.

Installation of Top Angle for Roof. (Item T-7)

(A) The inside height of the oven should be determined by the height of

the wall panels. All T-7 angles come in 10 ft. lengths. If the oven length is

longer than 10 ft., you need to add whatever length is needed. You must

keep angle the same from the floor to the top of the angle all the way down

complete length of oven installing Tek Screws as you go (see Dwg. 5-A).

(B) When you install top angle across back of oven, you must notch and

weld end to top angle of side walls.

Step 5.

Installation of Top Angle for Roof. (Item T-7)

(A) The inside height of the oven should be determined by the height of

the wall panels. All T-7 angles come in 10 ft. lengths. If the oven length is

longer than 10 ft., you need to add whatever length is needed. You must

keep angle the same from the floor to the top of the angle all the way down

complete length of oven installing Tek Screws as you go (see Dwg. 5-A).

(B) When you install top angle across back of oven, you must notch and

weld end to top angle of side walls.

Section C

Door Header and Side Wall Face Channel

Step 6.

Installation of Side Wall Face Channel and Door Header.

(A) You will have two (for single entry oven) and four (for double entry

oven) C4 x 5.4 channels wit h ¼” holes 12” apart (see customer prints for item

number).

(B) Install these by forcing them over the male end of the side wall panel.

Make sure top and bottom of channels are flat against panel (see drawing).

Put 4 ft. level on face of channel to insure face of the oven is plumb. If both

sides are not plumb, the doors will not seal properly. Install all Tek Screws

(Dwg 6-B).

face channel for door header. Place door header on mark.

The ¼” end

plates on the door header should be flush with outside of the face channel.

Tack door header in place (see Dwg 6-C) ( do not weld solid until door

opening is squared, after step 6-F).

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(D) Use tape measure and check to make sure the top and bottom

measurements are the same (outside of face channel).

(E) Measure from corner to corner to insure opening is square (see Dwg.

6-E).

(F) After all openings are square, tack a brace to hold in place (Dwg. 6-F).

Use a piece of T-7 angle for this. Weld door header solid at top in both ends,

and to floor channel on both sides at bottom. If the ¼” floor is used, weld

across front of face channel at bottom. With double entry oven this step must

be done on both ends.

Step 7.

Installation of Header Panel.

(A) Insulation needs to be placed in male side of header panel (see

customer panel layout for number).

(B) Force header panel down into header channel and install all Tek

Screws (see Dwg. 7-B).

T-7 mounted on side walls. Install Tek Screws and weld both ends (see Dwg.

7-C).

Note: A bead of oven cement needs to be placed on T-7 before installing

Tek Screws.

Step 7.

Installation of Header Panel.

(A) Insulation needs to be placed in male side of header panel (see

customer panel layout for number).

(B) Force header panel down into header channel and install all Tek

Screws (see Dwg. 7-B).

T-7 mounted on side walls. Install Tek Screws and weld both ends (see Dwg.

7-C).

Note: A bead of oven cement needs to be placed on T-7 before installing

Tek Screws.

Section D

Roof Assembly

Step 8.

Installation of Roof Panels.

(A) Put a bead of oven cement on all T-7 angles before you start to install

panels.

(B) Put insulation and oven cement on 1 st panel that attaches to header

panel (see customer drawing for the panel layout). Every panel must have

strip of insulation and bead of oven cement before they are installed (see

Dwg. 8-B).

customer drawings.

(D) Install two panels and measure on each side to maintain the same

measurements side to side. It is possible to get one side pushed in more

than the other, and they will not come out correct at the end. Install Tek

Screws in each panel after making sure both sides are even. Put Tek Screws

in each panel as they are installed.

Section E

Flashing – Wall & Roof (Interior & Exterior )

Step 9.

Installation of Interior and Exterior Flashing.

(A) The ovens that have an opening on one end only needs T-7 angle in

back two corners. Get measurement between top (T-7) angle and bottom (T-4

or T-6) at back. Cut two T-7 angles, apply oven cement to both legs of angle

(Dwg. 9-A), and tek screw in corners. After Tek Screws have been installed,

weld top and bottom of angles.

(B) Get measurement from bottom of T-7 attached to roof panel and

bottom of header channel (on door end), cut 2 pieces of T-7, apply oven

cement and tek screw in place. Weld top and bottom (see Dwg. 9-B).

(see Dwg. 9-C).

(D) Start T-9 flashing app roximately 18” from each corner. The four

fabricated corners (installed later) will take care of this 18”. If more than one

10 ft. section needs to installed (because of oven size), then overlap the two

pieces at least 6” (to keep from cutting you can overlap more than 6”) (see

Dwg. 9-D).

(E) After placing a section of T-9 on corner, use a framing square to keep

flashing square with walls and roof (see Dwg. 9-E).

(F) To install fabricated corners, place piece on each corner and using

Framing Square, install with Tek Screws as required.

Section F

Flashing – Openings

Step 10.

Installation of Opening Flashing (These openings will be for

heater box installation. See customer drawing for locations and

opening size).

(A) Install insulation in ends and edges of panel opening (see Dwg. 10-B).

(B) For each opening, cut four each of T- 20 (4” panels) or T - 21 (6” panels).

Cut two each for each direction. (Dwg. 10-B).

to panels as required.

Section G

Heater Box Installation - Floor Mounted

Step 11.

Heater Box

(A) Make sure the opening for the heater box has been properly flashed.

(B) Apply oven cement to both T-7 angles that are welded to box (see

Dwg. 11-B).

location.

(D) On the heater box is a section of duct extending out. This duct must

go through the opening in the wall (see Dwg. 11-D).

(E) Push heater box in flush and tight against wall. It must be tight for it to

seal properly.

(F)

Install Tek Screws as required.

(G) Get measurement across top of box and cut section of T-15 flat

flashing. Apply oven cement to top of oven and top of heater box as shown

(see Dwg. 11-G). Attach T-15 with Tek Screws as required.

Section H

Heater Box Installation - Top Mounted (Floor Mount not Required)

Step 12.

Heater Box

(A) In the kit there are four each fabricated supports that need to be

welded to the heater box before it is set on top. Get the item number from the

customer drawings. Install and weld solid per Dwg. 12-A. (There are 2 left

hand and 2 right hand).

(B) In the heater box there is a section of duct that extends out of the box.

This slides in the opening left when the roof panels were installed. When

installing the heater box, place the heater box so the duct and the opening

are in line. Do not put weight of box on oven at this time (see Dwg. 12-B).

support legs (see customer drawings for item number).

(D) To install legs, line them up under the fabricated supports that were

installed earlier. Use a level to make sure they are plumb, and then anchor

bottom with 3/8” floor anchors (not supplied) against oven wall. Install Tek

Screws all the way up the wall on legs.

(E) Apply oven cement to bottom of T-7 angle attached on four sides of

heater box as shown in Dwg. 12-E.

(F) Set the heater box down on oven and support legs. Make sure box is

flat down on roof panels so it will seal.

(G) Install all Tek Screws in the heater box angle to top of oven panels on

all four sides (see Dwg. 12-F).

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Section I

Installation of Duct Work

Step 13.

Duct Work

(A) Start with duct section that attaches to heater box first. Get item

number from customer drawings.

(B) In this section of duct there is an opening for duct extending out of

heater box. Center this opening on duct, make level and install Tek Screws

3” off edge of opening on all f our sides and in T-7 angle top and bottom of

duct (see Dwg. 13-B).

of these to go around heater box duct. Apply oven cement to both sides of

this angle (see Dwg. 13-C).

(D) Install this angle on four sides with Tek Screws as shown in Dwg. 13-

(E)

Place 14 ga. Cover plate over the opening and install Tek Screws.

(F) Each section of duct has angle frames attached so each section will

attach together and line up with the next section of duct (get number from

customer drawings). Clamp angle together and make sure duct is level.

Install Tek Screws in T-7 angle attached to top and bottom of duct. Angle

frames can be tek screwed together or welded (see Dwg 13-F).

(G) Continue on both sides of oven with each section of duct (get numbers

from customer drawings). Last section of duct will be capped on end.

Section J

Installation of Door Opening Support Channel

Step 14.

Door Opening

(A) Get item number from customer drawings for the door opening support

channel. Make sure the door opening is square.

(B) Make marks 18” back from face of channel on the end wall (see Dwg.

14-B).

extend 2” above top of oven. Install two Tek Screws in channel to hold in

place. Install 3/8” floor anchors (not supplied) in angle at bottom of channel.

Install channel on the other side of the door in the same manner.

(D) Place top channel on over top, line up with two vertical channels and

weld in place.

(E)

Install the rest of the Tek Screws.

(F) In the kit there are four short channels 17” long (see customer

drawings for item numbers). These braces weld to face channel and support

channel (see Dwg. 14-B).

(G)

Install Tek Screws as required.

Section K

Installation of Doors

Step 15.

Door

(A) When installing the doors, there should be a 1” gap at bottom and a ½”

gap at top. When the doors are installed there is a ½” gap between door and

face chann el (1” and ½” spacers are in package with latches).

(B) Lay two (2) 1” spacers on floor in front of oven and place door on

these. Put ½” spacers between door and face channel (see Dwg. 15 -B). If

the floor, doors, or openings are not perfect you can adjust by shimming

under the door on one side or the other to get the doors to line up with each

other (see Dwg. 15-B).

channel.

Section L

Installation of Door Seals

Step 16.

Door Seals

(A) In the kit there will be Fiberglass Tad Pole Gasket, hold down strip 10

ft. long (cut as required), and fiberglass drag seal (cut as required).

(B) Dwg. 16-B shows where gasket is to be installed down both sides and

across the top.

(C)

Tek screw strip on top of gasket as shown in Dwg. 16-B.

(D) The door stop tube on the left door needs the Fiberglass Tad Pole

Gasket installed on it (see Dwg. 16-C).

Section M

Installation of Latches and Handles

Step 17.

Door Latches

(A) There are mounting plates on the doors for the latches. Install 5/16” x

3/4” bolt and lock washer (see Dwg. 17-A).

(B)

The keeper for the latch has 3/8” spacer bolted to it.

correct spacing and weld spacer solid to door header channel (see Dwg.

17A).

Step 18.

Door Handles

(A) Locate handle the height needed and place handle on door channel

(14 ga.). Mark holes and drill 5/16” hole (see Dwg. 18 -A). In the bag with the

handles there are 4 each of 3/ 8” self threading screws to bolt handles on with.

Screw in and the bolts make their own threads.

Section N

Installation of Exhaust Fan & Fan Damper

Step 19.

Exhaust Fan

(A) There is a hole in one of the roof panels (see customer drawings for

panel number and location).

(B)

Set the exhaust fan near this hole.

Dwg 19-C).

(D) Slip 90 EL with 6” section of pipe inside hole with storm collar (F3)

loose on it.

(E) Move fan over and install 90 EL to ring on fan with Tek Screws. This

will put fan in correct location.

(F) There are “Z” braces attached to bottom of fan. These braces have ¼”

holes. Install Tek Screws in all holes.

(G) Push storm collar down against oven and tighten. Apply bead of oven

cement around top and bottom of collar.

Step 20.

Fan Damper

(A)

Install damper inside oven.

(B) Hold damper cover plate over hole as to completely cover hole and

mark each side (see Dwg. 20-B).

outside of line and attach with Tek Screws as shown in Dwg. 20-C.

(D) Slide damper cover plate into slide brackets after adjusting. One Tek

Screw can be installed later to hold damper cover plate in place.

Section O

Installation of Screen Over Return Air Opening

Step 19.

Return Air Screen

(A) Put expanded metal screen over opening as shown in Dwg. 21-A and

attach with Tek Screws.

Section P

Control Panel

Section Q

Safety Instructions

Introduction

In order to minimize the threat of fires, explosions, personal injury or death associated with an unsafe oven installation, great care must be taken to insure a safe installation. Installers, operators and maintenance personnel must recognize the potential hazards involved and act accordingly. This manual should be read and understood before installing and operating this oven. The National Fire Protection Association (NFPA) publishes the most accepted standard for the design, manufacture, installation, maintenance and operation of industrial ovens. All Col-Met Spray Booths, Inc. ovens are built to the standards of NFPA 86 (1999 Edition).

Safety Devices

This oven was designed with several safety devices used to protect the installation. Do not bypass or disconnect these safety devices during operation. These safety devices include, as a minimum, the following:

2.1 Safety Devices for Gas and Electric Ovens:

Motor Overloads Air Proving Switches Purge Timers Powered Exhaust

Guards for Moving Parts Explosion Relief Doors/Hatches High Limit Switch

1.2 Safety Devices for Gas Ovens Only: Safety Shutoff Valve

High/Low Gas Pressure Switch Combustion Safeguard System Proof of Closure Switch

Safe Oven Installation

The installation of an industrial oven requires special attention. Proper safety measures protect those installing the oven and those who will operate the oven on a long-term basis. Often, local building and mechanical authorities specify installation requirements. Consult these authorities for any respective instructions. Only qualified personnel should perform the installation of an oven. “Qualified personnel” typically include contractors or properly trained maintenance personnel. Contractors include: 1. Equipment riggers to unload and handle the oven 2. Electricians to install the electrical wiring and related equipment, and; 3. Mechanical contractors to connect the gas service, air service and exhaust stacks.

Starting up the Oven Safely

A safe installation includes a proper startup of the oven prior to allowing operation. Only qualified personnel should conduct the startup procedure for the oven. Qualified personnel include trained maintenance personnel or electricians. Unless specifically trained, oven operators do not usually qualify to start up the oven. Only qualified personnel should enter the control cabinet due to the high voltage involved. Detailed startup procedures are addressed in a separate section of this manual.

Operating the Oven Safely

The predominant causes of fires, explosions and personal injury related to industrial ovens are improper use. Inadequate training, lack of maintenance and poor housekeeping. The operator must take an active role in assuring that the workplace is safe. Operators should be thoroughly trained prior to their use of the oven. Their training should include operating instructions and review of the safety issues that immediately follow. Operating instructions are addressed in a separate section of this manual.

1.1

Maximum Solvent Content

This oven is designed to handle a limited amount of solvent per batch. Solvent levels in excess of the maximum allowed may create an explosive atmosphere in the oven. Operators should contact their managers if they do not know what portion of their load is solvent.

1.2

Paper, Wood and other Solid Combustibles

Do not load paper, wood or other solid combustibles without consulting Col- Met Spray Booths, Inc. for appropriate safety measures that must be taken for these processes. There is a danger of fires and explosions resulting in property damage, personal injury or death.

1.3

Maintenance – Periodic and On-demand

The operator has an important role in the proper maintenance of the oven. The operator should shut down the oven and immediately notify management if the odor of gas is present. The operator should immediately notify their supervisor of any changes in operating performance. The operator should NOT restart the oven if a high limit alarm exists. The operator should notify management and insure that the cause of the high limit trip is corrected before the oven is restarted.

1.4

Proper Housekeeping

In maintaining safe oven operation, it is important that proper housekeeping be performed at all times. Allowing varnish to build up in handling carts, for example, contributes to the maximum allowable solvent in the oven and could subsequently cause a fire or explosion. All drippings and combustible products should be cleaned regularly from handling carts and the oven interior. Certain applications cause flammable materials to accumulate in oven exhaust ducts. These items should be inspected and either cleaned or replaced as necessary.

1.5

Explosion Venting Hatches and Doors

Most ovens include explosion relief doors or hatches to allow the oven to vent itself in the case of an explosion. These hatches or doors should not be obstructed. Operators should not stand near these openings.

1.6

Belt Guards

This oven should not be operated if the guards over the moving parts have been removed. When purchased, all ovens include guards secured over all moving parts, i.e., conveyor belts and fan belts. Operators should turn off the oven and notify management if guards are not secured. Guards should be re- secured prior to returning the oven to operation.

1.7

High Voltage

This oven operates on voltages high enough to cause physical injury or death. Only qualified personnel should service the oven or open the control panels or junction boxes.

1.8

Maintain Unobstructed Airflow

In order to maintain a non-explosive atmosphere in the oven, it is important that the circulation and exhaust be unobstructed. Operators should load the oven in a manner that allows adequate air movement in the oven.

Periodic Maintenance

Proper maintenance contributes to a safe oven workplace. It is very important that only qualified personnel perform scheduled maintenance on the oven. See the maintenance instructions in a separate section of this manual for recommended maintenance. You may refer to Chapter 10 of NFPA 86 (1999 Edition) for details on required inspection, testing and maintenance. Turn off the power prior to opening control panels and electric boxes. Also, per NFPA 86 (1999 Edition), Section 5-7.2.4, all gas ovens require that safety shutoff valves be leak tested at least once every year.

Fire Protection

In accordance with NFPA 86 (1999 Edition), Chapter 11, “Ovens containing or processing sufficient combustible materials to sustain a fire shall be equipped with automatic sprinklers or wat er spray.” Consult NFPA 86 (1999 Edition), Chapter 11 (Fire Protection) for supporting details. Contact your local fire control specialist for assistance.

Manufacturer Support

Don’t hesitate to call Col-Met Spray Booths, Inc. at 972-772-1919 with any questions or needs for field support. Col-Met Spray Booths, Inc. offers field service for employee training, product modifications and upgrades, and product maintenance.

Section R

Startup Instructions

Introduction

Only qualified personnel should conduct the startup procedures for an oven. Qualified personnel include trained maintenance personnel or electricians. Operators, unless they have been specially trained, do not qualify to startup the oven. Only qualified personnel should enter the control cabinet due to the high voltage inside. These startup procedures should be followed carefully in order to assure proper installation. Startup supervision services are available from Col-Met Spray Booths, Inc.

Checklist for Beginning Startup

A successful startup is dependent upon a proper installation of the oven. A list of conditions should be checked prior to beginning the startup sequence.

1. Electric Service – Make sure that the proper three-phase power is connected to the oven.

2. Exhaust Stack – Make sure that the exhaust stack is attached to the oven. The airflow should not be obstructed.

3. Guards – Make sure that all the guards are secured properly. All moving parts should be protected from exposure in order to prevent possible injury to personnel.

4. Gas Service – Ensure that the proper gas pressure and volume are supplied to the oven. As stated in Chapter 3, the inlet gas supply pressure is 5 PSI.

Gas Valves Open – Verify that all manual gas valves are open.

6. High/Low Gas Pressure Reset – Reset the high and low switches on the High/Low Gas Pressure Switches.

Doors Operational – Verify that the oven doors are operating properly.

2.1

Addition for Ovens with Dry Chemical Fire Suppression System Only

1. System Activation – Verify that the fire suppression system has been activated.

Startup Sequence

Gas Ovens Only:

1. Verify that the manual value supplying gas to the oven is in the open position.

2. Contact your management for the operating temperatures to be used in the oven. Verify that the setting is well below the auto ignition point of any material to be processed in the oven. Verify that the setting does not exceed 50  F above the rated oven temperature.

Verify correct voltage, phase, etc.

Turn the power switch on.

5. Push the “Start” button for each fa n individually, allowing time for each fan to come up to full operating speed before starting the next one.

6. Check the rotation of the fans against the direction of the rotation tags. The direction of rotation is verified during testing at assembly. Do not change the rotation of the individual motors at the terminal box or in the control panel. If the rotation is wrong:

a. b. c. d.

Turn off the power to the oven.

Change the leads.

Turn the power to the oven back on.

Turn the power switch on.

e. Push the start button for each fan sequentially as described in paragraph 5 above. f. The fans should now be moving in the direction of the rotation tags. If rotation is correct, allow the oven to stay on. 7. After all motors are started; the PURGING indicator light is illuminated until the time- out sequence is accomplished. (The Purge time is factory set for adequate purge time of specified CFM of exhaust changes per minute. Any tampering with this timer will void the warranty and release Col-Met Spray Booths, Inc. from all related responsibilities.) 8. When the purging indicator light turns off, depress the IGNITION START button. The trial for ignition will take up to ten (10) seconds when the BURNER ON indicator light is illuminated. *Please note: If burner fails to light after trial for ignition, the alarm will sound. Depress the BURNER RESET button to reset burner flame monitor and repeat step 8. 9. After trial for ignition and burner on is accomplished, the Honeywell UDC temperature controller takes precedence and begins controlling the oven to desired set point.

AUTO TUNING TEMPERATURE CONTROLLER

Controller parameters are not locked out upon delivery to allow ease of set up for installation and startup. Controller is factory tested and set up to allow auto tuning to be accomplished. Auto tuning should only be done after all adjustments to burner and exhaust damper have been set to insure oven meets temperature capacities without nuisance shut downs.

1. Auto tuning may be accomplished by starting oven and setting desired set point needed for your process.

2. Depress AUTO TUNE , (allowing at least 100  F between desired set point) controller begins flashing, reverting from oven temperature to “Tune”

3. The UDC controller immediately starts controlling to the set point while it identifies the process. The tuning sequence will cycle the controller’s output two full cycles, above set point then below set point. 4. When Accutune is complete, the calculated tuning parameters are stored in their proper memory location in the controller, and the controller will control at the local set point using the newly calculated tuning constants.

5. To about Accutune and return to the last parameters simply press MAN- AUTO/RESET key to abort the Accutune process.

LOCKOUT OF PARAMETERS AFTER TUNING

Depress set up key until Tuning is displayed.

Depress the Function key until display reads lock (Factory set to none ).

Arrow up or arrow down until display reads ALL .

Exit by pressing display key and lockout is complete.

Section S

Operating Instructions

Introduction

Only trained personnel should operate this oven. This operator must take an active role in assuring that the workplace is safe and free from hazards that could cause personal injury. Every oven operator must be trained prior to operating an oven. This training should include; as a minimum, the safety instructions in the front of this manual and the operating instructions that follow:

Checklist Prior to Daily Operation

Operators have an important role in assuring that the oven workplace is safe. Operators must check for several conditions prior to daily operation. Should any safety concerns arise, the oven should not be started and maintenance personnel should be notified immediately. The following checklist should be completed daily:

1. 2. 3. 4. 5.

Verify that the control panel cover and all electric box covers are secure. Verify that explosion relief doors and hatches are unobstructed.

Verify that no volatiles are near the oven workplace. Verify that all guards are secure over all moving parts.

Verify that there is no gas leak detected.

6. Verify that the gas train is in the proper shutdown position. The safety shutoff valve should be closed and there should be no power to the combustion safeguard. 7. Verify that the load in the oven does not contain volatiles in excess of the maximum allowed levels. 8. Start the oven and verify: a. The oven purges before starting to heat. b. The oven ignites properly. c. There is no unusual noise or vibration; d. That the oven maintains the control temperature.

Operating Instructions

1. Turn the power switch to “ON” by means of the door disconnect. The “Power On” light indicates that you have power to the control panel.

2. Select “Time”. If the “Time” mode is desired, then you must set the batch timer to the desired length of time. The timer is preprogrammed to operate in minutes. Turn the respective knobs to increment or decrement the value of the corresponding digit.

Change the Temperature Controller Set Point . If it is not already set to the desired operating temperature. To set the controller:

(1)Depress display key to show set point temperature and change by depressing arrow up or arrow down accordingly for desired temperature.

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