Garmat Chinook II User manual

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Operations and Maintenance Manual
Garmat USA,Inc.
Chinook II Paint Spray Booths
Garmat USA, Inc. 1401 W. Standford Ave. Englewood, CO 80110
[phone] ph. [phone]
www.garmat.com

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OPERATIONS AND MAINTENANCE INSTRUCTIONS
OPERATIONS INSTRUCTIONS…………………………………………. Page 3
MAINTENANCE INSTRUCTIONS………………………………………. Page 7
MAINTENANCE SCHEDUAL.………………………………………….. Page 8
TROUBLESHOOTING…………………………………………………….. Page 10
OPERATION SEQUENCE………………………………………………… Page 10
FILTER CHANGE RECORD……………………………………………… Page 12
WARNING LABLES……………………………………………………… Page 13

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OPERATIONS INSTRUCTIONS ENCLOSED
PAINT BOOTH
Garmat® Booth/Oven
WARNING: FAILURE TO HEED
WARNINGS INCLUDED IN THIS MANUAL
COULD RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY, AND/OR DEATH.
The Garmat® Tier 1 Paint Booth is designed and
manufactured in the United States. The Garmat®
Tier 1 Paint Booth provides the optimal environment
for the application of fine automotive finishes.
Through continuous product design and
improvement, Garmat® is committed to providing
you and your customer with the finest automotive
finish possible. Thorough study of this manual will
not only aid you in your pursuit of a fine finish, it
will assist you in making your pursuit safer and
easier.
SUGGESTIONS FOR SAFETY
Before using this unit be sure to read all of the
operation instructions and these safety suggestions
carefully. Afterward, place them in the main control
panel of the booth for future reference. Take special
care to follow the warnings indicated on the unit, as
well as the operating instructions.
PREPARATION OF THE CAR
One of the key elements of a fine finish is a dust free
environment. The design of a Garmat® Tier 1 Paint
Booth is centered on providing a relatively dust free
environment. Your preparation of the car before it
enters the booth is very important to maintain a dust
free environment.
Before moving the car into the spray booth, after the
body of the car is properly prepared to accept the
finish, wash the entire vehicle. Attention during the
wash procedure should be directed to the underside
of the vehicle as well. When the vehicle is
completely dry and ready for refinishing, the entire
vehicle should be blown off with compressed air.
Again, attention must be paid to crevices around
the hood, trunk lid, doors, air vents, etc.
Masking of the vehicle should be performed
outside of the booth. Remember, your efforts to
introduce a clean vehicle into a relatively dust-free
environment provided by the Garmat Frontier
Paint Booth will assist you in your pursuit of the
finest finish with a minimum of work.
PREPARATION OF THE PAINTER
Proper protective clothing and gear is essential for
the safety of the painter and production of a quality
paint job. Paint suits are readily available in a
variety of styles. Garmat® recommends a close
weave nylon type that breathes and has a hood.
The suits should be cleaned regularly and should
be worn only when the painter is actually engaged
in painting. The painter should remove all dust
from his clothes before putting the paint suit on.
Whenever entering the Paint Booth, all dust should
be removed from the paint suit, and any
equipment. Anything that the painter brings into
the booth is a potential cause of dust.
WARNING: APPROVED RESPIRATORS
MUST BE WORN WHENEVER FINISHES
ARE APPLIED.
NOTE: THE BOOTH MUST BE
OPERATING WHENEVER ENTERING
THE BOOTH
The Painter should try to stay in the booth as much
as possible and limit going in and out between
paint coats. He should have enough paint in the
booth to complete that portion of the job.
PAINT BOOTH ENTRY
The Garmat® Tier 1 Paint Booth can be installed
in a variety of configurations. Your Paint Booth as
installed will include some of the following
features:

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FRONT ENTRY
DRIVE-THROUGH
Always center vehicle side-to-side, and front to back
on the floor.
NOTE: THE BOOTH FANS MUST BE
RUNNING WHENEVER A CAR IS MOVED
IN OR OUT. THIS WILL REDUCE THE
POSSIBILITY OF CONTAMINATION
FROM THE SHOP
FRONT ENTRY AND DRIVE THROUGH:
Before moving a vehicle into the booth, assure that
the vehicle and/or any attachments, i.e. mirrors,
antennas, etc. will fit through the door you intend to
use. All recommended preparation procedures
outlined above must be completed. The booth must
be operating. Vehicles should be driven slowly and
carefully. Rapid acceleration or hard braking should
be avoided at all times.
SUGGESTIONS FOR SAFETY
Before using this unit be sure to read all of the
operating instructions and these safety suggestions
carefully. Afterward, place them in the main
electrical control panel for future reference. Take
special care to follow the warnings indicated on the
unit itself as well as the operating instructions.
WARNING: IF YOU SMELL GAS:
1. OPEN WINDOWS.
2. DO NOT OPERATE ELECTRICAL
SWITCHES.
3. EXTINGUISH ANY OPEN FLAME.
4. IMMEDIATELY CALL YOUR GAS
SUPPLIER.
WARNING: DO NOT USE OR STORE
GASOLINE, PAINT, OR OTHER
FLAMMABLE MATERIALS NEAR THE
INTAKE AIR HEATER APPLIANCE (BOOTH
MECHANICALS).
WARNING: WHEN VEHICLES ARE
EQUIPPED WITH PROPANE (LPG) FUEL,
THE FUEL TANK MUST BE LESS THAN
HALF FULL BEFORE MOVING THE
VEHICLE INTO THE BOOTH. THE
PROPANE (LPG) TANK MUST HAVE
ROOM FOR EXPANSION WITHIN THE
TANK DURING BAKE CYCLE.
WARNING: DO NOT ENTER THE BOOTH
DURING THE BAKE CYCLE.
WARNING: APPROVED RESPIRATORS
MUST BE WORN WHENEVER FINISHES
ARE BEING APPLIED.
The booth fans must be running whenever a car is
moved into or out of the booth. The booth must be
running whenever personnel are entering the
booth.
Consult with your paint jobber or manufacturer
concerning recommended refinishing
temperatures, recommended bake temperatures
and times.
WARNING: DO NOT EXPOSE THIS
EQUIPMENT TO EXCESSIVE MOISTURE
OR RAIN. DO NOT PRESSURE WASH OR
HOSE WASH THE INTERIOR,
EXTERIOR OF THE CABIN OR ITS’
RELATED EQUIPMENT. THIS WILL
VOID THE CABIN WARRANTY.
Review the recommended maintenance procedures
and insure that the prescribed schedule is followed.
Disconnect all electrical supply and lock-off
whenever covers on the mechanicals are removed
for maintenance procedures.
Do not over-tighten the fan belts. Proper tension is
when there is ½” deflection at a mid point between
the pulleys with moderate pressure on the belt. Belt
tension testers are available from drive belt
suppliers. Drive belts should be adjusted after the

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first 40 hours of use and every three months after
that.
In addition to adjustments explained in the
maintenance instructions, you may attempt repairs
your self. However, if you are not sure how to repair
the unit, be sure to request service from a qualified
technician or your local distributor.
THE CONTROLS
Identification of components. The control
components are located on the face of the Remote
Control Panel. There are three available options for
control of the booth.
42004(X) Exhaust Only:
1. SPRAY SWITCH, is a black push button
switch that will start the exhaust fan when
pushed.
2. OFF SWITCH, is a black push button that
will turn the exhaust fan off when pushed.
3. LIGHT SWITCH, is a toggle switch, which
turns the lighting on and off.
42104(X) Intake & Exhaust, No Heat:
1. SPRAY SWITCH, is a black push button
switch that will start the intake and exhaust
fans when pushed.
2. OFF SWITCH, is a black push button
switch that will turn off the intake and
exhaust fans when pushed.
3. LIGHT SWITCH, is a toggle switch that
turn the lighting on and off.
4. INCREASE/DECREASE PRESSURE
SWITCHES, are black push buttons that
open and close the pressure damper.
83400 / 83600 /42106(X) WITH HEAT:
1. SPRAY SWITCH, is a black push button
switch that will start the intake and exhaust
fans when pushed.

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2. OFF SWITCH, is a black push button switch that
will turn off the intake and exhaust fans when
pushed.
3. LIGHT SWITCH, is a toggle switch that turn the
lighting on and off.
4. BURNER SUMMER/WINTER SWITCH, is a
toggle switch that turns on and off the burner circuit.
5. INCREASE/DECREASE PRESSURE
SWITCH, is a toggle switch that opens and closes
the pressure damper.
6. SUPPLY FAN PILOT LIGHT (GREEN)
indicates the supply fan is in operation when lit.
7. BURNER PILOT LIGHT (GREEN) indicates
the burner is in operation when lit.
8. SPRAY, PURGE, BAKE, COOL DOWN
PILOT LIGHTS (GREEN), when lit indicate
mode of operation that the paint booth is operating
in.
9. BAKE TIMER is energized only during the bake
mode. This timer features a bar (top portion of unit),
which initializes at 100% at the right and decreases
to 0 at the end of the timed period. The mode
indication (lower left corner of the timer) should be
set at C. The bake time is set via thumbwheels
(lower center). The timer function (lower right)
should be set at M for minutes.
9. TEMPERATURE CONTROLLER provides
readout of the booth internal temperature and current
set-point (one for spray and one for bake).
MAIN ELECTRICAL PANEL
The control panel is fully described in the
maintenance section of this manual.
The control panel is mounted to the side of the intake
plenum near the booth front. It is white in color and
contains the power and operational controls for the
booth.
WARNING: THE MAIN ELECTRICAL
PANEL IS SUPPLIED BY TWO SOURCES OF
ELECTRICAL POWER. INSURE BOTH
SOURCES ARE DISCONNECTED BEFORE
ANY ADJUSTMENTS IN THE PANEL ARE
MADE.
The purge timer is an internal function of the PLC
(Programmable Logic Controller) and is adjustable
in minutes. This timer should not be set any lower
than 3 minutes according to national codes.
Consult your paint supplier or manufacturer for
recommended flash-off time.
The bake timers are an internal function of the
PLC and are adjustable in minutes. Consult your
paint supplier or manufacturer for recommended
bake times.
The cool down timer is an internal function of the
PLC (Programmable Logic Controller) and is
adjustable in minutes. Generally this timer is set a
maximum of 10 minutes. This allows the operator
to set the paint booth to bake mode and go home in
the evening. The booth will complete the bake
cycle, cool down for 10 minutes, and then shut
down completely. The Off/Spray/Bake switch will
need to be set to the Off position to allow the booth
to operate after the system has gone through a cool
down cycle and shut off automatically.
Adjustment of the purge, bake, and cool down cycles
can be made at the face of the PLC by accessing the
parameter screen.
REMOVING THE CAR
Review the instructions for entering the booth.
Heed the warnings for the style of booth installed.
MAINTENANCE INSTRUCTIONS
ENCLOSED PAINT BOOTH
FILTERS
To assure that the optimum-finishing environment
designed into your Garmat® Tier 1 Paint Booth is
maintained, filter replacement at recommended
intervals and regular cleaning of the booth and the
air-handling units is essential. Use only
recommended filters and insure that the filters are
properly installed.

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The quality of finish produced by your Garmat®
paint booth is affected by the following:
a. The filter media used and the timeliness of filter
replacement.
b. The purity of compressed air used for applying the
finish. Use a quality filter and moisture trap on
compressed air lines supplying the booth. When
using a copper airline, make sure that all connections
to the equipment have di-electric unions.
c. Spray guns and other application equipment must
be maintained perfectly clean and in proper working
order.
d. Personnel clothing (paint suits) should be
established for use only in the booth.
e. DO NOT mix paint within the booth.
f. LIMIT ACCESS to the booth.
g. DO NOT open booth doors unless the booth is
operating.
FILTER LOCATION- Two main filter groups
control the dust entering the booth and the paint
particles emitted by the booth.
EXHAUST FILTER CHANGE AT 50-60 HOUR
INTERVALS
The exhaust filters are located in the two towers
located at the back of the booth. To access the filters
rotate the access door latches, swing the access doors
open and slide the filter racks out. The filter racks
consist of two halves with one half nested inside of
the other. Separate the two halves and remove the
filter material and place in an airtight container.
Sweep and/or vacuum up all debris and dust. Cut
new filter material slightly larger than the filter rack
and place in the larger half of the filter rack. Slip the
smaller half of the filter rack into the larger half.
Repeat this for each filter rack and then replace in
the exhaust towers. On the filter schedule at the back
of this manual, record the date, time and hour meter
reading. Re-start the paint booth.
WARNING: USED EXHAUST FILTER
MATERIAL IS FLAMMABLE AND IS
SUSEPTIBLE TO SPONTAINOUS
COMBUSTION. DISPOSE OF PROPERLY.
CEILING FILTER CHANGE AT 1000-1200
HOUR INTERVALS
NOTE: ALTHOUGH ONE MAN CAN
REPLACE THE CEILING FILTERS, IT IS
RECOMMENDED THAT TWO PEOPLE
INSTALL THE NEW FILTERS TO INSURE
PROPER PLACEMENT. USE HAND TOOLS
ONLY.
Ceiling Filters are held in place by a removable
filter frame in the ceiling of the cabin. Filter
support bolts secure the filter frame. Rotate the
support bolts clear of the frame, insuring that the
frame will not fall free, and remove from the filter
frame opening. Set filter frame on stands.
Remove the used filter media, and thoroughly
clean the filter frame with a tack rag. Place the
new filter media in the filter frame, tuck the media
into the ends of the frame, and then tuck the media
into the sides of the frame. Raise the filter frame
up into the filter frame opening. Rotate the support
bolts back into place and tighten by hand making
sure not to over tighten. The FLAME ROD in the
burner should be replaced at this time.

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MAINTENANCE SCHEDULE
DAILY
CHECK booth pressure and make sure the booth
pressure is operating in the proper range.
SWEEP the floor while the booth is in operation.
The booth floor may be mopped, with a well rung
out mop.
CHECK the exhaust filters.
1000-HOUR INTERVAL (ANNUALLY)
At each 1000-hour interval, the following
preventative maintenance checklist should be
reviewed. If any malfunction is found, it should be
repaired immediately.
MOTORS - Replace fan belts. Adjust for proper
tension.
NOTE: Proper tension is ½” deflection at a mid
point between the pulleys using moderate pressure.
Tension testers are available at local belt and drive
suppliers.
FANS- Check fan blade surfaces. Clean if
necessary. Oil the blade surfaces after cleaning. DO
NOT USE SILICON BASED OIL. In addition, oil
the changeover damper hinges. Some hinges will
have grease zerks.
BOOTH - Examine all door seals, replace with
Garmat approved seals only. Change ceiling filters.
Check exhaust filters and replace if necessary.
Lubricate the larger hinges provided with grease
zerks.
CAUTION: FAILURE TO PERFORM THE
REQUIRED LUBRICATION WILL CAUSE
PREMATURE FAILURE OF THIS EQUIPMENT.
The moving mechanical portions of this equipment
require regular lubrication not less than every 3
months. The items requiring regular lubrication
include and are not limited to: door hinges,
dampers, and motors. If you are unsure which
items need lubrication, contact the equipment
supplier. If extreme moisture is present, lubrication
may need to be performed weekly.
CONTROL AIR - The air supplied to the Garmat
USA, Inc. paint spray booth must be clean and dry
before the attachment to the electrical control
panel. Water separators, filter systems for
compressed air shall be installed up stream of the
Garmat USA, Inc. main electrical control panel
and filters, desiccant…etc. should be changed
annually. Examine the regulator/filter and oilier for
the control air (located at the side of the main
control panel). Pressure should be set between 45-
60 psi, drain the filter and refill the oilier with air
tool oil.
CONTROL PANEL - Review the following:
a: Pressure settings.
b: Temperature settings.
FINALLY - Run the booth a complete cycle of
operation and observe all functions.
AS RECOMENDED
MOTORS - In general, the motors supplied with
your Garmat paint booth require lubrication and
are fitted with grease zerks. Lubricate the motor
with a good quality grease quarterly making sure
not to force grease into the bearings. A ¼ squeeze
on a normal hand pump grease gun is sufficient.
Forcing grease into the bearing will damage the
bearing seals and shorten the motor life.
HEATER SECTION- Gas fired heaters require
little or no maintenance. However the burner
manifold should be inspected to make sure there is
no build up of debris or moisture. The flame rod in
the burner manifold should be replaced Annually.
Also the burner manifold should be completely
cleaned out every Four Years by a qualified
service technician.

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MAINTENANCE OF INTERNAL AND
EXTERNAL SURFACES
To clean, use a soft, dry cloth. If the surfaces are
extremely dirty, use a soft cloth, dipped into a soap
and water solution or a weak detergent solution.
Wring the cloth before wiping the surface. Wipe
again with a soft, dry cloth.
Never use alcohol, paint thinner, benzine, nor a
chemically treated cloth to clean this equipment.
Such chemicals may damage the finish of your
booth. Never pressure wash or hose down the
interior or exterior of the booth, electrical shorts or
shocks can occur. In addition, water will collect in
light fixtures and various components of the booth
cabin and rust deterioration will begin.
PRESSURE WASHING WILL VOID YOUR
WARRANTY.

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TROUBLESHOOTING
OPERATOR TROUBLESHOOTING CHART
SYMPTOM POSSIBLE CAUSE(S) ACTION
RECOMMENDED
NOTHING WORKS. Incoming 3 phase voltage Turn EM switch on. Check incoming 3
is off. The 110-v control breaker in main phase breaker at wall panel. Reset breaker
control panel is tripped. in main control panel.
NOTHING WORKS. Overload relay is tripped. Loss of a phase. Reset overload relay. Check for 3 phase.
Low 3 phase voltage. Measure motor amps. Measure 3 phase
voltage.
EVERYTHING WORKS Lighting breaker(s) are tripped. Reset lighting breaker(s). Check change-
BUT BOOTH LIGHTS. over damper.
TEMPERATURE DOES NOT Outside air temperature is greater than set- Increase set point temperature on
RISE. (BURNER GREEN LIGHT point temperature. Temperature controller. Booth temperature
IS ON). will not exceed 190°F
TEMPERATURE DOES NOT Pilot has failed during fire cycle. Push reset button on red enclosure
RISE. (BURNER RED LIGHT Pilot manual gas valve turned off. marked FIREYE. Turn manual valve ON.
AT FIREYE IS ON). High limit, low gas and/or high gas If lockout repeats, call a Garmat USA
pressure switch tripped. proof of closure authorized service-technician. Touch alarm
Open. on screen and follow instructions.
TEMPERATURE TOO HIGH Controller is set to Bake or second Set- Outside temperature above 70°F. Press the
DURING SPRAY MODE. Point. Moni/Mode button and press the up arrow to
Put the control into AUTO mode, press
Moni/Mode button to go back top the
normal display. Set SUMMER/WINTER
switch to SUMMER.
OPERATION SEQUENCE
This section is provided to assist a service technician
and explain in detail what is happening during
“normal” operation.
SPRAY/BAKE BOOTH OPERATION
The spray/bake booth has four separate modes of
operation: SPRAY, BAKE, COOL DOWN and
SHUTDOWN.
SPRAY:
The 110v and 24v control voltages are provided
from the secondary side of the control transformer.
The primary side of the control transformer is
connected to the incoming three-phase motor
voltage supply.
The 120v is connected through a jumper
connection provided for use with a NC contact
on an alternative fire suppression system that
requires shutdown of the booth fans. Breaking
the circuit at that point will shut down all booth
operations. The 120v continues through the
Off and SPRAY switchs in the remote control
panel, and NC overload contacts of each
Motor Starter. The 120v is then present at the
light switch, and the programmable logic
controller (PLC). If either motor trips to an

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overload condition, all booth operations quit.
Breakers protect control voltages, 110v and 24v.
Pressing the SPRAY button gives input “2”to the
PLC and the PLC outputs “Q1” giving power to the
exhaust motor starter and the temperature control.
The exhaust motor will begin to run and the
temperature control will energize and run through
the start up checks. After a 0 to 10 second delay the
PLC will output to “Q2” giving power to the intake
motor and the Supply Fan light. The Intake motor
will begin to run and the Supply Fan light will light
up. The paint booth will run in the Spray mode
indefinitely until the off switch or bake switch is
pressed, the fire suppression switch (jumper) is
opened, or a power outage occurs. When the doors
on the spray booth are closed, there will be input to
input “5” at the PLC the PLC will then output to
“Q3” giving power to the spray air solenoid and the
Spray Cycle light.
If the BURNER switch is in the WINTER position,
power is provided to the PLC and shows as “3” on
the PLC input display. The PLC then looks for input
“6” from the air flow switches. The PLC then
provides power to the gas train circuit shown as
“Q7” on the PLC output display.
BAKE MODE:
Touching the BAKE button begins the Bake Mode
and provides power to the PLC and shows as “4” on
the PLC input display. The PLC will perform a
purge time sequence, during which the output “Q3”
will be de-energized and “Q4” will be energized.
This will drop power to the spray air solenoid and
the Spray Cycle light and light the Purge Cycle light.
At the end of the purge cycle the PLC drop output to
“Q4” and give power to output “Q5”. This will shut
off the purge light and give power to the Bake Cycle
light, Bake timer and the RRB relay. The Bake timer
will begin to count down, the RRB relay will
energize the change over damper solenoid, bypass
the spray high limit switch and set the temperature
control to the second set point (bake temperature).
The PLC will then look for input an input 8 from the
bake timer.
COOL DOWN MODE.
When the bake timer completes cycle, the
timer will input “8” at the PLC. The plc will
then drop output at “Q5” and output to “Q6”
de-energizing the bake timer, RRB relay and
bake cycle light and energizing the Cool Down
light. The booth returns to the spray cycle
mode during the cool down cycle with the
compressed air non-functional. The internal
timer, from 0 to 10 minutes, for cool down
begins in the PLC.
SHUT DOWN MODE.
When the PLC internal cool down timer
makes, the booth will shut down and will not
restart until the spray button is pressed.

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CEILING 1000
/
INTAKE 1000
/
EXHAUST 1000
/
EXHAUST 950
/
EXHAUST 900
/
EXHAUST 850
/
EXHAUST 800
/
EXT & INT 750
/
EXHAUST 700
/
EXHAUST 650
/
EXHAUST 600
/
EXHAUST 550
/
EXT & INT 500
/
EXHAUST 450
/
EXHAUST 400
/
EXHAUST
3
50
/
EXHAUST
3
00
/
EXT & INT 250
/
EXHAUST 200
/
EXHAUST 150
/
EXHAUST 100
/
EXHAUST 50/
COMMENTS
SPEC/ACTUAL
FILTER HOURS DATE

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