GFS Ultra CTOF Booth User manual

Ultra®CTOF Semi-Downdraft Booth with
BT Air Heater (Single-Bay)
Installation Manual
Document Number: 239-142 rev 3
Publication date 05/01/2020
Read and keep this manual for future reference. All personnel operating the equipment described in this manual should review and understand
all instructions before use.

Table of Contents
Introduction ............................................................................................................................................ 4
About Global Finishing Solutions LLC .............................................................................................. 4
Contacting Global Finishing Solutions .............................................................................................. 4
Target audience .............................................................................................................................. 4
Conventions used in this manual ...................................................................................................... 5
Safety notices ......................................................................................................................... 5
Information notices ................................................................................................................. 5
General safety ........................................................................................................................................ 6
Booth safety ........................................................................................................................................... 8
Booth description .................................................................................................................................. 10
Preparing for installation ........................................................................................................................ 11
Accepting delivery of your booth .................................................................................................... 11
Gathering required documentation ................................................................................................. 12
Confirming site requirements ......................................................................................................... 13
Confirming booth layout ................................................................................................................ 13
About the Design Drawings document .................................................................................................... 15
Page elements ............................................................................................................................. 15
Page types ................................................................................................................................... 17
Required materials ................................................................................................................................ 19
Required tools .............................................................................................................................. 19
Recommended equipment ............................................................................................................ 20
Installation best practices ...................................................................................................................... 21
Unpack in stages .......................................................................................................................... 21
Sort parts by size .......................................................................................................................... 22
Remove protective coating ............................................................................................................ 22
Follow assembly guidelines ........................................................................................................... 23
Installation procedure ............................................................................................................................ 24
Prepare the floor ........................................................................................................................... 24
Mark the booth footprint ........................................................................................................ 24
Mark the air heater footprint ................................................................................................... 25
Mark the column positions for the booth frame ........................................................................ 25
Install the BT air heater ................................................................................................................. 26
If necessary: Install the intake stack now ........................................................................................ 26
Install the floor channel ................................................................................................................. 26
Attach the branding decal and truss cover panels ........................................................................... 27
Install the booth frame ................................................................................................................... 29
Assemble the walls for the front section of the booth ....................................................................... 30
Build the front section of the side wall that connects to the air heater ........................................ 30
Build the front section of the opposite side wall ....................................................................... 31
Install the plenum end panel .......................................................................................................... 32
Finish the side walls of the booth ................................................................................................... 33
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Build the back wall of the booth ...................................................................................................... 34
If applicable: Build a solid end wall ......................................................................................... 34
If applicable: Build a drive-through end wall ............................................................................ 34
Assemble the exhaust yoke ........................................................................................................... 35
Install the exhaust fan ................................................................................................................... 35
For roof height over 15 feet: Install the exhaust stack now ............................................................... 37
Assemble the top of the booth ....................................................................................................... 37
Install the high roof panels ..................................................................................................... 37
Install the hip light panels ...................................................................................................... 38
Install the roof support assembly ............................................................................................ 38
Install the filter ceiling ............................................................................................................ 38
Install the low roof panels ...................................................................................................... 38
If applicable: Install the AdvanceCure system ................................................................................. 38
If applicable: Install the AdvanceCure cover kit ............................................................................... 39
Install curtain track and bracket hardware ....................................................................................... 39
Install the personnel door .............................................................................................................. 39
If applicable: Install the corner covers ............................................................................................. 39
Install the diffuser assembly ........................................................................................................... 40
Install the intake and exhaust stacks .............................................................................................. 40
Assemble the intake stack ..................................................................................................... 40
Assemble the exhaust stack .................................................................................................. 41
If applicable: Install the guy-wire kit ........................................................................................ 42
Install the lights ............................................................................................................................. 43
If applicable: Install optional booth accessories ............................................................................... 44
Install the operator interface terminal .............................................................................................. 44
Install miscellaneous electrical devices ........................................................................................... 45
Install the air-sensing tube ..................................................................................................... 45
Install the temperature sensor ................................................................................................ 46
If applicable: Install the damper actuators ............................................................................... 46
Install the air solenoid valve ................................................................................................... 47
Install the Economy valve ...................................................................................................... 47
Install the air-proving switch for the exhaust stack ................................................................... 48
If applicable: Install the puff switch ......................................................................................... 48
Secure the wall panels to the floor profile ....................................................................................... 49
Caulk the booth ............................................................................................................................ 49
Prepare the air heater for startup ................................................................................................... 49
If applicable: Install the curtain ....................................................................................................... 49
Install booth filters ......................................................................................................................... 49
Install the filter racks and intake filters .................................................................................... 49
Install the exhaust filters ........................................................................................................ 50
Perform electrical hookup .............................................................................................................. 51
Perform commissioning and startup ............................................................................................... 52
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Introduction
About Global Finishing Solutions LLC
Leading the Industry in Paint Booth and Finishing System Technology
With decades of experience, Global Finishing Solutions is the leading manufacturer of paint booths and
finishing systems for many industries, including automotive refinish, aerospace and defense, industrial
manufacturing, woodworking, and large equipment. By combining high-quality components, strong
relationships with paint manufacturers, and our experienced distribution network, GFS provides the best
equipment and support to set your business up for success.
Contacting Global Finishing Solutions
General information
• Toll-free: 800-848-8738
• Fax: [phone]
• Email: inf[email protected]
• Online: www.globalfinishing.com
Technical support
• Toll-free: 800-848-8738
• Fax: [phone]
• Email: techser[email protected]
Parts and filters
• Toll-free: 800-848-8738
• Fax: [phone]
• Email: par[email protected]
Target audience
This document is intended for use by trained, experienced paint booth installers and maintenance
technicians. If you have questions about the installation procedure described in this manual, contact GFS
as described above.
Introduction
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Conventions used in this manual
This section describes how information is presented, organized, and referenced within this manual.
Safety notices
This manual uses the following standards to identify conditions related to safety hazards and equipment
damage.
Table 1. Safety notices
Symbol Description
DANGER Indicates an imminent hazard that will result in death.
WARNING Indicates a hazard that can result in serious personal injury or death.
CAUTION Indicates a hazard that can result in personal injury.
NOTICE Indicates a situation that can result in equipment or property damage, but poses no risk
of personal injury.
Information notices
In addition to the safety notices described above, this manual uses a boldface keyword to identify certain
other types of information.
Table 2. Information notices
Keyword Description
NOTE Denotes general information that provides additional context or guidance.
Important Denotes information to which you should pay special attention.
Reference Directs you to related content in a separate document.
Prerequisites Specifies other tasks that must be completed or conditions that must exist before you
perform the current task.
Scope Describes limitations to the current task or conditions under which the task applies or
does not apply to the procedure.
Introduction
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General safety
Follow all safety guidelines when assembling, operating, or servicing this product.
WARNING
There are inherent hazards associated with the operation and service of this equipment. For your personal
safety, observe all safety information. Failure to observe these safety practices can result in personal injury
or death.
WARNING
Operation and maintenance of this product must be performed properly by qualified personnel who observe
the warnings in all documentation and notes provided with and on the product.
WARNING
Follow all general standards for installation and safety for work on installations. Follow all good practices for
the proper use of lifting tackle and equipment. The use of protective equipment such as safety goggles and
protective footwear must be considered.
WARNING
All persons who will operate, service, inspect, or otherwise handle this product must read and understand
the safe operating practices, safety precautions, and warning messages in this documentation.
WARNING
Comply with OSHA guidelines and with all applicable local electrical, safety, and fire codes and standards.
WARNING
All field wiring provided must comply with local codes or, in the absence of local codes, the National
Electrical Code (NFPA 70). Article 516 covers applicable of flammable and combustible materials.
WARNING
Electrical installation should be completed by a qualified electrician. Installation must meet all applicable
national, state, and local electrical codes.
WARNING
Ensure that all electrical components are grounded to a central ground.
WARNING
Disconnect and lock out the main electrical service before installing, adjusting, or servicing the product.
WARNING
Lockout the main gas shutoff valve before maintenance or inspection of the air heater.
WARNING
Guards and covers that prevent contact with electrically energized or moving parts are required and must
not be removed or left open during operation.
General safety
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WARNING
Local fire and building codes require fire protection. Check with local inspector authorities for requirements.
CAUTION
Read and save these instructions before attempting to assemble, install, operate, or maintain the product
described. Protect yourself and others by observing all safety information. Failure to comply with
instructions could result in personal injury and/or property damage. Retain these instructions for future
reference.
CAUTION
This manual contains statements that relate to worker safety. Read this manual thoroughly and comply as
directed. Operate this equipment in accordance with the guidelines set forth in this manual. It is impossible
to list all potential hazards of this equipment. Instruct all personnel involved with this equipment in the safe
conduct and operation of the system. GFS recommends that only qualified personnel operate and maintain
this equipment.
CAUTION
Safety signs, panels, and labels that are normally affixed to the product must be replaced immediately if
illegible or missing.
CAUTION
New or replacement parts that are installed during repair or maintenance must include all safety signs,
panels, and labels as specified by the manufacturer. These must be affixed to the new or replacement parts
as specified by the manufacturer.
CAUTION
Where applicable, use earplugs or take other safety measures for hearing protection.
NOTICE
The product must be installed and serviced only by a trained, qualified service technician. Incorrect
installation may void the warranty.
NOTICE
If you have questions about the warranty, please contact your distributor prior to contacting GFS.
General safety
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Booth safety
DANGER
Ceiling panel load capacity for installation and maintenance: You must use temporary platforms that
span at least two structural frames for maintenance. Do not walk on or apply any pressure to lights or
explosion (deflagration) relief panels.
WARNING
All equipment must be operated and maintained in accordance with local, state, and federal (OSHA)
requirements governing occupational safety, fire protection, and booth operations. Operators must read and
understand GFS and included independent equipment and/or component manufacturer's instructions prior
to use. Disclaimer: GFS is not responsible for any injury, illness, or property damage that results from not
abiding by local, state, or federal (OSHA) requirements that govern occupational safety, fire protection,
spray booth, and oven operations. GFS is also not responsible for any injury, illness, or property damage
that is the result of not adhering to GFS and/or independent equipment/component operating, service,
maintenance, and/or installation requirement's or directives.
WARNING
Install the booth in compliance with locally enforced codes and standards.
WARNING
A fire suppression system is required by the International Fire Code and NFPA 33. A fire suppression
system is not supplied with this booth.
WARNING
Do not allow overspray to accumulate on the inside of the paint booth walls. When overspray accumulates,
remove it as soon as possible to prevent a possible fire hazard. Use a non-ferrous, non-sparking scraper to
eliminate any possibilities of igniting combustible material.
WARNING
Do not leave piles of paint sweepings in the booth as it creates a possible fire hazard.
WARNING
Treat used filters and any other paint-contaminated items as flammable products and dispose of them
safely.
WARNING
Improper disposal of used filters may cause spontaneous combustion. You must consult local authorities for
proper storage and disposal requirements. Guidelines include:
• Immediately remove all filters from the booth.
• Discard filters to a safe, detached location, place them in a non-combustible container with tight-fitting lid,
or place them in a water-filled metal container to prevent a possible fire hazard.
• Disposal varies depending on the type of paint that is being captured. Consult local authorities for storage
and disposal requirements.
Booth safety
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WARNING
Duct the exhaust air from the fan away from the working environment to the outdoors. Do not operate the
booth unless exhaust has been ducted properly.
WARNING
Isolate the outdoor vent from air-conditioning intakes, windows, and any other equipment that may re-
circulate the exhaust indoors.
WARNING
Turn on the exhaust fan before using the spray booth. Ensure that the exhaust fan is operating correctly
before entering the booth.
WARNING
Check local codes to see if a booth interlock is required. A booth interlock prevents the spray devices from
operating unless the booth fan is operating.
WARNING
Some spray activities may require the use of respiratory protection.
WARNING
Use an OSHA-approved paint spray respirator when spraying in the booth.
WARNING
This equipment is designed for the removal of particulate matter only. Reduction of volatile organic
compounds (VOCs) requires either coating reformulation or optional, additional equipment.
CAUTION
Become familiar with all controls before operating or servicing this booth.
CAUTION
Proper door alignment is critical to the operation of the booth. Ensure that there is equal space around the
doors. Move the bottom of the door jamb to the left or right or in and out until the doors are sealed and
plumb.
CAUTION
If this installation includes pumps or compressors, install and connect those devices in accordance with the
manufacturer’s documentation.
NOTICE
GFS recommends storing crates indoors pending installation. If you must store crates outside, protect
crates and their contents from moisture to prevent damage to equipment.
NOTICE
Install the control panel per NFPA 70 and local codes and standards.
NOTICE
Failure to anchor the booth structure to the floor properly may result in structural damage.
Booth safety
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Booth description
GFS' Ultra Closed-Top Open-Front (CTOF) Booth line provides a versatile, end-to-end finishing environment
that allows vehicles to be filled, primed, sealed, painted, and cured in one location.
The semi-downdraft booth is a hybrid, combining features of both crossdraft and downdraft booths. Air is
introduced to the working area through the ceiling in the first 25 to 30 percent of the booth. It is then pulled
across the working area, over the product, and into the filtered exhaust chamber at the rear of the booth.
Figure 1. Airflow in a semi-downdraft booth with a BT air heater
Booth description
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Preparing for installation
Accepting delivery of your booth
The booth is delivered unassembled, in multiple crates.
Upon delivery, count the number of crates you received and compare that number to the expected number
per the Bill of Lading. Also inspect each crate for any signs of damage during shipment.
NOTE
If you see shipping damage, note it on the freight carrier's paperwork; failure to do so may result in claim
denial.
If any parts are missing or damaged, contact Global Finishing Solutions at 800-848-8738 to speak to a
Technical Service Representative.
NOTICE
GFS recommends storing crates indoors pending installation. If you must store crates outside, protect
crates and their contents from moisture to prevent damage to equipment.
Preparing for installation
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Gathering required documentation
Ensure that you can locate these documents and that they are available during the installation procedure.
NOTE
Table 3 lists the location of the hard-copy documents that ship with the booth. The Installation Manual, Job-
Specific Guide, Design Drawings, Service/Operations Manual, and the appropriate control panel operator
manual are also provided electronically to distributors via box.com.
Table 3. Additional documents related to booth installation
Document Description How provided
Design Drawings Provides instructions for assembling this particular booth
and includes information about the booth order, configu-
ration, and components.
Ships in the “Miscellane-
ous” box
Electrical Drawings Provides wiring diagrams for electrical components. Ships inside the air heat-
er control panel
Control Panel Operator Manual Setup and operation instructions for the appropriate con-
trol panel:
• Engage®Control Panel Operator Manual
• LOGIC 3 Control Panel Operator Manual
• LOGIC 4 Control Panel Operator Manual
Ships inside the air heat-
er control panel
Air heater owner’s manual Installation, operation, and maintenance instructions for
the air heater; either:
• GUL/BT Series Owner’s Manual (for GUL and BT air
heaters)
• SpaceSaver®Series Owner’s Manual
Ships inside the air heat-
er control panel
Final Commissioning Document
(D0420) Includes all tasks related to booth startup and commis- sioning. Ships inside the air heat- er control panel
Preparing for installation
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Confirming site requirements
Before beginning the installation procedure, confirm that the site where the equipment will be assembled
meets the following requirements:
• The floor where you will assemble the paint booth is level.
NOTE
If the floor is more than 1 inch out of level, you must shim or grout the floor to avoid any misalignment.
• The area is large enough to allow a minimum of 3 feet (914 mm) of clear space on all four sides of the
booth, taking into account if additional space is needed for an air heater or Air Make-Up Unit. Check local
codes and refer to NFPA guidelines to determine particular space allowances.
• There is sufficient overhead clearance for the exhaust unit and exhaust ductwork in the area where the
equipment is to be located.
• A licensed electrician has verified that the incoming power meets the requirements specified for the
equipment. (The power specification is included with the submittal or provided at delivery.)
• The appropriate devices for lifting/rigging are available onsite. (Either purchased from GFS with the
booth, or obtained elsewhere by the customer.)
• The appropriate miscellaneous hardware kits are available on-site. (Either purchased from GFS with the
equipment, or obtained elsewhere by the customer.)
Confirming booth layout
Before beginning the installation procedure, review the booth configuration and layout with the end user. Be
sure you understand what options this booth includes and how the end user wants to arrange the booth.
The GA page of the Design Drawings shows one possible booth layout. However, end users might want
their booths arranged differently. During installation, you must make the appropriate adjustments to
the instructions to accommodate the actual booth layout.
For best results, review the GA page of the Design Drawings drawing with the end user and discuss the
items listed below:
• Where does the end user want to place the air heater? (See Table 4.)
• Right side, toward front of booth
• Left side, toward front of booth
• Is this booth a drive-through booth (a booth with a product door or curtain on each end) or a solid-back
booth?
• Where does the end user want to locate the personnel door?
• On the left or right side of booth?
• At which panel position?
• Where does the end user want to place the operator interface terminal/HMI?
NOTE
Per NEC, the operator interface terminal cannot be located within 3 feet of any door opening. Refer to the
HMI Installation page of the Design Drawings for more information about placement restrictions.
Preparing for installation
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• On an exterior booth wall? (If so, specify which.)
• On a nearby wall? (If so, determine distance and orientation relative to booth.)
•If applicable: Within the booth’s interior, how does the end user want to arrange the wall lights?
• If the booth includes standard options and accessories, where should those items be located? (Examples
include additional light fixtures, rotating access tables, observation windows, parts hangers, additional
personnel doors, etc.)
Table 4. Air heater positions
Air heater position relative to booth
Layout1Description
Right-front2Right side, toward front of booth
R
L
BF
Left-front Left side, toward front of booth
R
L
BF
1Air heater position is defined by the booth wall to which the heater connects (left side wall, right side wall, or back wall). When the air
heater connects to the left or right side wall, the description also indicates whether the air heater is closer to the front or back of the
booth.
2The “right-front” air heater position is the default layout depicted on the GA page of the Design Drawings.
Preparing for installation
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About the Design Drawings document
Use this manual in conjunction with the provided Design Drawings document. This Design Drawings
document defines the overall layout and detailed structure of your particular booth. If applicable, it also
includes exploded-view diagrams and parts lists for each section (or subassembly) of the booth.
Page elements
Pages within the Design Drawings document contain the following elements:
•Title block: The title block is located along the right edge of each page. It contains the model
information, drawing identification label or number, the order/serial number, and other information.
•Model Info: Contains text that identifies each page within the Design Drawings document, e.g., “Overall
Assembly". When the installation instructions refer you to a specific page within the Design Drawings,
look for that text in the Model Info field. (For a description of the various page types that might be
included in your Design Drawings document, see “Page types” (page 17).)
•Scale: If the drawing is to scale, the scale is defined here (e.g., 3/16" = 1' 0"). Otherwise, this field
contains "NTS," or "Not to Scale."
•Drawings: The main area of each page can contain any or all of these types of drawings:
• An exploded and/or assembled view of the product or subassembly
• Additional views or “Detail” drawings
•Bill of Materials: Any page that includes a drawing with labeled parts also includes a table that lists each
item number with its corresponding part number and quantity.
•Quantity per Booth: Pages that show a subassembly of the product and list the quantity provided of that
particular subassembly.
•Notes: Pages within the Design Drawings often contain notes that provide information about how to
install that particular section or subassembly.
About the Design Drawings document
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A: Title block
B: Model info
C: Drawing number
D: Drawings: Main view (exploded and/or assembled)
E: Drawings: Detail view
F: Bill of materials
G: Quantity per booth
H: Notes
About the Design Drawings document
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Page types
The Design Drawings document may contain any of the following pages that apply to your particular
product.
Table 5. Page names in the Design Drawings document
Page name Description
AdvanceCure Provides instructions for installing the optional GFS AdvanceCure System.
NOTE
This page applies only to booths that include AdvanceCure.
AdvanceCure Intake & Dis-
charge Cover Kit Shows how to install cover plates at locations where the optional GFS AdvanceCure System integrates with the booth.
NOTE
This page applies only to booths that do not include the AdvanceCure.
Air Heater Provides instructions for installing the air heater base and burner.
Air Inlet Hood Shows how to assemble the air inlet hood that goes on top of the intake stack.
Basement Ramp Assembly Shows how to assemble vehicle ramps.
NOTE
This page applies only to downdraft booths that use a raised basement instead of a tradi-
tional pit.
Booth Caulking Guide Provides instructions for applying caulk to the booth.
Corner Light Harness Shows how to run the wire harness cables to the optional corner light from the control panel.
Corner Light Installation Shows how to install optional corner lights.
Diffuser Assembly Shows how to install the diffuser for an air heater with side-entry into the booth plenum.
Discharge Hood Assembly Shows how to assemble the discharge hood that connects the air heater to the booth ple-
num.
NOTE
This page applies only to booths that have a BT or GUL air heater.
Exhaust Yoke Shows an exploded view of the exhaust yoke located at the rear of the booth.
NOTE
This page applies only to semi-downdraft booths.
Filter Ceiling Shows how to install the filter ceiling.
Floor Profile Shows how to install the floor channel and floor-leveling components.
Floor Profile Tek-Screw Detail Shows how to secure the wall panels to the floor profile.
Front Wall Shows an exploded view of a drive-through end wall (a wall that accepts a product door).
NOTE
A Front Wall assembly is always installed at the front of the booth. For drive-through booths
(which have a product door at each end), a Front Wall assembly is also installed at the rear
of the booth.
About the Design Drawings document
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Page name Description
GA Provides a top view of the booth as well as front, side, and rear elevations.
NOTE
The GA page shows the standard booth arrangement and is provided for reference only; it is
not customized for the booth you are building.
NOTE
The actual placement of some components (such as the air heater, personnel door, wall
lights, etc.) might be different than shown on this page. Always consult with the end user
for placement details, as described in “Confirming booth layout” (page 13).
Hip Panels Shows how to install the hip light panels.
HMI Installation Provides instructions for installing the operator interface terminal.
Install Curtains Shows how to install curtain mounting tracks.
Locking Rod Shows how to install the locking rod assembly for product doors.
Label Placement Instructions Shows where to place various booth labels, including exit, maintenance, and safety labels.
Light Fixture Details Shows how to install booth lights.
Overall Assembly Shows an exploded view of the entire booth; identifies the major components and sub-as-
semblies of the booth.
Personnel Door Shows how to install a personnel door and its associated hardware.
Rear Wall Shows an exploded view of a solid end wall.
NOTE
This page applies only to booths that are not drive-through booths.
Recirc Duct Assembly Shows how to assemble and install the ductwork that goes between a recirc air heater and
the exhaust yoke.
Reflector Light Fixture Shows how to install the optional light-reflector kit.
Roof Panels Shows how to install the roof panels.
Roof Support Assembly Shows how to install the roof support assembly.
Side Wall Shows an exploded view of a side wall.
NOTE
The Design Drawings always contains two Side Wall pages: one that includes a personnel
door, and one that does not include a door.
Temp Sensor & Diffuser/Baffle Provides instructions for installing the temperature sensor and a diffuser (for an air heater
with side-discharge into the booth) or a baffle (for an air heater with down-discharge into the
booth).
Wire Harness Shows how to run the wire harness cables for the lights to the air heater control panel.
About the Design Drawings document
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Required materials
This section lists the tools, equipment, and documentation required for installing your booth.
NOTE
Depending on the type of booth you are installing, additional tools or equipment may be required.
Required tools
• Screwdrivers
• Wrenches and socket set
• Hammer and mallet
• Load bar that can extend to at least 9 feet (108 inches)
• Filter-insertion tool (metal pizza cutter; approximately 3-inch to 4-inch diameter)
• Drift pins (two per person; 1/8-inch to 5/8-inch taper)
• Caulk gun
• Impact driver and drill
• Unibit or step drill bits
• Chalk and/or felt-tip marker (for marking initial measurements on floor)
• Chalk-line tool
• 4-foot box level
• Laser level (Suggested: Quad laser or rotary laser level)
• Tape measures (35-foot and 100-foot)
• Tin snips
• Duct crimping tool
• Torque nut runner
• Reciprocating saw
•Optional: Torch and welder in case modifications need to be made on site
• Tools required for decal placement:
• Stiff squeegee
• Spray bottle with soapy-water mixture
• Paper towels
• Scissors
• Masking tape
• Marker
Required materials
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Recommended equipment
• Ladders (6-foot and 8-foot)
• Two or more sawhorses
• Two 26-foot T scissor-lift platforms
• Warehouse forklift with 5000-pound lift weight and a maximum lift height higher than 16 feet
NOTE
Lifts and cranes are not required, but they may improve both the safety and speed of installation.
NOTE
The end user is responsible for providing any lifts, cranes, and material handlers. Alternatively, the end user
can coordinate with the installer so the installer can rent those items before starting the work.
Required materials
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