M:/Electrical/OVEN MANUAL/MANUAL/GEN AND MISC INSTRUCTIONS/Oven General Instructions

M:\Electrical\OVEN MANUAL\MANUAL\GEN AND MISC INSTRUCTIONS\Oven General Instructions.
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GENERAL INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
FOR OVENS

TABLE OF CONTENTS

1 SHIPPING DAMAGE & HANDLING

2 PROPER OVEN APPLICATION
2-1 General
2-2 Flammable Solvents
2-3 Combustible Material
2-4 Personnel Hazards
2-5 Maintenance and Inspection

3 INSTALLATION
3-1 Location
3-2 Building Considerations
3-3 Clearances
3-4 Ventilation
3-5 Exhaust Ductwork
3-6 Fuel Gas Supply
3-7 Electrical

4 PRIOR TO PLACING OVEN IN SERVICE
5 PROCESSING
6 SAFETY EQUIPMENT
7 MAINTENANCE
8 TROUBLE SHOOTING
9 APPENDIX A - SAFETY EQUIPMENT, DESCRIPTION & OPERATION
10 APPENDIX B - REFERENCES
11 APPENDIX C - MINIMUM PERIODIC MAINTENANCE REPORT
12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE
13 APPENDIX E - WARRANTY AND LIMITATIONS OF REMEDIES

Following these GENERAL INSTRUCTIONS in your manual are the following:

-OPERATING INSTRUCTIONS SPECIFIC FOR YOUR EQUIPMENT
-MECHANICAL PARTS LIST
-ELECTRICAL WIRING AND COMPONENT PARTS LIST
-LITERATURE AND INSTRUCTIONS ON COMPONENTS

These GENERAL INSTRUCTIONS have been written for many different types of ovens,
therefore, some equipment or components referred to may not be present on your
particular piece of equipment.

After reading these GENERAL INSTRUCTIONS, also read the specific OPERATING
INSTRUCTIONS written for your equipment. An additional copy of the OPERATING
INSTRUCTIONS is provided in a plastic cover. Post these instructions at the oven for
the operator to reference.
M:\Electrical\OVEN MANUAL\MANUAL\GEN AND MISC INSTRUCTIONS\Oven General Instructions.doc

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1 SHIPPING DAMAGE AND HANDLING

DO NOT RETURN DAMAGED MERCHANDISE TO US.
FILE YOUR CLAIM AS OUTLINED BELOW

This merchandise has been thoroughly inspected and carefully packed before leaving our plant.
The carrier assumed responsibility for its safe delivery at the time of shipment. Claims for loss
or damage to the contents must be made with the carrier, as follows:

1-1 VISIBLE LOSS OR DAMAGE

Any external evidence of loss or damage must be noted, at the time of delivery, on the freight
bill or express receipt and signed by the carrier's agent. Failure to adequately describe such
external evidence of loss or damage may result in the carrier refusing to honor a damage
claim. Make a written request for inspection by the carrier's agent within fifteen days of the
delivery date. Review the inspection report and do not sign it unless it adequately describes
the damage.

A claim must be filed with the carrier since such damage is the carrier's responsibility.

1-2 CONCEALED LOSS OR DAMAGE

Concealed loss or damage means loss or damage, which does not become apparent until the
merchandise has been unpacked. The contents may be damaged in transit due to rough
handling even though the carton may not show external damage. When the damage is
discovered upon unpacking, contact the carrier and make a written request for inspection by
the carrier's agent within fifteen days of the delivery date. Review the inspection report and do
not sign it unless it adequately describes the damage.

A claim must be filed with the carrier since such damage is the carrier's responsibility. By
following these instructions carefully, we guarantee our full support of your claims to protect
you against loss from concealed damage.

1-3 RETURNING DAMAGED EQUIPMENT

Damaged equipment will not be accepted at our factory unless we have been advised and
instructions provided on how it should be returned. A copy of the freight claim must be
provided prior to returning the equipment.

1-4 HANDLING

After inspection, store and handle all equipment and components in their original crates until
ready for installation. Handle with care. The equipment may be heavy but some components
are of a delicate nature. If the equipment is to be stored, keep it in the original crates and
store in a location free from excessive dust, heat and moisture until ready for installation.


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2 PROPER OVEN APPLICATION

2-1 GENERAL

2-1.1 While ovens are extremely versatile, they are usually purchased with a specific
application in mind. If your process has changed significantly or if you should have
reason to doubt that a specific application is a proper use of the equipment, consult the
factory before proceeding.

2-1.2 Explanatory Material (Annex A1.1) of National Fire Protection Association Publication
86 "Standard for Ovens and Furnaces" states; in part:

"Explosions and fires in fuel-fired and electric heat utilization equipment constitute a
loss potential in life, property and production.

Most failures can be traced to human error. The most significant failures include
inadequate training of operators, lack of proper maintenance, and improper
application
of equipment.

2-1.3 To protect the oven, oven contents, property and personnel, a responsible person
should be in attendance during operation. Do not operate oven unattended. Special
attention must be paid to:

-Setting correct temperature.

-Placing flammable solvents in an oven not designed for that purpose.

-Placing combustibles in an oven that does not have adequate fire
protection.

-Allowing the product to remain in the oven too long, thereby encouraging
combustion.

-Using an oven for a process other than that for which it was designed.

2.2 FLAMMABLE SOLVENTS

2-2.1 Processing solvents in a non-solvent oven, exceeding the design temperature, or
exceeding the maximum amount of solvent allowed in an oven, could result in fire or
explosion and bodily injury or property loss.

If flammable solvents or vapors will be present in an oven, the Occupational Safety &
Health Administration (OSHA) requires that it have a separately powered forced
exhauster of adequate size and other related safety devices not supplied as standard
equipment. Ovens designed for this purpose have a caution plate and Safety Design
Form showing the maximum gallons of solvent, or pounds of powder coating, and the
maximum operating temperature for which that specific oven has been designed. If in
doubt, consult factory for details.

2-2.2 It shall be the user's responsibility to ensure that the amount of flammable solvent
placed in the oven and the operating temperature does not exceed the design capacity
-- see Safety Design Form and oven caution nameplate.

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2-2.3 In areas outside of the oven where flammable solvents are given off by material prior
to entering the oven, provisions shall be made to exhaust these vapors to atmosphere
to prevent them from being pulled into the oven or collecting and creating a flammable
mixture.

2-3 COMBUSTIBLE MATERIAL

2-3.1 Introduction of combustible materials (such as paper, cardboard or wood) into the oven
should be avoided because it might cause a fire. Do not use combustible racks, trays,
holders, spacers, etc. Periodically, clean all combustible material from non-
combustible racks, trays, holders, spacers, etc. If combustible products must be
processed in an oven, extreme care must be taken to ensure that the operating
temperature does not exceed the ignition temperature of the product.

2-3.2 Ovens containing or processing sufficient combustible materials (including
consideration for combustible drippings or deposits) to sustain a fire shall be equipped
with an automatic fire protection system including areas in exhaust ducts that could
accumulate combustible material. Fire protection systems should be installed in
accordance with the applicable National Fire Protection Guidelines:

-Sprinkler Systems in accordance with NFPA 13
-Water Spray Systems in accordance with NFPA 15
-Carbon Dioxide Extinguishing Systems in accordance with NFPA 12
-Foam Extinguishing Systems in accordance with NFPA 11
-Dry Chemical Extinguishing Systems in accordance with NFPA 17
-Water Mist Systems in accordance with NFPA 750

The extent of protection required will depend upon the construction and arrangements
of the oven as well as the materials handled. Fixed protection, such as automatic
sprinklers or other types of fire extinguishing systems should be designed and installed
by a qualified contractor.

2-3.3 Drip pans shall be provided to collect any combustible materials that may accumulate
beneath the product. A maintenance program must be developed to remove any such
accumulation before a substantial build up occurs that could spontaneously ignite and
cause a fire. If you cannot acquire drip pans locally, contact us for a quotation.

2-4 PERSONNEL HAZARDS

2-4.1 You must analyze your use of this equipment and determine if it creates a confined
space hazard, as defined by OSHA, in your work place. You are responsible for
posting appropriate warnings and complying with applicable OSHA STANDARDS
pertaining to confined space hazards. Reference ANSI Z117-1 Safety Requirements
for Confined Spaces; see Appendix B.

2-4.2 If inert atmospheres are to be used, keep in mind that inert gases displace air and
create oxygen-deficient atmospheres. For this reason, they can cause suffocation.
Moreover, some inert gases, such as argon, are heavier than air and can collect in low
lying or sealed areas creating oxygen-deficient pockets within the work place. Use
inert atmospheres only in large work places with good ventilation. Do not breathe in or
enter an inert atmosphere piece of equipment until it has been thoroughly purged with
air.

2-4-3 Explosion venting door latches will allow oven doors to open if pressure develops in
the oven. For this reason doors should face away from main aisles and work areas.


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2-4.4 Heat processing equipment must always be used with caution. Proper equipment
such as insulated gloves, safety goggles and tongs should be used for reaching into
hot equipment. Proper supervision is essential and only trained personnel should be
allowed to operate the oven.

Always remember you are working with elevated temperatures.

-Do not touch surfaces - they could be hot and burns could result.

-Do not breathe hot oven air. Heated air could burn lungs.

-Many items become dangerous when heat is applied. Explosion or fire
could result. Make sure you know what you are putting in the oven can
be heated safely at the oven operating temperature.

2-4.5 Disconnect power before servicing equipment. Ovens operate under high voltage and
electrical shock is possible. Proper panel lockout procedures should be followed.

2-4.6 Disconnect other sources of potential energy such as compressed air, before
servicing. Proper lockout procedures should be followed.

2-4.7 Do not operate mechanical or electrical equipment with guards removed. Operating
with guards removed could result in bodily injury.

2-4.8 Ovens with vertical lift doors or top-loading doors must be blocked open before
passing beneath them. A falling door may cause bodily injury. A safety pin or support
strut is provided for this purpose.

2-5 MAINTENANCE AND INSPECTION

2-5.1 Regularly scheduled inspection and maintenance of all safety devices shall be
performed by user. Failure to do this may result not only in fire or explosion damage,
but also contribute to accidental shutdowns and loss of production. See Section 7
Maintenance and Appendix C Minimum Periodic Maintenance Report.

2-5.2 Regularly scheduled inspection of the oven interior, heat chamber and ductwork shall
be performed by user to determine need for cleaning and repair. Failure to do this
may result in internal fires or component failure resulting in oven damage and loss of
production.

2-5.3 It shall be the sole responsibility of the user to establish, schedule and enforce the
frequency of and the extent of the inspection/maintenance program (as well as the
corrective action to be taken) because only the user can know what the actual
operating conditions are. Contact your insurance authority, Factory Mutual or the
National Fire Protection Association, whose addresses are listed in Appendix B, for
more information on inspection/maintenance programs.

2-5.4 It shall be the responsibility of the end user to determine that current processing is
within the scope of the original design of the equipment.

2-6 RETROACTIVITY

This equipment has been designed and manufactured in accordance with applicable National
Codes in effect as of the date of manufacture. It is the responsibility of the end user to update
equipment as necessary to comply with future code changes. If you are in doubt, contact
manufacturer to review your equipment design against current National Codes.


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3 INSTALLATION

3-1 LOCATION

3-1.1 Ovens shall be located to protect them from damage by external heat, vibration and
mechanical hazards.

3-1.2 Ovens shall be located to make maximum use of natural ventilation, to minimize
restrictions to adequate explosion relief, and to provide sufficient air supply for
personnel. Room volume should be at least 10 times the oven volume.

3-1.3 Ovens shall be located to minimize exposure to power equipment, process equipment
and sprinkler risers. Unrelated stock and combustible materials shall be maintained at
a fire-safe distance but not less than 10 feet from an oven, an oven heater or
ductwork.

3-1.4 Ovens shall be located to minimize exposure to people from the possibility of injury
from fire, explosion, asphyxiation, and hazardous materials and shall not obstruct
personnel travel to exit ways.

3-1.5 If the oven control panel is located away from the oven, operators must be allowed
access to the control panel and/or main disconnect to allow them to shut down the
oven in an emergency.

3-1.6 Ovens shall be located to prevent an ignition source to flammable coating dip tanks,
spray booths and storage and mixing rooms for flammable liquids, and to prevent
exposure to flammable vapor or combustible dust clouds. Ovens should not be
located in hazardous (classified) locations unless they are designed to comply with the
applicable requirements of NFPA 70 National Electrical Code (see Appendix B).

3-1.7 Equipment shall be protected from corrosive external processes and environments,
including fumes or materials from adjacent processes or equipment that produces
corrosive conditions when introduced into the oven environment.

3-1.8 The oven is not intended for outdoor installation and must be sheltered from weather.
Unheated shelters may result in non-uniform temperatures or insufficient heat to attain
maximum operating temperature. Condensation may also occur which would be
detrimental to the steel structure and electrical components.

3-1.9 Suitable portable fire extinguishers should be available and operators trained in their
use. All such fire protection equipment should be inspected periodically in accordance
with appropriate standards. Reference NFPA 10 Standard for Portable Fire
Extinguishers (see Appendix B).

3-2 BUILDING CONSIDERATIONS

3-2.1 When selecting the location for an oven, consideration must be given to the possibility
of fire, building damage and personal injury. Hazards to be considered include
overheating of material in the oven and escape of fuel gas or exhaust into the work
place.

3-2.2 Ovens shall be located and erected so that the maximum anticipated temperature
does not affect the building structural members adversely or by the additional loading
caused by the oven and load.

3-2.3 Ovens should be placed on noncombustible floors or on structures approved for use
over combustible floors such as concrete floor slabs or hollow tiles.

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3-2.4 If necessary, level the oven using shims. Due to expansion, larger ovens may change
shape when heated and require the shims to be adjusted when the oven is hot. Where
mounting holes are provided, anchor the oven securely. Shims should be permanently
mounted to the oven after installation.

3-3 CLEARANCES

3-3.1 Ovens shall be located with adequate space above and on all sides to allow for
inspection, maintenance and operator access. Provisions also shall be included for
unobstructed discharge of building sprinklers, the installation of automatic fire
protection system within the oven, if necessary, and the proper functioning of
explosion relief doors and panels.

3-3.2 Do not place the oven up against a wall. A minimum air space of 3 inches must be
provided on all sides to allow for air circulation, with additional space being provided
for ovens operating over 450F (232C) to keep temperature at adjacent structures
and materials below 160F (71C). Local, city and state codes may specify building
requirements and special provisions for locating ovens.

3-3.3 The oven should be located so there is unrestricted air circulation around all motors for
proper cooling.

3-3.4 Do not store material on top of oven. Material may get hot, ignite and cause a fire. The
oven is not designed to carry exterior loads and, if equipped with explosion venting
roof panels, material stored on top of the oven will restrict explosion venting panel
operation.

3-3.5 To prevent ignition of combustible material, combustible material shall be located at a
safe distance from the oven and oven ductwork. The National Fire Protection
Association (NFPA) Standard 86 specifies a minimum distance of 2-1/2 feet; Factory
Mutual (FM) specifies at least 10 feet.

3-3.6 The oven doors have explosion-venting latches, which will allow the doors to open if
pressure develops in the oven. The door travel must not be restricted and should face
away from main aisles, work areas and automatic sprinkler risers, feeds and cross
mains.

3-3.7 If the oven is equipped with explosion venting roof panels, the panels must not be
obstructed in any way. Explosion venting roof panels will have the panel edges
exposed - if in doubt, consult factory. Sufficient headroom must be provided for the
panels to lift completely out of the oven. Minimum clearance is the oven wall thickness
plus 12".

3-4 VENTILATION

3-4.1 Where ovens are located in basements or enclosed areas, sufficient room ventilation
shall be supplied to provide required combustion air for fuel-fired equipment and to
prevent the hazardous accumulation of vapors from processing.

3-4.2 Ovens designed for use with fuel gas having a specific gravity greater than air (such as
propane) shall be located at or above grade and shall be located to prevent the escape
of the fuel gas from accumulating in basements, pits, or other areas below the oven.

3-4.3 Fresh air inlets and exhaust outlets must never be restricted. If filtered air is provided,
there must be adequate filter capacity to prevent any reduction in airflow even under
adverse loading of the filter. The filters must be periodically inspected and replaced as
required.

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3-4.4 A sufficient quantity of building make-up air should be admitted to oven rooms and
buildings to provide the air volume required for oven safety ventilation and adequate
combustion air for fuel fired equipment. Buildings should not operate under a negative
pressure.

3-4.5 The oven is equipped with an exhaust outlet. This outlet must be connected to an
exhaust stack for discharge to an outside location, and in a manner in accordance with
local codes and requirements; or connected to outside indirectly through a fume
incinerator or other approved pollution device. The exhaust outlet is sized to fit
standard stove pipe components. Exhaust gas temperature is the same as internal
oven temperature. Caution must be taken to protect combustible building materials
from coming in contact with the hot exhaust stack.

3-4.6 The minimum safe exhaust rate must be confirmed for ovens equipped with a powered
forced exhauster to handle flammable solvent vapors or products of combustion from
fuel fired equipment. The exhaust rate has been set at the factory and dampers cut off
and screwed in place or in some other manner limited to prevent exhaust rate from
being reduced below safe minimum exhaust rate.

After installation, this exhaust rate must be confirmed. This must be done at the outlet
of the stack from the building. The exhaust rate must meet or exceed the minimum
rate indicated on the Safety Design Form located on the side of the oven. If it is
necessary to open the exhaust damper to increase the exhaust rate, it must be cutoff
or locked in position to prevent accidental closing.

Exhaust rate must be checked again if any changes are made to ventilation system,
duct work, or building ventilation. Adding additional equipment, which requires
ventilation, to the building will require additional make up air to the building to prevent
the building from operating under negative pressure. Operating building under
negative pressure will reduce exhaust rate from oven to below safe minimum exhaust
rate.

3-4.7 For additional ventilation information, refer to NFPA 31 Standard for the Installation of
Oil-Burning Equipment, NFPA 54 National Fuel Gas Code and NFPA 91 Standard
for Exhaust Systems for Air Conveying of Vapors, Gases, Mists and Noncombustible
Particulate Solids (see Appendix B).

3-5 EXHAUST DUCTWORK

3-5.1 Wherever oven ducts or stacks pass through combustible walls, floors, or roof, either
non-combustible insulation or clearance (or both) shall be provided to prevent
combustible surface temperatures from exceeding 160F (72C).

3-5.2 Where ducts pass through non-combustible walls, floors or partitions, the space
around the duct shall be sealed with non-combustible material to maintain the fire
resistance rating of the barrier. Ducts that pass through fire walls should be avoided.
Local, city and state codes may apply to duct installation.

3-5.3 Exhausts systems should be installed in accordance with Chapter 1, 2 and 3 of NFPA
91 Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and
Noncombustible Particulate Solids (see Appendix B).

3-5-4 Ducts shall be constructed entirely of sheet steel or other non-combustible material
capable of meeting the intended installation and conditions of service. The installation
shall be of adequate strength and rigidity and shall be protected where subject to
physical damage.

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3-5.5 Ducts handling fumes that leave a combustible deposit shall be provided with clean-
out doors and such doors should be equipped with tight fitting doors or covers. It is
important that ovens and ducts be kept clean if they are subjected to a build-up of
flammable deposits of condensed solvent, oil vapors, dust or other combustible debris.
The build-up of condensed vapors or combustible debris is a major cause of fires.
Frequency of cleaning should be based on never allowing build-up to exceed 1/8"
thickness in any location.

3-5.6 No portions of the building shall be used as an integral part of the duct.

3-5.7 All ducts shall be made tight throughout and shall have no openings other than those
required for the operation and maintenance of the system. All interior laps in the duct
joints should be made in the direction of the flow.

3-5.8 All ducts shall be thoroughly braced where required and substantially supported by
metal hangers or brackets.

3-5.9 Ducts handling flammable vapors shall be designed to minimize the condensation of
the vapors out of the exhaust stream onto the surface of the ducts. One method is to
insulate the ducts. If flammable condensation cannot be avoided, ducts should be
pitched to drain to suitable traps or other safe locations.

3-5.10 Ducts handling combustible solids shall be designed to minimize the accumulation of
solids within the ducts.

3-5.11 Exhaust ducts that will contain combustible deposits of any type require automatic
sprinklers in accordance with NFPA 13 Standard for Installation of Sprinkler Systems
(see Appendix B).

3-5.12 Exhaust ducts shall not discharge near building openings or other air intakes that allow
re-entry of effluents into the building.

3-5.13 Clearance between metal ducts and stored combustible material should be at least
2-1/2 feet. Guards should be installed to assure this clearance.

3-5.14 Multiple exhaust fans manifolded together should have manifold designed so that
operation of one or more exhaust fan does not create a hazard such as back flow to an
idle oven or reduced exhaust flow due to increased manifold pressure.

3-5.15 Duct work should not include dampers that could be closed and restrict flow within the
ductwork.

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3-6 FUEL GAS SUPPLY

3-6.1 Piping from the point of delivery to the equipment should comply with NFPA 54,
National Fuel Gas Code. Local, city and state codes should be followed. Gas source
pressure must be less than 60 psig.

3-6.2 A gas filter or strainer and sediment trap with vertical leg (drip leg) at least 3 pipe
diameters long (3 minimum) of same size as supply piping, shall be installed in the fuel
gas supply piping to protect the downstream safety shutoff valves and regulator from
materials that could interfere with their operation.

3-6.3 All gas-heated equipment shall be provided with an individual gas pressure regulator
properly sized to supply the pressure and volume required. The oven nameplate lists
the gas pressure and the burner capacity. Gas pressure regulator should have the
following characteristics:
a. The regulator must be of the full lock-up type; gas pressure must be regulated
even under no flow condition.
b. Incoming pipe size should not exceed 2 diameter
c. Self contained with no external static or control piping
d. Single port with correctly sized orifice for the maximum gas pressure at the
regulator inlet.
e. Valve seat is of resilient material designed to withstand abrasion of gas, impurity in
gas, cutting by the valve and to resist permanent deformation by the valve port
f. Capable of regulating downstream pressure under no flow conditions to not more
than 150 percent of the discharge pressure under flow conditions.
If these criteria are not met, a pressure relieving or limiting device is required as
outlined in NFPA 54 National Fuel Gas Code.

3-6.4 A remotely located emergency manual shutoff valve shall be provided to allow the fuel
to be turned off in an emergency and shall be located so that fire or explosion at the
oven does not prevent access to this valve. Operators should be instructed on the
location of this valve and allowed access to shut off fuel flow in an emergency. Valve
shall have permanently affixed visual indication of position and operable without tools.

3-6.5 An equipment isolation shutoff valve must be provided at each piece of equipment.
Valve shall be quarter turn with stop, permanently affixed visual indication of position,
and operable without tools. Valve handle must remain affixed and be parallel to pipe
when open and perpendicular to pipe when closed.

3-6.6 Regulators and high or low gas pressure switch vent lines shall be piped to a safe
location outside the building according to local codes. Protect outlet from water entry
and provide bug screen.

3-6.7 Vent lines from regulator and switches of a single oven may be manifolded together in
such a manner that diaphragm rupture of one regulator or switch does not back load
others. The cross section of the vent manifold should be not less than the area of the
largest vent line plus 50% of additional lines.

3-6.8 Vent lines from multiple ovens shall not be manifolded together.

3-6.9 A normally open vent valve between safety valves shall not be combined with other
vents. Care must be taken to terminate a vent valve line in a safe approved location..


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3-7 ELECTRICAL

3-7.1 All electrical connections should be made in accordance with the appropriate local and
national codes. Refer to NFPA 70 National Electric Code (see Appendix B).

3-7.2 Properly size the electrical supply using information provided on the oven nameplate.
Electric supply must include a safety shut off such as a circuit breaker or fused
disconnect switch between your power supply and the equipment.

3-7.3 The oven must be adequately grounded. Grounding wire must be sized in accordance
with local codes. Where more strict codes do not exist, refer to the National Electrical
Code - NFPA 70. A grounding lug has been provided near the power input terminals.

3-7.4 Care must be taken during installation of electrical service to the control panel that
metal chips or filings do not get into electrical components. Cover components when
drilling or cutting control panel.

3-8 STEAM SUPPLY

3-8.1 Piping and fittings of steam supply shall be in accordance with ASME B31.1 Power
Piping (see Appendix B).


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4 PRIOR TO PLACING THE OVEN IN SERVICE

4-1 Read instruction manual completely. Additional copies of the Operating Instructions
have been provided in plastic covers for posting at the oven.

4-2 The excess temperature limit interlock should be connected to your alarm system. The
wiring schematic indicates where the alarm relay should be located for this alarm circuit.

4-3 After the installation is completed, replace all doors, covers and guards that had been
removed for shipment or installation. At no time should equipment be operated if covers
or guards are open, removed or partially closed.

4-4 When the equipment is placed in operation, check all blowers for proper rotation. Rotation
directional arrows are located near each blower. Three phase motors may be reversed by
interchanging any two (2) of the three (3) wires, which supply power to the oven. Do not
switch leads at the motor starter or motor. Single-phase motors are correctly set at the
factory but correct rotation should still be confirmed.

4-5 The exhaust rate must be checked on ovens equipped with a powered forced exhauster to
handle flammable solvent vapors or products of combustion from gas heated equipment.
This must be done at the outlet of the stack from the building. The exhaust rate must
meet or exceed the minimum rate indicated on the Safety Design Form located on the side
of the oven. If it is necessary to open the exhaust damper to increase the exhaust rate, it
must be cutoff or locked in position to prevent accidental closing.

4-6 Check incoming voltage against that shown on the nameplate.

4-7 Check operating current against the amperage shown on the nameplate.

4-8 On gas-heated equipment, purge gas line to oven of all air and check gas pressure
against that shown on the oven nameplate.

4-9 Tighten all terminals, especially on power connections, to minimize terminal and
component failure due to poor contact. Connections should be checked periodically for
tightness and signs of overheating.

4-10 All ovens will produce smoke and odors when first heated. The smoke and odors come
from three sources:

1) Surfaces that have been painted after test;
2) Binders that remain in the insulation;
3) Moisture that has been absorbed by the insulation.

If during the initial run of the oven, the smoke and odors become objectionable, set the
temperature at 300F and allow the oven to remain at 300F until the smoke is no longer
generated. Increase the temperature in steps until youve reached the maximum
operating temperature. It may take several days of running at the maximum operating
temperature to eliminate all smoke and odors.

If the oven is not heated for an extended time period, moisture may accumulate in the
insulation. When heated, this moisture will be driven out and the above process may have
to be repeated.


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4-11 Commissioning is required prior to releasing equipment for production. The party
responsible shall insure that installation is complete and done correctly. Safety systems
should be tested and operators trained. At the time of commissioning the first Periodic
Maintenance Inspection should be performed to familiarize personnel with the equipment.
See Section 5 - PROCESSING and Section 7 - MAINTENANCE.

4-11.1 Set points of all safety interlocks shall be documented for future reference.

4-11.2 Supply piping shall be checked for leaks.

4-11.3 Personnel operating, maintaining or supervising shall be instructed and trained in their
job functions and be required to demonstrate an understanding of the equipment, its
operation and safe operating procedures including emergency shutdown.

4-11.4 Equipment shall be operated in accordance with original design parameters.

4-11.5 Personnel operating, maintaining or supervising shall be informed of the danger of
removing, or rendering ineffective, safety devices.


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5 PROCESSING

5-1 DO NOT LEAVE THIS EQUIPMENT IN OPERATION UNATTENDED
When using any heat processing equipment there is always the risk of overheating due to
a component malfunction. A trained operator should always be present. If this is not
possible, the oven should be located where overheating will not cause damage to the
building, adjacent stock or endanger personnel. Special consideration should be made for
the potential of smoke damage should a fire ensue. Fire suppression equipment should
be installed to protect the oven and building. The excess temperature limit interlock
should be connected to the building alarm system.

5-2 For start-up, emergency shut down and operation of optional equipment refer to the
specific operating instructions for your equipment located elsewhere in the manual. A
second set of these specific operating instructions is provided for posting at the oven for
the operator.

5-3 When loading an oven care must be taken to avoid touching or insulating the
thermocouple or temperature sensor. Free air movement around this sensor is essential
for safe and correct temperature control.

5-4 The excess temperature limit interlock should be set slightly above the operating
temperature to protect the workload. Overheating of material is a major cause of fire loss.
Excess temperature limit interlock should indicate in the same temperature units (F or C)
as the main controller.

5-5 An alarm should be installed that will sound upon the excess temperature limit interlock
being activated. This alarm should be installed in an area where it will attract the attention
of plant personnel properly trained to take corrective action. The wiring schematic
provided in this manual indicates where the alarm relay should be located for this alarm
circuit.

5-6 Ovens handling flammable solvents and fuel-fired ovens have a minimum safe exhaust
rate. These ovens have cut off dampers on fresh air and exhaust. Do not close the fresh
air or exhaust beyond these settings.

5-7 Ovens that are designed for flammable solvent processing and/or are fuel fired, include a
purge timer. This timer is factory set based upon a specific application. DO NOT change
the purge timer setting. Purge time is calculated to exhaust four (4) oven volumes of fresh
air prior to allowing the heat to be turned on. Reducing purge time could result in failure to
remove combustible vapors from oven before heat is turned on. This could result in an
explosion and fire. A caution nameplate is located next to the purge timer indicating the
correct setting.

5-8 Do not overload the oven. Air circulation is very important to the proper operation of an
oven.

5-8.1 Ovens designed for shelf loading should not have parts placed on floor of workspace.
This surface could be hotter than air temperatures and it is not designed to support a
load.

5-8.2 Leave space between articles on each shelf to allow air to move between parts.

5-8.3 Parts should be staggered from one shelf to another, to prevent dead spots in the air
pattern.

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5-9 Open the exhauster and fresh air dampers enough to prevent fouling of the work. Where
significant amounts of smoke or moisture are being driven off in the oven process, it is
necessary to exhaust enough air to remove this material. Failure to provide sufficient
ventilation may result in condensation of oil or solvent vapors inside oven walls with a
resulting risk of fire.

5-9.1 When the exhaust is increased, the fresh air intake must also be increased. Failure to
do this will result in cold spots within the oven, particularly around the doors, since air
will be drawn in past the gaskets. When the fresh air intake damper is properly
adjusted, there will be a slight leaking of hot air out of the door gaskets. The fresh air
intake damper is located on the wall of the heat chamber or around the blower shaft
opening.

5-9.2 Proper balance of the fresh air inlet and exhaust outlet are essential for uniform air
temperature. Room air entering the fresh air inlet expands when heated and
pressurizes the workspace forcing air out the exhaust or past the door gasket. Too
much fresh air (or too little exhaust) can result in excessive leakage of hot air at the
door seal.

5-10 Where ovens are equipped with louvered ductwork, the louvers may be adjusted to give
the best performance for your particular process. The louvers were originally set at the
factory in an empty oven. Loading of your parts may affect uniformity. These louvers are
not designed for frequent adjustment and should only be changed when absolutely
necessary. Louvers should be opened where the workspace is cold and closed where it is
hot.

5-11 Hot loads, tongs and other hot tools or fixtures such as shelves and loading trucks, should
be located in areas clearly marked to warn plant personnel of the potential danger of burns
or fires caused by the hot parts.


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6 SAFETY EQUIPMENT

6.1 Practically all explosions and fires in ovens can be traced back to human error. It should
be noted that:

6-1.1 For the protection of personnel and property, careful consideration should be given to
the supervision and monitoring of conditions that could cause, or could lead to, a real
or potential hazard on any installation.

6-1.2 The presence of safety equipment on an installation cannot, in itself, ensure absolute
safety of operation.

6-1.3 There is no substitute for a diligent, capable, well-trained operator.

6-1.4 Highly repetitive operational cycling of any safety device can reduce its life span.

6-2 Electric relays and safety shutoff valves should not be used as substitutes for electrical
disconnects and manual shutoff valves.

6-3 Regularly scheduled inspection, testing, and maintenance of all safety devices shall be
performed. (See Section 7 - MAINTENANCE and Appendix C - MINIMUM PERIODIC
MAINTENANCE REPORT)

6-4 Safety devices shall not be removed or rendered ineffective by bypassing them electrically
or mechanically.

6-5 New equipment includes the safety equipment listed below as required by NFPA 86 for
ovens not processing flammable solvents or vapors. Additional safety equipment is
required for ovens processing flammable solvents or vapors. Other processes may
require additional safety equipment. See Appendix A SAFETY EQUIPMENT
DESCRIPTION & OPERATION for detailed explanation of each item.

6-5.1 For electric ovens:
-manual reset excess temperature limit interlock
-separate heating element control contactors
-recirculating blower air flow switch

6-5.2 For gas heated ovens:
-recirculating blower airflow switch
-powered forced exhauster
-exhauster airflow switch
-purge timer
-combustion air flow switch
-high gas pressure switch
-low gas pressure switch
-two (2) main safety shut off valves and test stations
-two (2) pilot safety shut off valves and test stations

6-5.3 For steam heated ovens:
-separate back-up steam valve
-recirculating blower air flow switch

6.6 No matter how much safety equipment is provided on the oven, it cannot protect the
operator, other personnel or property from unsafe conditions caused by poor judgement or
misapplication. Common sense must be used for safe operation. If in doubt, contact the
factory. Check the process periodically to ensure oven is being used as originally
intended.

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7 MAINTENANCE

7-1 For safe oven operation, a preventive maintenance program must be developed and
followed for each individual oven application. The user should review recommendations
from their insurance underwriters. We suggest the review of Factory Mutual (FM)
Specification 6-9 on Industrial Ovens and Dryers and the National Fire Protection
Association (NFPA) Specification 86 on Ovens and Furnaces. We also recommend a
Maintenance Report be developed which lists tests and inspections performed. A copy of
this report should be kept on file for future review.

A Minimum Periodic Maintenance Report is provided in Appendix C as an example for
developing your own periodic maintenance schedule and report.

7-2 Regularly scheduled inspection and maintenance of all safety devices shall be performed
by the user to ensure proper function. At a minimum, the unit should be fully inspected
annually.

7-3 Disconnect fuel, electric power, steam, compressed air and any other energy source
before servicing equipment. Ovens operate under high voltage and electrical shock is
possible. Proper OSHA required lockout procedures should be followed.

7-4 Ovens with vertical lift doors or top-loading doors must be blocked open before entering.
Falling door may cause bodily injury. A safety pin or support strut is provided for this
purpose.

7-5 Do not operate mechanical or electrical equipment with guards removed. Operating with
guards removed could result in bodily injury.

7-6 The oven work space or heat chamber may constitute a confined space as defined by
OSHA. If so, comply with OSHA confined space hazard requirement (ANSI Z117-1).

7-7 RECOMMENDED MAINTENANCE ITEMS:

It shall be the sole responsibility of the user to establish, schedule and enforce the
frequency of and the extent of the inspection/maintenance program (as well as the
corrective action to be taken) because only the user can know what the actual operating
conditions are. Personnel who are familiar with the equipment should make the tests. It is
usually better that maintenance personnel from mechanical and electrical departments
check the equipment rather than regular oven operators. These additional observers may
find changes that may be otherwise overlooked.

The following are minimum maintenance items we recommend be covered. Your list will
vary depending upon the specific oven and operating conditions.

7-7.1 Application

7-7.1.1 The user is responsible to ensure that the oven process has not changed from the
conditions for which it was designed and that the oven is not modified.
Specifically, it must be ensured that the design exhaust rate is obtained, and that
amount of flammable solvents placed in the oven and the operating temperature
does not exceed the design capacity.

7-7.2 Electrical

7-7.2.1 Periodically tighten all terminals, especially on power connections, to minimize
terminal and component failure due to poor contact.

7-7.2.2 Periodically inspect contacts in contactors, relays, motor starters, etc., for signs of
wear or sticking.

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7-7.3 Oven Body

7-7.3.1 The exterior of the oven should be touched up whenever scratches occur to
prevent rusting.

7-7.3.2 Do not allow accumulation of combustible material or other foreign matter in the
work space, heat chamber (including heating element or steam coil surfaces)
ductwork, air inlets, exhaust outlets, filters, control enclosures, motors, safety
switches, door latches, and door hinges. Care must be taken in cleaning any
combustible build-up to avoid creating a source of ignition (spark). Scraping with
non-sparking tools or melting with steam is suggested. Lint and dust should be
removed by vacuum cleaning. Blowing with compressed air or steam should be
avoided if there is a possibility of explosion from a combustible dust cloud.

7-7.3.3 Do not allow accumulation of combustible material on work holders, drip pans or
on floor of oven.

7-7.3.4 Temperature control and excess temperature limit interlock thermocouples must
be inspected periodically for damage. Location of the thermocouples cannot be
changed. Thermocouples must be located in free air not touching any portion of
oven body, load-handling material such as shelves, racks, or the work load.

7-7.3.5 Roof and wall explosion relief panels with or without latches must not be restricted
by storage material or other items placed on or near panels, which can limit
operation.

7-7.3-6 Oven repair by cutting, welding or any other method that could produce a source
of ignition (spark) should be avoided and only then after all combustible deposits
or debris have been removed.

7-7.4 Duct Work

7-7.4.1 It is important oven ducts be kept clean. If they are subjected to a build-up of
flammable deposits of condensed solvent, oil vapors, dust or other combustible
debris they must be periodically cleaned. The build-up of condensed vapors or
combustible debris is a major cause of fires. Cleaning frequency should be
determined by process requirements.

7-7.5 Lubrication

7-7.5.1 Electric motors having oil holes require lubrication after every 25,000 hours or 3
years of light duty operation. Use a good grade of SAE 10 electric motor oil or as
recommended by the manufacturer of the motor. Larger motors in the integral
horse power range, which require grease, should be greased every six (6) months
or more frequently where the severity of the service would dictate. No special
heat resistant grease is necessary.

7-7.5.2 All bearings, including those on blowers, exhauster or conveyor system, should
be greased every six (6) months or 500 hours of operation with a good grade of
machine grease. No special heat resistant grease is necessary.

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7-7.5.3 Explosion relief door latches must be inspected regularly, at least every two
months, for adequate lubrication and freedom of movement. Restricted door
movement could result in limited explosion venting. Heavy grease should be
applied to the latch spring and cam. SAE 30 grade oil should be used on the
pivot joint.

7-7.6 Doors/Gaskets

7-7.6.1 The oven doors should be inspected regularly to see that latches are holding the
door firmly and uniformly against the oven providing a maximum sealing force.
Slots in the mounting brackets and adjusting screws are available for this
purpose. NOTICE: Before attempting these adjustments, be sure the oven is
level. If the oven is not on a solid level base, it could twist out of square resulting
in a poor seal, which cannot be corrected by hinge and latch adjustment. If
double doors do not line up across the top, it is an indication that the oven is not
level. In these cases, shim the front corner of the oven as necessary to allow
doors to line up across the top.

7-7.6.2 The door should be inspected for damage, which would allow excessive leakage
of hot air. The gasket should be replaced when damaged or when an adequate
seal cannot be maintained.

7-7.6.3 The door and associated venting latches should be checked periodically.
Normally, a moderate push or pull by one person on the door or panel should
cause the door and latches to operate. Actual push/pull tests with pressure
release measurements or spring-loaded scales should be performed annually.
Maximum release pressure is 20 pounds per square foot of door area.

7-7.7 Blowers and Exhausters

7-7.7.1 Tighten set screws between bearings and shaft before operating and check
periodically. Loose bearings will allow shaft movement resulting in wear to the
shaft within the bearing race. Setscrews on blower wheels must also be checked
and tightened.

7-7.7.2 Recirculation and exhaust blowers that are V-belt driven shall be checked for
proper sheave alignment to prevent excessive belt wear and to make sure belts
are not slipping.

7-7.7.3 Inspect to make sure all blowers; exhausters and other fans are rotating in the
correct direction. Refer to Section 4-4 for changing rotation.

7-7.7.4 Periodically inspect and clean blower and exhauster wheels to remove any build
up of deposits on the blade surfaces. Accumulation of deposits could possibly
reduce volume of airflow and cause a dangerous reduction in safety ventilation.

7-7.7.5 Air flow test should be conducted on the exhaust flow under oven operating
conditions, with volume controls at their minimum settings, to ensure that the
safety ventilation required is achieved. Reference Safety Design Form for
required ventilating. See Section 8 - TROUBLE SHOOTING for inadequate
ventilation symptoms.

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7-7.8 Electric Ovens

7-7.8.1 Temperature controller should cycle main contactor(s), or SCR power controller,
only. Separate (back-up) contactor(s) should not cycle.

7-7.8.2 All safety switches should open both main contactor(s), or SCR power controller,
and separate (back-up) contactor(s).

7-7.8.3 Inspect heating elements for contamination, distortion and adequate support.

7-7.8.4 Check electrical heating element connections at terminals for tightness.

7-7.9 Fuel Gas Ovens

7-7.9.1 Check main safety shut off valves for leakage. (See Appendix D - Main Safety
Shutoff Valve Leak Test Procedure)

7-7.9.2 Check pilot safety shut off valves for leakage. (See Appendix D - Pilot Safety
Shutoff Valve Leak Test Procedure)

7-7-9.3 Check that vent valve is closed when main burner is firing. (Note: Vent valve is
only installed by specific request of customer.)

7-7.9.4 With pilot burner lit, check low gas pressure switch setting by turning gas
pressure switch setting up until pilot is shutdown. Reset to original setting as
indicated on electrical wiring diagram.

7-7.9.5 With main burner firing, check high gas pressure switch by turning gas pressure
switch setting down until burner is shutdown. Reset to original setting as
indicated on electrical wiring diagram.

7-7.9.6 Lubricate gas cocks and operate to confirm free movement

7-7.9.7 Locate remote emergency valve, lubricate and operate to confirm free movement.

7-7.9.8 Safety valves should be replaced when the number of safety valve cycles
reaches 90% of lifetime cycle rating. Number of cycles can be estimated by
multiplying years of service by 260 work days per year (5 day work week) and the
number of times oven is turned on and off per day. Lifetime cycle rating for
valves is at least 1 million cycles. Replace valves if estimated number of cycles
exceeds 900,000.

7-7.9.9 Check that pilot and main burner lights easily and that flame appears blue with
yellow tips.

7-7.9.10 Check gas pressure against oven nameplate and adjust as necessary.

7-7.9.11 Inspect flame rod; clean and reposition as necessary.

7-7.9.12 Inspect control valve linkage to motor operator for free and smooth operation.

7-7.10 Steam Heated Ovens

7-7.10.1 Heat exchanger (steam coil) shall be inspected and cleaned as necessary to allow
free movement of recirculated air through heat exchanger.

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7-7.11 Safety Switches

7-7.11.1 Check each air flow safety switch operation by disconnecting both of the air
tubes from each air flow switch to make sure oven heat is shutdown.

7-7.11.2 Check purge timer setting against Safety Design Form. Check purge time
against a clock to check timing operation.

7-7.12 Temperature Controls

7-7.12.1 Heat oven to operating temperature and check oven temperature at control point
against a separate reliable temperature indicator to make sure temperature
controller calibration is correct.

7-7.12.2 Heat oven above setting of excess temperature limit interlock and make sure
excess temperature limit interlock shuts down oven heat.

7-7.12.3 Disconnect one side of thermocouple connection to confirm upscale break
protection is operative on both the main controller and the excess temperature
limit interlock.

7-7.13 Location

7-7.13.1 The user is responsible to determine that facility changes in the vicinity of the
oven have not created a hazardous condition. Specifically, the oven should be
protected from external heat, vibration, mechanical hazards and corrosive
environment.

7-7.13.2 Processes involving flammable liquids or creating explosive vapor or combustible
dust clouds must not be located near the oven.

7-7.13-3 Portable fire extinguishers located in the vicinity of the oven must be inspected
periodically.

7-7.13.4 Fire suppression system installed in the oven should be periodically tested. All
sprinkler heads in oven and ductwork should be periodically inspected and
cleaned.


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8 TROUBLE SHOOTING

8-1 NO HEAT

8-1.1 Air flow switch
An airflow switch (which can be located at any blower) may be holding the control
circuit open. The airflow switch senses a pressure differential across the blower. If
there is no pressure differential, the heat control circuit is not closed. If the air flow
switch opens, it will also reset the purge timer (if one exists). Operation and
adjustment of the airflow switch are described on the manufacturers literature. While
the switch itself may be defective, an open switch may also be indicating other
problems such as reverse blower rotation, slipping belts, obstructed ductwork, or a
loose pressure connection or electrical connection at the switch itself.

8-1.2 A fuse burned out
In addition to the fuses in your fused disconnect switch, one or more fuses may be
located inside the control panel as shown on the wiring diagram. Depending upon the
particular oven involved, it is possible for a fuse to open without affecting the pilot
lights (or provide other visible sign) and still affect the heat circuit.

8.2 REDUCED OR INCORRECT OVEN TEMPERATURE

8-2.1 Excessive Exhaust
Due to unusual stack conditions, the amount of heated air removed from the oven may
be excessive and result in a reduced operating temperature. In this case, the oven
heater will be running continuously, i.e., 100% output. This can be corrected by
closing the exhaust damper until the maximum operating temperature is achieved.
CAUTION: If the oven is equipped for use with flammable solvents or is gas-heated
equipment, the exhaust capacity must not be reduced below the amount indicated on
the Safety Design Form. See Section 5 - PROCESSING, for information on balancing
fresh air and exhaust settings.

8-2.2 Door Leakage
Damaged door gaskets or truck track seals (if applicable) combined with excessive
exhaust could result in cold air being drawn in around the doorway. Replace or repair
gaskets and adjust fresh air inlet. See Section 5 - PROCESSING for adjustment of
fresh air inlet.

8-2.3 Reduced Blower Speed
Loose or worn drive belts could prevent the recirculating blower from attaining its
design speed. This results in reduced air flow and inefficient heat transfer from the
heat source to the work space.

8-2.4 Incorrect Blower Rotation
This results in reduced airflow and inefficient heat transfer from the heat source to the
work area. Check blower rotation with respect to arrows located on oven or motor
mount. Run each blower briefly and watch shaft rotation to ensure correct rotation.
See Section 4 - PRIOR TO PLACING OVEN IN SERVICE, to correct blower rotation.

8-2.5 Defective or Improperly Calibrated Temperature Controller
See the temperature controller manufacturer's instructions for the proper operation and
adjustment for the specific controller used.


23 of 36 10/2011
8-2.6 Defective Thermocouples
Most temperature controllers and excess temperature controllers are provided with
thermocouples for sensing. These sensors are subject to drift over time. Compare
known reading at sensor inside oven to controller display. If it varies grossly, sensor
may have to be replaced. If sensor is damaged or broken open, the controller display
may give thermocouple error codes (see controller manual for proper error code
meanings).

8-2.7 On Electrically Heated Ovens - Improper Line Voltage
Voltage at the oven should be measured to determine if an excessive line drop is
causing reduced power input to the heating elements on an electrically heated oven.
This could be caused by too many devices connected to the same circuit or by
undersized wiring between the oven and the power source. Measure the voltage with
the oven heating elements on and all other equipment on the same circuit operating.

8-2.8 On Gas Heated Ovens, Burner or Gas Pressure Adjustment
Contact your local gas company's service engineers. It is recommended to have them
check all installations as they are aware of the many variables, which can affect your
operation. Correct gas pressure is essential. Measure gas pressure at the beginning
of the oven gas pipe train to ensure pressure agrees with the oven nameplate
requirement. If pressure drops as burner approaches high fire, there is insufficient gas
supply.

8-3 EXCESS TEMPERATURE LIMIT INTERLOCK ACTUATION
Depending upon the specific device used, it may be tripped by either an excessively high
oven temperature or a sensing element failure. Before placing the equipment back into
operation, it should be determined what caused the excess temperature limit interlock to
actuate and the condition be corrected. See the excess temperature limit interlock
manufacturer's literature for the proper operation and adjustment of the control used.
CAUTION: If the oven is equipped for use with flammable solvents or vapors, the excess
temperature limit interlock is factory set at the maximum temperature allowed and should
not be set to a higher temperature.

8-4 THE MOTOR STARTER OVERLOADS TRIPPED
All line voltage motors have current sensitive protective features in the motor starter. On
magnetic motor starters, the "motor running" pilot light will not remain on if the overloads
have tripped. The reset button is located on the motor starter inside the control panel.
Measure motor amperage and compare to nameplate. If over amperage, determine cause
and correct. If motor is only slightly over amperage, the overload can be increased to
compensate. Motor amperage of blowers will drop as the oven heats up and the air thins
out reducing the load on the motor.

8-5 ON GAS HEATED OVENS, PILOT WILL NOT LIGHT
A safe-start timer is built into the flame safety relay, which will shut the system down if the
pilot is not proven in approximately 10 seconds. If this timer trips, press the reset button
on the flame safety relay near the gas burner. When the burner is inaccessible, a reset
button will be on the control panel. See TROUBLE SHOOTING GAS HEATED
EQUIPMENT procedures which is included in your manual if you have a gas heated oven.


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8-6 INADEQUATE VENTILATION SYMPTOMS
Vapor explosions often occur some time after ventilation becomes inadequate. Investigate
the following symptoms and take corrective action immediately:

a. A cold exhaust duct or stack while the oven is operating usually indicates reversal of
flow in the stack.

b. Evidence of negative pressure in the oven room, with respect to adjoining rooms and
outdoors when the door to oven room is opened, may indicate inadequate safety
ventilation and sometimes reversal of airflow in the exhaust stack.

c. A record of fires or puffs from work in a particular oven may indicate inadequate safety
ventilation, dangerously high vapor concentrations, the probability of an eventual
serious oven explosion.

d. A record of work leaving the oven with paint incompletely dried is an indication of
inadequate safety ventilation.

e. Heavy deposits of condensed paint vapors at the exhaust stack outlet may indicate
that interior fouling has dangerously reduced the safety ventilation.

f. Deposits around oven door cracks may indicate higher pressure inside the oven than
in the oven room, and a lack of positive safety ventilation.


25 of 36 10/2011
9 APPENDIX A - SAFETY EQUIPMENT DESCRIPTION & OPERATION

9-1 MANUAL RESET EXCESS TEMPERATURE LIMIT INTERLOCK (All)

This device will detect and be actuated when the temperature in the oven workspace
exceeds a preset level. On actuation, the manual reset excess temperature limit
interlock will open the control circuit to the main heat. In electrically heated ovens the
circuit is opened to the heating element contactors (or SCR power controller) and
separate contactors. On gas heated or steam heated equipment, the control circuit is
opened to the control and safety valves.

To restore operation, the operator must manually reset the excess temperature limit
interlock. This should be done only after determining the cause of overheating and
correcting it. The manual reset excess temperature limit interlock is normally factory set
at 15F. above the maximum temperature of the oven or, when known, 15F. above your
maximum process operating temperature. See the manufacturers operating instructions
for adjusting the manual reset excess temperature limit interlock.

9-2 SEPARATE CONTACTOR(S) (Electric heat only)

A separate contactor(s) is connected in series with the main control contactor(s) (or SCR
power controller) to open the circuit providing power to the heating elements. These
separate contactors are powered through a series of safety interlocks including the
manual reset excess temperature limit interlock. When any one of the safety interlocks
open, the control circuit to the separate contactors is opened. The separate contactors
provide additional protection, which cannot be obtained with the main heating element
contactors (or SCR power controller) alone. The redundant separate contactors provide
a second cutoff device to the heating elements, which does not cycle to maintain
temperature and for this reason is less subject to wear.

9-3 SEPARATE BACK-UP STEAM VALVE (Steam heat only)

A separate steam valve is connected in series with the main control steam valve to close
the pipeline providing steam to the steam coil. This separate steam valve is powered
through a series of safety interlocks including the manual reset excess temperature limit
interlock. When any one of the safety interlocks open, the control circuit to the separate
steam valve is opened. The separate steam valve provides additional protection, which
cannot be obtained with the main control steam valve alone. The redundant separate
steam valve provides a second cutoff device to the steam coil, which does not cycle to
maintain temperature and for this reason is less subject to wear.

9-4 MAIN SAFETY SHUTOFF VALVES (Gas heat only)

Two (2) separate gas shutoff valves are connected in series with the gas control valve to
close the pipeline providing gas to the main burner system. When all other safety
equipment indicates proper operation and the gas burner pilot has been proven ignited,
these devices are electrically energized and allow flow of gas to the main burner system.
These gas shutoff valves are powered through a series of safety interlocks including the
manual reset excess temperature limit interlock. When any one of the safety interlocks
open, the control circuit to the gas shutoff valves are opened. The gas shutoff valves
provide additional protection, which cannot be obtained with the gas control valve alone.
The redundant gas shutoff valves provide gas flow shutoff devices, which do not cycle to
maintain temperature and for this reason are less subject to wear.


26 of 36 10/2011
9 APPENDIX A (continued)

9-5 PILOT SAFETY SHUTOFF VALVES (Gas heat only)

On burners with a separate pilot burner, two (2) separate pilot gas shutoff valves are
connected in series with the pilot burner to close the pipeline providing gas to the pilot.
When all other safety equipment indicates proper operation and the gas burner pilot has
been proven ignited, these devices are electrically energized and maintain flow of gas to
the pilot burner. These pilot shutoff valves are powered through a series of safety
interlocks including the manual reset excess temperature limit interlock. When any one
of the safety interlocks open, the control circuit to the pilot shutoff valves are opened.

9-6 TEST DEVICE (Gas heat only)

On gas heated equipment, the test device is used as part of an inspection program to
ensure that the main and pilot shutoff valves are sealing properly. (See Appendix D -
Main Safety Shutoff Valve Leak Test Procedure and Pilot Safety Shutoff Valve Leak Test
Procedure.)

9-7 VENT VALVE (Gas heat only, if requested by customer)

On gas-heated equipment, the vent valve is used to vent the section of gas piping
between the two main safety shutoff valves. This valve is installed only at the
customers request. Customer must pipe outlet of vent valve to a safe location outside
their building (in accordance with local codes) where any leaking gas will be safely
disbursed to the atmosphere.

9-8 POWERED FORCED EXHAUSTER (All)

As a safety device, the powered forced exhauster is used to remove a definite volume of
air when flammable solvents, vapors, gases or products of combustion are present in the
oven atmosphere. The exhaust rate must be properly sized to give safe operation and is
determined from the quantity of material in the atmosphere and the operating
temperature of the oven. Reduced exhaust could result in an explosion or fire and bodily
injury or property loss.

9-9 AIR FLOW SWITCH (All)

This device senses pressure differential across an exhaust blower, recirculating blower
or combustion burner blower to indicate that these blowers are moving air. When there
is no pressure differential, the air flow switch opens and turns off the control circuit to the
main heat. In electrically heated ovens the circuit is opened to the heating element
contactors (or SCR power controller) and separate contactors. On gas fired or steam
heated equipment, the control circuit is opened to the control and safety valves. Where
failure of the air supply is critical to prevent a dangerous situation, this device is
mandatory. The air flow switch picks up typical failures such as when a motor fails to
turn the blower or when the blower drive belts are broken.


27 of 36 10/2011

9-10 PURGE TIMER (All)

Where it is necessary to ventilate the oven prior to turning the heat on, a purge timer is
installed. This purge period is typically required in gas-heated equipment or when
flammable solvents are present in the ovens load. The purge timer ensures that the
recirculating blower(s) and powered forced exhauster(s) are operating for a preset
period of time prior to turning the heat on. The purge time is typically based on allowing
sufficient time for the powered forced exhauster to pull four (4) oven volumes of fresh air
through the oven. The time period is factory preset and is calculated based on the
exhaust rate and total volume of the oven within the insulated walls. The exhaust rate is
based on the quantity of flammable solvents entering the oven and the operating
temperature. In the case of gas-heated equipment, the exhaust rate is also based on
the combustion venting required for the burner.

9-11 HIGH GAS PRESSURE SWITCH (Gas heat only)

This device is used on gas heated equipment to sense an abnormally high gas pressure
which would affect the operation and safety of the equipment. If the gas pressure
exceeds a preset level, the control circuit is opened to the control and safety valves.
Customer must pipe the vent port on this switch to a safe location outside the building (in
accordance with local codes) where any leaking gas will be safely disbursed to the
atmosphere. Each such vent must be piped separately

9-12 LOW GAS PRESSURE SWITCH (Gas heat only)

This device is used on gas-heated equipment to detect an abnormally low gas pressure
which would affect the operation and safety of the equipment. If the gas pressure drops
below a preset level, the control circuit is opened to the control and safety valves.
Customer must pipe the vent port on this switch to a safe location outside the building (in
accordance with local codes) where any leaking gas will be safely disbursed to the
atmosphere. Each such vent must be piped separately.

9-13 FLAME SAFEGUARD (Gas heat only)

On gas-heated equipment, a solid state, electronic flame safeguard monitors each gas
burner by use of a flame rod or ultraviolet sensor. This device prevents burner operation
unless the pilot burner has been proven and maintained.

9-14 HEAT CHAMBER MANUAL RESET EXCESS TEMPERATURE LIMIT INTERLOCK (All)

This device is similar to the manual reset excess temperature limit interlock described
previously except that the sensor is located in the heating element chamber or gas
burner combustion chamber of the oven

This device will detect and be actuated when the temperature in the oven heat chamber
exceeds a preset level. On actuation, the heat chamber manual reset excess
temperature limit interlock will open the control circuit to the main heat. In electrically
heated ovens the circuit is opened to the heating element contactors (or SCR power
controller) and separate contactors. On gas fired (or steam heated) equipment, the
control circuit is opened to the control and safety valves.


28 of 36 10/2011

To restore operation, the operator must manually reset the heat chamber excess
temperature limit interlock. This should be done only after determining the cause of
overheating and correcting it. The heat chamber manual reset excess temperature limit
interlock is set at the maximum temperature appropriate for the heat chamber. Typically
the heat chamber will run substantially hotter than the oven workspace. See the
manufacturers operating instructions for adjusting the heat chamber manual reset
excess temperature limit interlock.

9-15 HEAT CHAMBER TEMPERATURE CONTROLLER (All)

Similar to the heat chamber excess temperature limit interlock but this device is not
manual reset. This device limits the heat chamber maximum temperature. When
temperature of the heat chamber exceeds the setting on the temperature controller, the
heat will automatically be cycled off. When the heat chamber cools down, the heat will
be automatically cycled back on. While this device may slow down oven heat-up rate, it
is designed to protect the heat chamber from excessive temperatures. The heat
chamber temperature controller is typically installed on ovens operating over 1100F to
limit the heat chamber temperature to below 1450F.


29 of 36 10/2011
10 APPENDIX B - REFERENCES

The following sources of additional information are provided for reference. This is not presented
as a complete list of all possible reference sources.

10.1 Factory Mutual Engineering Corporation
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, Massachusetts 02062
Attn: Publications Order Processing
Specifications 6-9, Industrial Ovens and Dryers

10.2 National Fire Protection Association
One Batterymarch Park
Quincy, Massachusetts 02209-9101
Most current issue of:
NFPA 86 - Ovens and Furnaces
NFPA 70 - National Electric Code
NFPA 54 - National Fuel Gas Code
NFPA 10 - Standard for Portable Fire Extinguishers
NFPA 11 - Standard for Low-Expansion Foam
NFPA 12 - Standard on Carbon Dioxide Extinguishing Systems
NFPA 13 - Standard for the Installation of Sprinkler Systems
NFPA 14 - Standard for the Installation of Standpipe and Hose Systems
NFPA 15 - Standard for Water Spray Fixed Systems for Fire Protection
NFPA 17 - Standard for Dry Chemical Extinguishing Systems
NFPA 17A-Standard for Wet Chemical Extinguishing Systems
NFPA 25 - Standard for the Inspection, Testing and Maintenance of Water-Based
Fire Protection Systems
NFPA 30 Flammable and Combustible Liquids Code
NFPA 31 - Standard for the Installation of Oil-Burning Equipment
NFPA 34 - Standard for Dipping and Coating Processes Using Flammable or
Combustible Liquids
NFPA 58 - Liquified Petroleum Gas Code
NFPA 79 - Electrical Standard for Industrial Machinery
NFPA 91 - Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists
and Noncombustible Particulate Solids

10.3 ASME Publications
American Society of Mechanical Engineers
345 East 47
th
Street
New York, NY 10017
The most current issue of:
ASME Boiler and Pressure Vessel Code
ASME B31.1 - Power Piping
ASME B31.3 - Process Piping

10.4 ANSI Publications:

American National Standards Institute
11 West 42
nd
Street, 13
th
Floor
New York, NY 10036
The most current issues of:
ANSI Z117-1 - Safety Requirements for Confined Spaces


30 of 36 10/2011
11 APPENDIX C MINIMUM PERIODIC INSPECTION REPORT

Model:_________________________________________________ Serial No.: _______________
Inspected By____________________________________________ Date: ___________________
BEFORE APPLYING POWER CHECK THAT:
1. ____ No changes in process have been made including types of materials processed and
temperature:

-Oven originally designed for (reference previous Inspection Report) _______________
______________________________________________________________________
______________________________________________________________________

-Oven being used for: ____________________________________________________
_____________________________________________________________________
______________________________________________________________________

2. ____ If flammable solvents are involved in process, quantity entering oven and operating
temperature are within oven design parameters -- see Operating Manual for Safety
Design Form.

-Oven designed for __________ gallons of solvent (per batch or per hour) at a maximum
of _________F.

-Oven being used for __________ gallons of solvent (per batch or per hour) at an
operating temperature of _________F.

3. ____ All electrical connections are tight without stray strands.

4. ____ All contactors, relays, motor starters and other components with contacts have been
inspected for wear or sticking.

5. ____ Oven body inspected and painted surfaces touched up to prevent rusting.

6. ____ Oven interior inspected for component assembly and positioning, cleaned, and all foreign
matter removed from:
________ Floor
________ Heat chamber (including heating element or steam coil surfaces)
________ Ductwork
________ Air inlets
________ Exhaust outlets
________ Filters
________ Control enclosure and components
________ Door hinges or support mechanism

7. ____ Remove and clean all drip pans. Inspect and clean all work racks, trays, holders or
spacers.

8. ____ Locate temperature control and excess temperature limit interlock thermocouples;
inspect for damage. Make sure thermocouples are in free air and not touching anything.

9. ____ Explosion venting panels on roof of oven or heat chamber are free to move and not
obstructed; no material is stored on top of oven.

10. ____ Doors are free to move and not obstructed.

11. ____ Exhaust duct work from oven has been inspected and cleaned; all foreign matter
removed.

12. ____ Fresh air duct work and/or filters have been inspected and cleaned; all foreign matter
removed.


31 of 36 10/2011
13. ____ Lubricate motors.

14. ____ Lubricate bearings on blower and exhauster shafts, belt conveyor shafts, door lift
mechanisms and other bearings.

15. ____ Lubricate explosion relief door latches and check for freedom of movement.

16. ____ Adjust door latches and hinges for good seal around edges of door; gasket needs to only
touch sealing surface, it does not need to be crushed. Inspect doors for damage and
replace worn gasket if necessary.

17. ____ Check doors for explosion relief; maximum relief pressure of 20 lbs. per square foot of
door area.

18. ____ Inspect and tighten set screws between bearings and shafts on blowers, exhauster,
combustion blowers, belt conveyor shafts, and other bearings on shafts.

19. ____ Inspect and replace, if necessary, V-belts on blowers, exhausters, combustion blowers
and other fans.

20. ____ Inspect blowers, exhauster, combustion blowers and other fans for residue build-up on
fan blades and housing. Clean as necessary. Tighten set screws holding fan to shaft.

APPLY POWER AND CHECK:
21. ____ Supply voltage agrees with oven nameplate - measure between all three (3) phases and
record; ______/ ______/ ______.

22. ____ Amperage (with everything running) agrees with oven nameplate - measure all incoming
lines and record; ______/______/______.

23. ____ Check that all blowers, exhausters, combustion blowers and other fans are rotating in the
correct direction.

24. ____ Check exhaust rate if it is critical for safe operation such as required for removing
flammable solvents or combustion venting. This test should be with all volume controls
(dampers) at minimum setting. Reference Safety Design Form for required exhaust rate.

ELECTRIC OVENS
25. ____ Check that temperature controller does not cycle separate (back-up) contactors.

26. ____ Shut down oven and make sure main contactors (or SCR power controller) and separate
contactors all open.

27. ____ Inspect heating elements for contamination, distortion and adequate support.

28. ____ Check electrical connection at heating element terminals for tightness.

FUEL GAS OVENS
29. ____ Check pilot safety shutoff valves for leakage. (See Appendix D for details.)

30. ____ Check main safety shutoff valves for leakage. (See Appendix D for details.)

31. ____ Check that vent valve (if installed) is closed when main burner is firing.

32. ____ Turning up low gas pressure switch setting shuts all valves and resets purge timer.
Return to original setting. Low gas pressure switch set at ________.

33. ____ Turning down high gas pressure switch shuts all valves and resets purge timer. Return
to original. High setting gas pressure switch set at _______.

34. ____ Lubricate gas cocks.


32 of 36 10/2011

35. ____ Locate remote emergency shut off valve, lubricate and operate to confirm free
movement.

36. ____ Number of safety shut off valve cycles should be estimated and safety shut off valves
replaced after 90% of lifetime cycles have been reached. Cycle estimate can be made
by multiplying number of years of service by 260 days per year (5 day work week) by
number of times oven is turned on and off daily.

37. ____ Pilot and main burner light easily.

38. ____ Main flame blue with yellow tips.

39. ____ Gas pressure set at pressure shown on oven nameplate. Setting is ________________

40. ____ Flame rod clean and positioned correctly.

41. ____ Control valve linkage tight and operates smoothly over full range of travel.

STEAM OVENS

42. ____ Heat exchanger (steam coil) inspected and cleaned to allow free air movement through
coil.

SAFETY SWITCHES

43. ____ Disconnect both air tubes at each air flow switch to make sure oven heat is shut down on
air flow switch deactivation.

44. ____ Check that purge timer is set for purge time shown on Safety Design Form and Caution
nameplate installed adjacent to purge timer. Confirm purge time by checking against
clock and record: _________

TEMPERATURE CONTROLS:

45. ____ Heat oven to operating temperature and check temperature controller calibration.

46. ____ Compare temperature controller indication and excess temperature limit interlock
indication to confirm they are similar.

47. ____ Disconnect one side of thermocouple connection to confirm upscale break protection is
operating on main temperature controller and excess temperature limit interlock.

48. ____ To check excess temperature limit interlock function, heat oven above excess
temperature limit interlock setpoint. Make sure excess temperature limit interlock shuts
down heat by opening main contactor (or SCR power controller) and separate contactors
on electric ovens and closes all gas valves on gas oven. On steam oven, separate back-
up steam valve will close.

49. ____ Excess temperature limit interlock is set no higher than 15F above maximum operating
temperature of oven.


33 of 36 10/2011

LOCATION:

50. ____ No changes in the oven area have created a hazardous condition such as external heat,
vibration, mechanical hazard or corrosive environment.

51. ____ No process change has resulted in flammable liquids or explosive vapors or dust cloud
being stored or produced in vicinity of oven.

52. ____ Portable fire extinguishers in the area have been inspected.

53. ____ Fire suppression systems, such as a sprinkler system, have been inspected.

54. ____ Sprinkler heads in oven and duct work have been inspected and cleaned.

TRAINING

55. ____ Review job function, oven operation and emergency shutdown with operators and
supervisors.


34 of 36 10/2011
12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE

FIRST PILOT SHUT OFF VALVE (1PSOV)

1. Make sure all gas cocks ahead of equipment are open to allow gas flow to equipment and
turn off electrical power to the control panel to assure that there is no power to the pilot shut
off solenoid valves so that they are closed (1PSOV & 2PSOV).

2. Make sure the manual test petcock (A) is closed.
3. Remove the leak test tap plug (B) and connect 1/4" tube to the petcock.
4. Close the pilot gas cock located between the pilot shut off solenoid valves and the burner.
5. Immerse the 1/4" tube vertically inch into a jar of water.
6. Slowly open the test petcock (A).
7. Gas will bubble through the water and stop. If bubbles continue, the valve is leaking and
must be replaced. Do not continue to operate burner until valve is replaced.

8. Close the test petcock (A), remove the 1/4" tube and replace the leak test tap plug (B).

FIRST SAFETY SHUT OFF VALVE (1SSOV)
turn off electrical power to the control panel to assure that there is no power to the safety
shut off solenoid valves so that they are closed (1SSOV & 2SSOV).

10. Make sure the manual test petcock (C) is closed.
11. Remove the leak test tap plug (D) and connect 1/4" tube to the petcock.
12. Close the main gas cock located between the safety shut off solenoid valves and the burner.
14. Slowly open the test petcock (C).

16. Close the test petcock (C), remove the 1/4" tube and replace the leak test tap plug (D).


35 of 36 10/2011
12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE (contd)
SECOND PILOT SHUT OFF VALVE (2PSOV)
power is provided to the control panel. Turn on the Exhauster but do not turn HEAT switch
to start to assure that there is no power to the pilot shut off solenoid valves so that they are
closed (1PSOV & 2PSOV).

18. Make sure the manual test petcock (E) is closed.
19. Remove the leak test tap plug (F) and connect 1/4" tube to the petcock.
20. Close the downstream pilot gas cock located between the pilot shut off solenoid valves and
burner.

22. Depress and hold the VALVE TEST button located at the burner junction box to open the
first pilot shut off solenoid valve (1PSOV) and allow gas pressure to the second pilot shut off
solenoid valve (2PSOV).

23. While holding VALVE TEST button in, slowly open the test petcock (E).


25. Release VALVE TEST button. Close the test petcock (E), remove the 1/4" tube and replace
the leak test tap plug (F).

26. Open the pilot gas cock located between the pilot shut off solenoid valves and the burner.

SECOND SAFETY SHUT OFF VALVE (2SSOV)
27. Turn on the Blower (Gas cocks open and exhauster still running from step 17) and turn the
HEAT switch to START. System will purge and ignite pilot causing main safety shut off
valve (1SSOV) and secondary safety shut off valve (2SSOV) to open.

28. Make sure the manual test petcock (G) is closed.
29. Remove the leak test tap plug (H) and connect 1/4" tube to the petcock.
30. Close the main gas cock located between the safety shut off solenoid valves and burner.
31. Immerse the 1/4" tube vertically1/2 inch into a jar of water.

32. Depress and hold VALVE TEST button located at burner junction box to cause secondary
safety shut off solenoid valve (2SSOV) to close. (NOTE: If customer requested vent valve is
installed, vent valve will also close at this point. Check to make sure vent valve closes and
that no gas is passing from vent valve outlet. To do this, the location of the outlet vent pipe
must be found where it exits the building.)

33. While holding VALVE TEST button in, slowly open the test petcock (G).

must be replaced. Turn HEAT switch to OFF. Do not continue to operate burner until
valve is replaced.

35. Close the test petcock (G). Release test button. Remove the 1/4" tube and replace the leak
test tap plug (H).

36. Open the main gas cock located between the safety shut off solenoid valves and burner.


36 of 36 10/2011

13 APPENDIX E - WARRANTY AND LIMITATIONS OF REMEDIES

Any equipment sold by GRIEVE is warranted for one (1) year after the Purchaser receives the
equipment to be free from defects of material and workmanship. THERE ARE NO WARRANTIES
WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF; WITHOUT LIMITING
THE GENERALITY OF THE FOREGOING, GRIEVE EXPRESSLY DISCLAIMS ALL IMPLIED
WARRANTIES, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THE PURCHASERS EXCLUSIVE REMEDY FOR ANY BREACH OF
THIS WARRANTY SHALL BE FOR THE REPAIR OR REPLACEMENT (AT GRIEVES OPTION)
OF THE DEFECTIVE EQUIPMENT OR PART.

Parts under warranty are shipped via ground transportation. Express or expedited shipping costs
are the sole responsibility of the customer. In order to obtain repair or replacement under this
warranty, the user must deliver the defective product or part to GRIEVEs factory on a prepaid basis
promptly after discovery of the defect. GRIEVEs warranty ceases to be effective if the equipment
is altered or modified, repaired other than by persons authorized by GRIEVE, misused, used by any
person in an unsafe or unreasonable manner or used other than in accordance with GRIEVEs
written instructions. Although GRIEVE makes no additional or extended warranty with respect to
thermostats, recorders, control equipment or other accessories, to the extent such items may also
be warranted by their respective manufacturers, those warranties are passed on to you by GRIEVE
as agent of the respective manufacturer and not as a separate warrantor.

In no event shall GRIEVE be liable for any direct, indirect, special, incidental or consequential
damages hereunder, whether such damages are sought based on breach of warranty, breach of
contract, negligence, strict liability in tort, or any other theory of legal liability.

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