GFS Ultra CTOF Booth Installation Manual

Semi-downdraft booth with bt air heater (single-bay)

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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.

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Summary of Contents for GFS Ultra CTOF Booth

Page 1 ® 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.
Page 2 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 ............................
Page 3 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 .......................
Page 4 • Email: parts@globalfinishing.com 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. Global Finishing Solutions...
Page 5 Introduction 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 Indicates an imminent hazard that will result in death.
Page 6 General safety 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.
Page 7 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.
Page 8 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.
Page 9 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.
Page 10 Booth description 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.
Page 11 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. Global Finishing Solutions...
Page 12 Preparing for installation 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.
Page 13 • 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.) •...
Page 14 Preparing for installation • 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? •...
Page 15 About the Design Drawings document 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 16 About the Design Drawings document 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 Global Finishing Solutions 239-142 rev 3...
Page 17 Provides instructions for installing the optional GFS AdvanceCure System. NOTE This page applies only to booths that include AdvanceCure. AdvanceCure Intake & Dis- Shows how to install cover plates at locations where the optional GFS AdvanceCure System charge Cover Kit integrates with the booth. NOTE This page applies only to booths that do not include the AdvanceCure.
Page 18 About the Design Drawings document Page name Description 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.
Page 19 Required materials 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 •...
Page 20 Required materials 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.
Page 21 Installation best practices Installation best practices Unpack in stages As you begin each section of the installation procedure, unpack the crate(s) that contain the parts for that section. In general, the skids are organized so the parts that go together during assembly are packed on the same skid.
Page 22 Installation best practices Sort parts by size To help installation proceed more efficiently, sort all parts by size as you unpack them (Figure 3). Each part has a specific part number. The part number is either etched into the part or printed on a label affixed to the part (Figure 4).
Page 23 Installation best practices Follow assembly guidelines Follow these guidelines when assembling the booth: • Assemble the booth in sections, following the sequence provided in this document. • As you build each section, tighten the bolts only to finger-tight. • Before tightening the bolts within a section, confirm that the section is plumb and square. •...
Page 24 • If the floor is more than 1 inch out of level over the full length of the booth, shim or grout the floor as needed to get it to within 1 inch of level. GFS does not provide shims.
Page 25 Installation procedure Mark the air heater footprint Prerequisites: The booth footprint must already be marked on the floor as described in “Mark the booth footprint” (page 24). NOTE The location where the air heater is placed must meet the following requirements: •...
Page 26 Installation procedure Install the BT air heater Prerequisites: The air heater footprint must already be marked on the floor as described in “Mark the air heater footprint” (page 25). Reference: • Refer to the Air Heater page of the Design Drawings while completing this task. •...
Page 27 • For steps related to wall assembly, refer to the Front Wall page of the Design Drawings. • For steps related to the GFS Ultra CTOF decal, refer to the Label Placement Instructions page of the Design Drawings. Also see “Required tools” (page 19) for a list of tools required for decal placement.
Page 28 Installation procedure Pull back one side of the decal as far as possible (up to where the center of the decal is taped to the panel) and liberally spray the panel beneath with soapy water. Create a starting point near the center of the decal for peeling off the backing: Working as closely as possible to where the center of the decal is taped to the panel, carefully separate the backing from the decal.
Page 29 12. Attach the truss cover panels (with decal already applied) to the truss. NOTE Ensure that the GFS Ultra CTOF decal faces the booth’s exterior. NOTE After installing the panel, double-check for hand prints or smudges; clean the panel, if necessary.
Page 30 Secure the columns to the floor with two expansion anchors. NOTE GFS does not supply the anchors. Use a forklift to lift the truss into position, then secure it between the two foremost columns. Install temporary bracing on either the left or right side of the frame.
Page 31 Installation procedure NOTE When building a wall that includes a door, use the Side Wall page of the Design Drawings (with personnel door) as a guide, but adjust the position of the door depending on where the end user wants the door located.
Page 32 Installation procedure Reference: Refer to the Side Wall page of the Design Drawings. NOTE The Design Drawings contain two Side Wall pages: one that includes a personnel door, and one without a personnel door. Use the appropriate page depending on whether the particular side wall you are building includes a personnel door or not.
Page 33 Installation procedure • For a 24-foot booth: The plenum end panel connects to the bolt holes on the rear-most flange of the first plenum panel on each side wall. • For a 27-foot booth: The plenum end panel connects to the holes on the first stiffener of the second plenum panel (from the front) on each side wall.
Page 34 Installation procedure Build the back wall of the booth Prerequisites: The side walls of the booth must be completed as described in “Finish the side walls of the booth” (page 33). NOTE Depending on the specific configuration for the booth, the back wall consists of either a solid wall or a curtain.
Page 35 Installation procedure Ensure that the completed wall is plumb, square, and level. Tighten all bolts in the wall to snug-tight. Assemble the exhaust yoke Prerequisites: All four booths must already be assembled. Reference: Refer to the Exhaust Yoke page of the Design Drawings. Tek-screw each exhaust-yoke angle to the adjoining end-wall panel.
Page 36 Installation procedure Reference: Refer to the diagram below and to the RH Side Elevation view on the GA page of the Design Drawings. A: Exhaust-stack base plate B: Plain duct section C: Clean-out duct (plain duct section with clean-out door) D: Fan ring (flange up;...
Page 37 Installation procedure NOTE Refer to the GA page of the Design Drawings to see how the fan motor should be oriented relative to the booth. Bolt the fan to the fan ring using 8-mm hardware (nuts, bolts, and washers). NOTE Tighten the bolts to finger-tight until they are all installed;...
Page 38 (installed in “Install the plenum end panel” (page 32)) to the exhaust yoke. Reference: Refer to the Roof Panels page of the Design Drawings. If applicable: Install the AdvanceCure system Scope: This task applies only if this booth includes the GFS AdvanceCure System. Global Finishing Solutions 239-142 rev 3...
Page 39 Drawings. If applicable: Install the AdvanceCure cover kit Scope: This task applies only if this booth does not include the optional GFS AdvanceCure System. Prerequisites: The roof panels must already be installed. Reference: Refer to the AdvanceCure Intake & Discharge Cover Kit page of the Design Drawings.
Page 40 Installation procedure Reference: Refer to the appropriate page of the Design Drawings depending on the type of end wall that adjoins each corner. • For a solid end wall: Use the Rear Wall page of the Design Drawings. Install the diffuser assembly Prerequisites: The booth walls must already be installed and the discharge opening must already be cut in the appropriate panel on the wall that connects to the heater.
Page 41 Installation procedure If applicable: Continue connecting all necessary plain duct sections as required for the intake stack. NOTE Follow the procedure for connecting duct sections together in the notes at the beginning of this task. Assemble the air inlet hood. NOTE For instructions, refer to the Air Inlet Hood page of the Design Drawings.
Page 42 Installation procedure A: One or more sections of plain duct B: Automatic Roof Ventilator (ARV) Confirm that a fan ring is bolted to the top of the exhaust fan. NOTE If the fan ring is not present, install it now as directed in . Connect a section of plain duct to the fan ring.
Page 43 Installation procedure A: #10 Tek screw B: For each connection, use one cable thimble; one 5/16-inch x 1-1/2-inch bolt; two 5/16-inch flat washers; one 5/16-inch lock washer; and one 5/16-inch nut. C: Duct strap D: Cable clamps (2) E: Thimble F: Turnbuckle G: Cable;...
Page 44 Installation procedure If applicable: Install optional booth accessories Scope: This task applies only to booths that include optional accessories (for example, a parts hanger, tool cabinet, and so on). Prerequisites: The booth lighting must already be installed as directed in “Install the lights” (page 43). References: •...
Page 45 Installation procedure Install miscellaneous electrical devices NOTE Ensure that the placement of all electrical devices meets the NEC requirements for clearance from combustible areas. NOTE This section provides instructions for installing miscellaneous electrical devices. As you install each device, retain any unused hardware. Place unused hardware in a bag and tape it to the device so that it will be available for the electrician.
Page 46 Installation procedure Run tubing through the bulkhead fitting and attach it to the high-pressure fitting inside the control panel. Attach a short tube (2-3 inches) to the low-pressure fitting inside the control panel. Install the temperature sensor Reference: Refer to the following sections of the Temp Sensor & Diffuser/Baffle page of the Design Drawings: •...
Page 47 Installation procedure Install the air solenoid valve Prerequisites: The booth’s air supply line must already be installed. NOTE This task covers the installation of the directional valve in the compressed air line piping, and is usually performed by a plumber or mechanical contractor. An electrician will perform the wiring from the valve to the control panel, as described in “Perform electrical hookup”...
Page 48 For information on locating the Electrical Drawings document, refer to “Gathering required documentation” (page 12). If applicable: Install the puff switch Scope: This task applies only if the booth includes the GFS AdvanceCure System and the site purchased the optional puff switch with their booth. Global Finishing Solutions...
Page 49 Installation procedure NOTE A puff switch is a switch located inside the booth that can be used to turn AdvanceCure on and off. It can be mounted anywhere on the inside of the booth. Mounting hardware and instructions are provided with the device.
Page 50 Installation procedure Obtain a filter rack and place it on two sawhorses, with the flat side of the filter rack facing down. Place the filter media on top of the filter rack, with the writing on the filter media facing down. Use a filter-insertion tool (metal pizza cutter) to push the filter media into the slot all around the perimeter.
Page 51 Installation procedure A: Rubber tip B: Filter grid Place the grids into the openings in the exhaust chamber filter racks; then install the filters onto the grids. NOTE Pay attention to the orientation of the filter, as shown in the accompanying diagram. A: Exhaust filter B: Air-leaving side (dense side of filter) C: Air-entering side...
Page 52 Installation procedure NOTE For information on locating the Electrical Drawings document, refer to “Gathering required documentation” (page 12). Connect the building’s Main Power supply to the air heater control panel. NOTE Refer to electrical data plate for electrical requirements. WARNING Do not energize until you are ready to test motor rotation during commissioning and startup (see “Perform commissioning and startup”...
Page 53 • An electrician must have completed the electrical hookup. NOTE A trained GFS Distributor usually performs booth startup. The person who performs booth startup is responsible for completing the Final Commissioning Document and returning a signed copy to GFS. Reference: Refer to the Final Commissioning Document. (For information on locating the Final Commissioning Document, see “Gathering required documentation”...

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Ultra Ultra ctof