GFS Ultra XL Service & Operation Manual
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GFS Ultra XL Service & Operation Manual

Automotive refinish paint booths
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Automotive Refinish Paint Booths
Service & Operations Manual
Document Number: 239-062 rev 5
Publication date 12/07/2020
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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  • Page 1 Automotive Refinish Paint Booths Service & Operations Manual Document Number: 239-062 rev 5 Publication date 12/07/2020 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

    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 Adjust belt tension ........................ 38 Replace fan belts ........................39 Check V-belt drive alignment ....................39 V-belt drive considerations ..................... 41 Replace fan bearings (SpaceSaver) ..................41 Common causes of excessive vibration .................. 41 Air heater service procedures ......................42 Check air heater belt tension (SpaceSaver) ................

  • Page 4: Introduction

    • 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: Conventions Used In This Manual

    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 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: Booth Safety

    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 Booth safety WARNING Isolate the outdoor vent from air-conditioning intakes, windows, and any other equipment that may re- circulate the exhaust indoors. WARNING Turn on the exhaust fan before using the spray booth. Ensure that the exhaust fan is operating correctly before entering the booth.

  • Page 10: Safety Features

    Safety features Safety features For operator safety, compressed air may only enter the spray gun when the booth is in Spray mode, the fans are operating, light covers are in place, airflow switches are satisfied, and the doors are closed. The following safety features are included with every booth: •...

  • Page 11: Booth Overview

    Booth Overview Air management For the best operating environment, GFS automotive refinish paint booths are designed to help create and maintain optimal air velocity, airflow, and air pressure balance. Use the information provided below to help you control and maintain your booth for optimal airflow.

  • Page 12: Semi-Downdraft Airflow

    Booth Overview • Ultra XD and XS CTOF Semi-downdraft airflow The semi-downdraft booth is a hybrid, combining features of both crossdraft and downdraft booths. Air is introduced to the working area through the ceiling in the first 25 to 30 percent of the booth. It is then pulled across the working area, over the product, and into the filtered exhaust chamber at the rear of the booth.

  • Page 13: Booth Components

    Booth Overview Booth components This section describes the main components of your booth. Doors Paint booths can have two types of doors: • Product doors that allow you to move parts and equipment in and out of the booth • Personnel doors that allow people to enter and exit the booth In pressurized booths, the doors are monitored to detect when the door is open or closed.

  • Page 14: Exhaust Fan(S)

    All GFS fan assemblies are statically and dynamically balanced to Balance Quality Grade G6.3. Each fan is factory run-tested for vibration in accordance with ANSI/ AMCA 204-96 “Balance Quality and Vibration Levels for Fans”...

  • Page 15: Service And Maintenance

    Service and maintenance Service and maintenance Maintenance schedule The frequency of the following maintenance checks depend upon the material being sprayed (amount and kind). The booth operators and maintenance technicians should perform these checks at regular intervals to reduce fire hazards, maintain booth efficiency, prevent freshly painted objects from becoming blemished, and hinder booth corrosion and wear.

  • Page 16: Daily Maintenance

    FOLLOW GFS' RECOMMENDED REPLACEMENT PROGRAM FOR FILTERS. Use GFS replacement filters for the plenum, the air heater, intake, exhaust, and other components as needed. GFS filters are designed to provide high-efficiency particulate removal and will maintain balanced airflow during the life of the filter.
  • Page 17 Service and maintenance WARNING Improper disposal of used filters may cause spontaneous combustion. You must consult local authorities for proper storage and disposal requirements. Guidelines include: • Immediately remove all filters from the booth. • Discard filters to a safe, detached location, place them in a non-combustible container with tight-fitting lid, or place them in a water-filled metal container to prevent a possible fire hazard.
  • Page 18 Service and maintenance Replace the exhaust filters in a semi-downdraft booth The exhaust filters are located in the filter racks of the exhaust bridge chamber. Remove and safely dispose of used filter media. WARNING Treat used filters and any other paint-contaminated items as flammable products and dispose of them safely.
  • Page 19 Service and maintenance Figure 4. Filters in booth ceiling Perform these steps to replace the intake filters. NOTE Work from one side of the filter grid to the other. Use a ladder to access the filter clips on the appropriate section of the filter grid. Use a drill with socket wrench bit or a socket wrench to loosen one of the outer corner filter clips.
  • Page 20 Service and maintenance Remove the filter rack from the booth ceiling and place it on two sawhorses, with the flat side of the filter rack facing down. NOTE You can replace more than one intake filter at a time. The image above shows two filter racks. Remove and safely dispose of used filter media.
  • Page 21 Service and maintenance Replace air heater filters (GUL and BT) WARNING Before servicing, lockout/tagout the air heater, including the main electrical service and the main gas supply. Perform these steps to replace the air heater filters: On the air heater, locate the panel that houses the filter. Remove the four wing-head thumb screws.
  • Page 22 NOTE Pay attention to the orientation of the filter inside the unit. Making sure the filter is oriented the same way, slide the new GFS pocket filters along the track into the air heater. Reattach the panel and secure it with the four wing-head thumb screws.
  • Page 23 Service and maintenance If necessary, loosen the bolts (1/2-inch hex bolt head) securing the gas train access panel, and lift panel out of place. The filter access panel is located within the chamber. Remove the six bolts (1/2-inch hex bolt heads) to gain access.

  • Page 24: Remove Overspray Buildup

    Service and maintenance Making sure the filter is oriented the same way, slide the new GFS pocket filters along the track into the air heater. Replace filter access panel, and then replace the gas train access panel. If applicable: Replace combustion blower filters Scope: This procedure applies only to air heaters with Low NOx burners.

  • Page 25: Check Operation Of Product Doors

    Service and maintenance • Floor NOTE If you use protective booth paper or coating, replace it when it becomes worn or dirty. • Doors/curtains NOTE Check to make sure the door opens and latches without difficulty. Visually inspect all other surfaces for accumulated buildup; remove overspray or clean as required. Check operation of product doors NOTE Perform this task for each product and personnel door installed in the booth.

  • Page 26: Monthly Maintenance

    Service and maintenance Monthly maintenance This section contains tasks that should be performed on a monthly basis. Increase or decrease frequency as needed for specific operating conditions and use of booth. Clean booth components A: Intake Duct B: Discharge duct C: Intake plenum D: Exhaust plenum (confined space) E: Exhaust ductwork...

  • Page 27: Inspect And Clean The Air Heater

    Service and maintenance WARNING Before servicing, lockout/tagout the air heater, including the main electrical service and the main gas supply. Inspect the intake and exhaust ductwork. If needed, scrape off any build-up; then sweep or vacuum it up. Dispose of build-up or other waste safely. WARNING Paint-contaminated items are flammable and may cause spontaneous combustion.
  • Page 28 Service and maintenance WARNING Before servicing, lockout/tagout the exhaust fan, including the main electrical service and the main gas supply. Check that the fan inlet and the intake areas (the approaches to the exhaust fan) are clean and free from obstructions. Check the bearings for excessive play and replace, if necessary.

  • Page 29: Yearly Maintenance

    Service and maintenance Yearly maintenance This section contains tasks that should be performed on a yearly basis. Increase or decrease frequency as needed for specific operating conditions and use of booth. NOTE Once each year, perform these tasks in addition to the monthly maintenance tasks. If applicable: Inspect and clean an air heater with a standard burner Scope: Perform this procedure if the air heater has a standard burner.

  • Page 30: If Applicable: Inspect And Clean An Air Heater With A Low Nox Burner

    • The tip should be clean and free of dirt and carbon. If not clean, replace the spark rod. • The porcelain must be intact. If the porcelain is cracked, replace the spark rod with Spark Plug, GFS part number 117-208.

  • Page 31: If Applicable: Inspect The Cycle Damper (Bt And Gul)

    Then, inspect the spark rod. • The tip should be clean and free of dirt and carbon. If not clean, replace the spark rod. • The porcelain must be intact. If the porcelain is cracked, replace the spark rod (GFS part number 908513_5246-43).
  • Page 32 Service and maintenance • Test nipples installed in the downstream pressure tap port of each automatic safety shutoff valve • Transparent glass of water filled at least 1 inch from the bottom • Leak test tube: aluminum or copper 1/4-inch rigid tube with a 45 degree cut at the end •...

  • Page 33: If Applicable: Check The Gas Pressure Switches

    Service and maintenance Type Allowable Valve Seat Leak- # of Bubbles in 10 age up to 7 PSI inlet s Natural Gas DMV D(LE) 701/622 239 cc/hr DMV-D(LE) 702/622 464 cc/hr DMV-D(LE) 703/622 464 cc/hr IMPORTANT If leakage values are exceeded, replace valve immediately. Repeat the same procedure for valve V2 (port 3).
  • Page 34 Service and maintenance Measure the resistance. If the resistance is more than 1.0 ohm, remove the switch from service. Connect the meter to the NC and COM contacts. Cause a low-pressure fault condition using one of methods below: NOTICE Do not simulate fault conditions while the burner is firing. •...
  • Page 35 Service and maintenance Connect a meter capable of reading +/- 0.1 ohms to the NC and COM contacts. Measure the resistance. If the resistance is more than 1.0 ohm, remove the switch from service. Connect the meter to the NO and COM contacts. Cause a high-pressure fault condition using one of methods below: NOTICE Do not simulate fault conditions while the burner is firing.

  • Page 36: General Service Procedures

    Service and maintenance General service procedures This section contains procedures that can be performed as needed to correct problems or as directed by the preventive maintenance schedules in “Daily maintenance” (page 16), Weekly maintenance, “Monthly maintenance” (page 26), and “Yearly maintenance” (page 29). Replace a defective bulb NOTE Perform this task if a specific light bulb is burned out or is noticeably dimmer than the other bulbs.
  • Page 37 NOTE GFS recommends that you use Light Fixture Lens Protector or GFS Booth Shield to protect your booth lights from overspray. Lens Protector is a plastic peel-off film; Booth Shield is a peelable coating. Both products are available from your local distributor or from the GFS Parts Department.

  • Page 38: Adjust Belt Tension

    Service and maintenance Adjust belt tension Belt tension is very important to the proper operation of a fan and to the service life of a V-belt drive. The belts on a new fan are properly adjusted; however, all V-belts stretch in the first few hours of operation. It is necessary to readjust the belt tension after eight hours of running.

  • Page 39: Replace Fan Belts

    Service and maintenance Apply the force from the following table evenly across the width of the belt at the center of the belt span and measure the deflection. NOTE A strip of keystock or similar material may be used to distribute the force evenly across the belt width. Table 4.
  • Page 40 Service and maintenance Check that the fan and motor sheaves are in axial alignment; adjust sheaves as required. NOTE Shafts are parallel in both the vertical and horizontal planes. A: Motor B: Fan C: Drive A: Motor B: Fan C: Drive Side view (vertical alignment) Top view (horizontal alignment) Check that the fan motor sheaves are in radial alignment;...

  • Page 41: V-Belt Drive Considerations

    Most GFS fans are provided with an adjusting screw as a part of the motor base for easy setting of belt tension. However, small fans or fans using small horsepower motors may have only a slotted base plate.

  • Page 42: Air Heater Service Procedures

    Service and maintenance • The blade set screw is loose. • Material has accumulated on the blade. Air heater service procedures Reference: For detailed air heater service procedures, see the air heater owner's manual that shipped with your booth. Check air heater belt tension (SpaceSaver) WARNING Operating drives without guards in place can result in severe injury or death.

  • Page 43: Reset The Air Heater Flame Safety Control

    Service and maintenance Apply the force from the following table evenly across the width of the belt at the center of the belt span and measure the deflection. NOTE A strip of keystock or similar material may be used to distribute the force evenly across the belt width. Table 5.

  • Page 44: Spare Parts And Accessories

    • Purchase order number or credit card number • Preferred shipping method (UPS, Federal Express, truck, air, etc.) • Complete shipping and billing address NOTE Visit www.globalfinishing.com/parts-filters and the GFS Accessories Catalog for information about paint booth parts and components. Global Finishing Solutions 239-062 rev 5...

  • Page 45: Accessories

    Spare parts and accessories Accessories Refer to the following table for commonly used accessories that can help keep your booth clean and organized. Table 7. Accessories Image Name and description Part number ™ BoothBox 2 218-002 The BoothBox 2 is a magnetic, double compartment cabinet and double spray gun holder, designed for the interior of paint booths.
  • Page 46 Spare parts and accessories Image Name and description Part number ™ Single GunHanger 218-004 The Single GunHanger is a magnetic spray gun holder designed to hold all types of spray guns and most types of air tools. A soft edge guard eliminates scratching of the spray gun or gun cup.
  • Page 47 Spare parts and accessories Image Name and description Part number ® Booth Shield Walls: Booth Shield protects booth interiors • 236-067 (water-based wall prep; and increases brightness, improving 1 gallon) visibility and overall product quality. • 236-061-5PL (wall prep; 5 gal- Booth Shield coatings are easy to apply lons) and quickly dry on your paint booth’s...
  • Page 48 DirtTrack Mat 217-240 (24-inch x 30-inch mats; 1 pad of 60 peelable sheets) Prevent contaminants from entering the booth with GFS DirtTrack mats. Position 217-241 (36-inch x 60-inch mats; 1 the multilayered, adhesive mat in front pad of 30 peelable sheets) of product or personnel doors to trap dirt and dust from shoes or tires.

  • Page 49: Control Panel

    For detailed information about using the control panel, see the operator manual for your control panel type: ® • Engage Operator Manual (GFS part number 239-058) • LOGIC 3 Operator Manual (GFS part number 239-059) • LOGIC 4 Operator Manual (GFS part number 239-060) Global Finishing Solutions 239-062 rev 5...

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