Table of Contents
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GENERAL INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
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APPENDIX C - MINIMUM PERIODIC MAINTENANCE REPORT
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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.
INSTRUCTIONS is provided in a plastic cover. Post these instructions at the oven for the
operator to reference.
W:\Electrical\MANUAL\OVEN OPERATING INSTRUCTIONS\GENERAL INSTRUCTIONS\Oven General Instructions
FOR OVENS
TABLE OF CONTENTS
An additional copy of the OPERATING
1 of 38
Rev. B.doc
10/2018
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Summary of Contents for Grieve AA-550
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Page 1: Table Of Contents
GENERAL INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS FOR OVENS TABLE OF CONTENTS SHIPPING DAMAGE & HANDLING PROPER OVEN APPLICATION 2-1 General 2-2 Flammable Solvents 2-3 Combustible Material 2-4 Personnel Hazards 2-5 Maintenance and Inspection INSTALLATION 3-1 Location 3-2 Building Considerations 3-3 Clearances 3-4 Ventilation 3-5 Exhaust Ductworks 3-6 Fuel Gas Supply... -
Page 2: Shipping Damage & Handling
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... -
Page 3: Proper Oven Application
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. -
Page 4: Combustible Material
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. -
Page 5: Personnel Hazards
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. - Page 6 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.
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Page 7: Installation
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. -
Page 8: Clearances
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. 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. -
Page 9: Exhaust Ductworks
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. - Page 10 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.
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Page 11: Fuel Gas Supply
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 inch minimum) of same size as supply piping, shall be installed in the fuel gas supply piping to protect the downstream safety shutoff valves and... -
Page 12: Electrical
3-6.8 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. 3-6.9 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. -
Page 13: Prior To Placing Oven In Service
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. - Page 14 4-12 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.
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Page 15: Processing
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. - Page 16 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.
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Page 17: Safety Equipment
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. -
Page 18: Maintenance
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. - Page 19 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. 7-7.3 Oven Body 7-7.3.1 The exterior of the oven should be touched up whenever scratches occur to prevent rusting.
- Page 20 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. 7-7.5.3 Explosion relief door latches must be inspected regularly, at least every two months, for adequate lubrication and freedom of movement.
- Page 21 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.
- Page 22 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. 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.
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Page 23: Trouble Shooting
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). - Page 24 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).
- Page 25 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.
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Page 26: Appendix A - Safety Equipment Description & Operation
9 APPENDIX A - SAFETY EQUIPMENT DESCRIPTION & OPERATION 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. - Page 27 9 APPENDIX A (cont’d) 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.
- Page 28 9 APPENDIX A (cont’d) 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 oven’s 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.
- Page 29 APPENDIX A (cont’d) 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.
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Page 30: Appendix B - References
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, MA 02062 Attn: Publications Order Processing Specifications 6-9, Industrial Ovens and Dryers 10.2 National Fire Protection Association... - Page 31 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: ______________________________________________...
- Page 32 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. 13. ____ Lubricate motors. 14. ____ Lubricate bearings on blower and exhauster shafts, belt conveyor shafts, door lift mechanisms and other bearings.
- Page 33 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.
- Page 34 TEMPERATURE CONTROLS 46. ____ Heat oven to operating temperature and check temperature controller calibration. 47. ____ Compare temperature controller indication and excess temperature limit interlock indication to confirm they are similar. 48. ____ Disconnect one side of thermocouple connection to confirm upscale break protection is operating on main temperature controller and excess temperature limit interlock.
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Page 35: Appendix D - Safety Shut Off Valve Leak Test Procedure
12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE FIRST PILOT SHUT OFF VALVE (1PSOV) 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 &... - Page 36 12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE (cont’d) SECOND PILOT SHUT OFF VALVE (2PSOV) Make sure all gas cocks ahead of equipment are open to allow gas flow to equipment and 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 &...
- Page 37 12 APPENDIX D - SAFETY SHUT OFF VALVE LEAK TEST PROCEDURE (cont’d) SECOND SAFETY SHUT OFF VALVE (2SSOV) (cont’d) Close the test petcock (G). Release test button. Remove the 1/4" tube and replace the leak test tap plug (H). Open the main gas cock located between the safety shut off solenoid valves and burner.
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Page 38: Appendix E - Warranty And Limitations Of Remedies
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;...
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What is the size required for the ventilation duct