Despatch S Type User Manual

“S” TYPE

“S” TYPE“S” TYPE INST

INSTALLATION

INSTINST

ALLATION MANUAL

ALLATIONALLATION

MANUAL

MANUAL MANUAL

REVISION 11/2007

TABLE OF CONTENTS DESCRIPTION PAGE

INSTALLATION INSTRUCTIONS.........................................................................................1

DESPATCH POLICY FOR ACCEPTING BACK CHARGES................................................2

GENERAL INFORMATION ...................................................................................................3-4

INSTALLATION OF BATCH OVENS ....................................................................................5-8

INSTRUCTIONS FOR MIXING AND CURING DES-CRETE INSULATING

FLOOR MATERIAL................................................................................................................9

EXPLODED BODY ASSEMBLY ILLUSTRATION ................................................................10

FLOOR CHANNEL ASSEMBLY ILLUSTRATION.................................................................11

OVEN BODY PANEL ASSEMBLY ........................................................................................12-13

OVEN BODY SEALING PROCEDURE.................................................................................14

BODY CROSS SECTIONS FOR ASSEMBLY......................................................................15-19

DUCTWORK ASSEMBLY ILLUSTRATIONS .......................................................................20-23

STANDARD DOOR HINGE ASSEMBLY..............................................................................24

CONTROL AND HI-LIMIT THERMOCOUPLE MOUNTING.................................................25-27

FAN AIRFLOW SWITCH PIPE MOUNTING.........................................................................28

BBC AND FC FAN WHEEL POSITIONING..........................................................................29

SETTING HEATER BOX ON TOP OF OVEN.......................................................................30

OVEN AIRFLOW ADJUSTMENT..........................................................................................31-35

STANDARD SUPPLY AND RETURN DUCT/SLIDE

BASELINE ADJUSTMENT (SUPPLY ADJUSTABLE LOUVERS).......................................36-58

STANDARD SUPPLY AND RETURN DUCT/SLIDE

BASELINE ADJUSTMENT (SUPPLY DIAMOND NOZZLES)..............................................59-81

EXHAUST ASSEMBLIES ......................................................................................................82-84

MOTORIZED EXHAUST SET-UP.........................................................................................85

"S" TYPE OVEN FRONT AND SWING DOOR INSTALLATION..........................................86-87

SWING DOOR TROUBLESHOOTING INFORMATION.......................................................88-89

OPTIONAL "S" TYPE OVEN VERTICAL LIFT DOOR INSTALLATION...............................90-91

LIFT DOOR TROUBLESHOOTING INFORMATION............................................................92-94

INSTALLATION INSTRUCTIONS

The enclosed drawings, installation instructions and general information sheet are for use by the purchaser to enable them to contract local qualified personnel to erect an oven with a minimum of lost motion and without the services of a Despatch Engineer.

It is suggested that the person selected to supervise the erection read the general information sheet and installation instructions thoroughly, referring to the specific drawings and details for your oven which should be included in this packet. Then follow the installation instructions as listed.

WARNING - THESE INSTRUCTIONS ARE BASED IN PART ON SAFETY CONSIDERATIONS, THEREFORE, ONLY QUALIFIED PERSONNEL SUCH AS EXPERIENCED RIGGERS SHOULD ATTEMPT THIS INSTALLATION.

If you receive your oven with body set up, then you may disregard those steps that have already been completed. However, we would recommend reading this manual completely to understand more about your oven and how it is built. Illustration 17 will be especially helpful in placing the heater box on top of the oven.

The instructions are not intended to describe in detail or provide a solution for all the problems which could arise, as each unit presents its own peculiar problems. With good judgment and the use of the enclosed information, minimal difficulties should be encountered.

If you would like to investigate the use of an experienced Despatch Installation Supervisor, contact our Service Department at the telephone number listed below.

DESPATCH INDUSTRIES 8860 207th St. West

Lakeville, MN 55044 TELEPHONE: 952-469-5424 or Despatch Help Line: 1-800-473-7373

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DESPATCH POLICY FOR ACCEPTING BACK CHARGES

Drawings and instructions supplied with the equipment ordered from Despatch generally result in trouble-free erection and start-up. However, occasionally discrepancies in materials supplied by Despatch will require rework or adjustment during installation. The policy in such an occurrence requires that the Purchaser receive prior authorization from Despatch for the cost of work to correct discrepancies. If there is any questions in regard to this policy, the Purchaser is instructed to contact the local Despatch representative.

If erection and start-up has not been purchased from Despatch, we urge the purchase of the services of an erection supervisor. Generally, presence of an erection supervisor will minimize time lost should discrepancies occur. This also ensures efficient and correct erection of Despatch's ovens and furnaces.

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GENERAL INFORMATION

1. Panels are marked with part numbers (example 270832).

A. Part numbers are referenced by item numbers on the body drawings.

2. Return Duct items numbered 1, 2, 3, etc., indicate the recirculation or return duct which

corresponds to duct items on duct detail assembly drawings. Items are identified with part numbers.

3. Supply Duct items numbered 1, 2, 3, etc., indicate the supply duct which also

corresponds with drawings. Exhaust Duct 1, 2, 3, etc., indicates exhaust duct.

4. Floor channels are not used at door (front) end of oven. On double end ovens, floor

channels are used on sides only.

5. Outside of oven panels are not painted unless ordered (refer to assembly drawing).

Attention must be paid to direction of panel joints.

6. When moving or storing oven parts, place panels on edge. This eliminates crushing of

panels and the desired numbered panel will be accessible without any shuffling.

7. Roof angles are designed to come to 1/2" of front and rear panels, i.e., roof angles are 1"

shorter than inside dimension of oven.

8. WEJ-IT anchors require a hole same diameter as the WEJ-IT and full length of

unthreaded part. Be sure wedges are fully seated in wedge pockets before inserting into hole. Insert WEJ-IT until washer is flat against work surface and tighten nut two to three full turns.

9. Self-drilling sheet metal screws are used for fastening all sheet metal components. It is

very important not to over-tighten the screw. The manufacturer recommends using torque-sensing drive tools which are easily adjustable to provide positive seating without stripping. Drill motors are not recommended. Tools with brakes are recommended to minimize the possibility of stripping. The following are guidelines only and the installer should always begin at a setting less than the guidelines listed below.

Panel Joints 85-95 in.lb. Torque

Double sheet (ie. Roof angles, floor channels): 45-55 in.lb. Torque Single sheet (ie. Inside flashing, outside flashing): 35-45 in.lb. Torque

10. Lap joints are used on duct connections. See duct assembly drawing for details.

11. A. 1/2" bolt requires 9/16" clearance drill and 7/16" body drill for tapping.

B. The new 1/2" Hex washer head, thread forming bolt requires a .469 diameter hole

(15/32" drill). C. 3/8" bolt requires 7/16" clearance drill and 21/64" body drill for tapping. D. The new 3/8" Hex washer head, thread forming bolt requires a .345 diameter hole

(11/32" drill).

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12. Gas-fired heaters model number indicates capacity in BTU per hour, i.e., DG-350 rated at 350,000 BTU per hour

DG-500 rated at 500,000 BTU per hour DG-750 rated at 750,000 BTU per hour DG-1000 rated at 1,000,000 BTU per hour DG-1500 rated at 1,500,000 BTU per hour

13. A.F.S. indicates airflow switch. Refer to Illustration #15.

14. A. If oven is to be mounted on wood floor, insurance requirements are such that 4" clay

building tile are required between wood floor and bottom of oven. Tile must be placed with openings in tile in line to permit free flow of air across the short axis of the oven. (Insulation batts for joint packing may be cut into strips with a “butcher knife” or equivalent, using a sawing motion.)

B. It is required for ovens operating above 350°F to have an insulated floor. If the oven is to be mounted on an existing concrete floor, a pit must be added and filled with insulating floor material (“DES-CRETE” or other. See mixing & curing instructions on page 9).

15. Bolted connections on structural platforms, heater box support structural, etc., are for

erection ease only. These connections should be welded after erection unless noted otherwise on the drawings. This is especially critical at connections where fan vibration is possible.

16. The fresh air and exhaust damper settings should be in the closed position unless they

have been preset at the factory. Minimal adjustments to enhance certain requirements (ie: temperature uniformity, pressure balance) can be made. Allowing too much fresh air in can result in increased exterior wall temperatures. Opening the exhaust damper can introduce cool air from outside the oven that can affect temperature uniformity. See ‘Damper Operation’ in the Oven Instruction Manual for additional information.

17. If there is a variable speed drive for the recirculation fan it is important not to change the

fan speed without understanding the consequences. Pressure changes or changes in air velocity in the heater box can be affected. Consult the factory with any questions or concerns.

18. As part of a preventative maintenance program all fasteners should be inspected on a

regular basis. All loose fasteners should be tightened.

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INSTALLATION OF BATCH TYPE OVENS

1. Note overall dimensions of oven on assembly drawing and check for sufficient

clearances from walls, overhead, etc. (6" minimum from wood construction).

2. With chalk line or scribe, lay out on floor the outside dimensions of the oven rear walls

and front. See Illustration #2 and body detail.

3. Working with the above markings add the outside chalk line for the sidewalls. If oven

has panel type floor, set panel floor and omit Steps 4 through 8.

4. Place sidewall floor channels on floor inside sidewall chalk lines. Sidewall channels are

1/2" shorter than the inside dimension of oven. The same applies to the rear wall channel. Refer to floor channel drawing.

5. Place rear wall floor channel on floor with the ends of the two sidewall channels and rear

channel touching. With a tape line, measure diagonally corner to corner of channels shifting sidewall channels until measurements are equal. Check again for sufficient aisle, overhead, etc., clearances.

6. Mark floor through predrilled holes in channels for location of anchor bolts. Three

anchors are required per ten lineal feet.

7. Scribe across end of floor channels for reference marks and with drill, drill holes for 3/8"

WEJ-ITS provided.

8. Replace channels over anchors and fasten with 3/8" nuts and washers. Recheck floor

channels for square. Holes in channel are enlarged to allow for errors in drilling concrete and expansion. Should floor have excessive pitch, level channels by using steel shims and grout with concrete grout mix to close the gap between the floor and floor channels. Gaps under floor channels must be sealed to eliminate fresh air leakage which will effect oven uniformity.

9. Starting with the rear corner panels, pack bottom void of panels with insulation provided,

and set the two corner panels in place. Square, flash inside, pack outside corner with insulation, and install outside flashing. See Illustrations #1, #3, #4, #5, #6, #6a, #6b and #7 for details of insulating and sealing panel joints.

10. Prepare next wall panel, packing with insulation. Slide panel in place. Each panel joint

lap approximately 1" depending on the type of panel (see body detail print). Illustrations #3 and #4 show panel engagement and assembly techniques.

11. Bolt roof angle to wall and corner panels using 1/4" self-drilling sheet metal screws with

flat washer and, in special cases, 3/8" machine bolts and nuts at special roof tee junctions as noted, and use standard 3/8" flat washer under bolt head. If roof tees are required, at roof tee areas holes must be drilled on each side of the roof tee support in panels for fastening roof angles to panels. This will give a more positive hold to the roof panel. Refer to Illustration #6 for detail.

12. Referring to oven body detail and panel numbers, continue working both ways from first

corner panel (tying together with roof angle) until only the front section remains.

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13. Slide front section in place making sidewall panel joints simultaneously, and using a 3'

level or plumb-bob, plumb the oven front and fasten as required to the sidewall panels and floor channels. Refer to "S" Type Oven Front and Swing Door Installation in the manual body and detail drawings for particulars.

14. With tape line, measure diagonally corner to corner at top of panels and square up

accordingly, shifting rear corner panels in slotted roof angles.

15. Starting at front of oven, set roof panels in place. See Illustration #1 for roof panel detail.

Check centerlines of panel duct openings against heater box openings as dimensioned on oven body detail and heater details before fastening roof panels to roof angles with self-drilling sheet metal screws.

16. Fill voids formed by roof and wall panels with insulation provided, compressing slightly as

shown on Illustrations #3, #6, #7 and #8.

17. Using self-drilling sheet metal screws fasten roof corner flashings. Fasten front and rear

flashings, then side flashing, cutting to length if required. Be sure to fasten oven front to the roof angle or to the roof corner flashing (see your specific oven drawing).

18. Following the supply duct assembly drawing and the duct detail drawing, assemble the

bottom corner portion of the heat supply duct at the floor and install both oven sidewall duct runs, installing duct faces last. Work up the vertical runs and complete the crossover duct at the roof, installing duct fronts last. Refer also to Illustration #9.

19. Place a layer of 1" mineral wool insulation around the perimeter of the duct connection

outside of the collars. Insulation will pack down once the heater box is set down in place. See Illustration #17 for illustrated procedure.

20. Using lift truck or chain falls, lift and set heater box, with support channels attached, on

top of oven. Align duct openings in heater box with roof panel duct openings. Heater unit weighs 1,200 to 3,000 pounds, depending on the size of the heater. Be safe, do not overload your lifting equipment, and be sure to use an experienced rigger for this job. Do not fasten heater down at this time. See Illustration #17 for complete procedure in placing heater on top of oven.

21. Slip supply duct collar through roof panel opening into supply opening in heater box and

fasten to roof panels with self-drilling sheet metal screws. Pack the void around the heater box opening with insulation. Refer to Illustration #11. (Shift heater box unit if necessary.)

22. Slip return duct collar through roof panel opening into recirculation opening in heater box

and fasten to roof panels with self-drilling sheet metal screws. Pack the void around the heater box opening with insulation. Refer to Illustration #10. (Shift heater box unit if necessary.)

23. Fasten supply duct/back units to roof panels and the vertical drops to the side panels.

See Illustration #9 for fastening details.

24. Fasten return duct or return baffle to roof panels with self-drilling sheet metal screws.

Refer to recirculation duct assembly drawing for assembly instructions and dimensional

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location.

25. Secure lap joints with self-drilling sheet metal screws.

26. Position perforated or louvered air discharge supply duct faces end to end, referring to

assembly drawing for dimensions and using 3' level , level ducts. Fasten ducts to sidewall panels with self-drilling sheet metal screws. See Illustrations #9 and #11 for details.

27. Supply/discharge opening settings can be made later after fan is operating. See step 38.

28. Anchor heater box support columns.

29. Connect exhaust duct or exhaust fan and damper linkage to oven. Mount inside exhaust

baffle plate over exhaust opening (small opening in ceiling). Refer to oven damper linkage picture reference in this manual showing exhaust damper set-up, or detail drawings if linkage is complicated. Refer to pages 81, 82, 83 and 84.

30. Refer to door and front installation in manual.

Options are as follows:

· "S" Type Oven Front and Swing Door installation

· "S" Type Oven Vertical Lift Door Installation

31. If a Descrete poured insulated floor is used, set tracks (if used) into position, referring to

end elevation of oven assembly drawing for dimensional data and check these dimensions with the truck that will be used on the job. Then pour floor. Refer to mixing and curing instructions included in this manual. Purchaser to furnish all Portland cement required, as due to spoilage, it is not practical to ship Portland cement with oven.

32. Carefully locate and mount control and high limit thermocouple (refer to oven assembly

drawing for location) and fasten to supply duct face. See detail Illustration #13 and #14. Do not kink. Avoid bends with a radius smaller than 1". See Illustration #14.

33. On electric models, make electric service connections, referring to electrical drawings for

connection points and total load amperage. On gas models, make electrical and gas connections, referring to electric and piping drawings. On gas models, a manual shut-off valve immediately ahead of burner piping is required.

34. For exhaust fan locations refer to the assembly drawing. Smaller direct drive exhaust

fans mount directly over oven panel exhaust opening and exhaust fan is fastened to roof panel with self-drilling sheet metal screws. Larger belt driven exhaust fans will mount to a structural base which sets on top of the oven. Holes must be drilled into the heater box side for mounting base steel and fastened or welded to the oven roof flashing at the opposite end. Refer to pages 81, 82 and 83.

35. Large exhaust fans require an inlet duct assembly which sets in the roof opening and

laps over the exhaust fan inlet collar. Refer to page 83.

36. Field mounting of the inside exhaust baffle is required. Refer to pages 81, 82 or 83 for

further detail and mounting instructions.

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37. Run exhaust stack to exterior of building as required. Avoid horizontal runs and elbows

wherever possible. When running exhaust stack through wood ceilings, partitions, etc., distance from wood should be at least 6" on all sides. Refer also to local ordinances. See recommended exhaust duct installation sheet in the operating instruction book.

38. Refer to Operating Instruction Book for start-up procedure.

39. Initial Air Adjustment—Set all duct slots or perforations to give uniform air velocity. See

illustration titled Oven Airflow Adjustment located at the end of the installation manual for baseline ductwork settings. Refer to pages 31 through 80.

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