i. Tech 3 OSDs User Manual

OSD SERIES

DIRECT GAS-FIRED AIR HEATER

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FOR USE ONLY IN PAINT SPRAY BOOTHS AND DRYING OVEN APPLICATIONS

READ MANUAL CAREFULY BEFORE INSTALLING

OR OPERATING THE FURNACE

FOR YOUR SAFETY FOR YOUR SAFETY

If you smell gas follow these instructions, The use and storage of gasoline or other flammable

1) Open windows. vapors and liquids in open containers in the

2) Do not touch electrical switches. vicinity of this appliance is hazardous.

3) Extinguish any open flame.

4) Call the gas supplier immediately.

MODEL: SERIAL NUMBER:

JOB: DATE OF INSTALLATION:

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE CAN

CAUSE PROPERTY DAMAGE, INJURY OR DEATH. PLEASE READ THE

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTION

THOROUGHLY.

*THIS UNIT IS TO BE SERVICED BY QUALIFIED PERSONNEL*

**DO NOT TAMPER WITH THE UNIT OR CONTROLS**

INSTALLER’S RESPONSIBILITY

Installer please note: This equipment has been test fired and inspected. It has been shipped free from defects from

our factory. However, during shipment and installation, problems such as loose wires, leaks or loose fasteners may

occur. It is the installer’s responsibility to inspect and correct any problems that may be found.

THIS EQUIPMENT SHALL BE INSTALLED AND WIRED IN ACCORDANCE WITH THE REGULATIONS OF
THE NATIONAL BOARD OF FIRE UNDERWRITERS, CANADIAN ELECTRIC CODE AND LOCAL
GOVERNING BODIES. THE INSTALLAION CODE FOR “GAS BURNING, APPLIANCES AND
EQUIPMENT, CAN 1-B149”, AND APPLICALBLE PROVINCIAL REGULATIONS FOR THE CLASS, WHICH
SHOULD BE FOLLOWED CAREFULLY IN ALL CASES.

INSTALLER/SERVICE CONTRACTOR

NAME:

ADDRESS:

TELEPHONE:

CONTACT:

GENERAL INFORMATION

GENERAL NOTES

This Direct Fired OSD Spray/Bake Unit, dual air dual temperature unit is designed to provide make up air to satisfy the
exhaust requirement of the paint spray booth. 100% volume on the spray cycle and 50% volume on the dry cycle. Normal
discharge temperature on spray cycle is between 70° F and 80° F. Normal discharge temperature on dry cycle is between
120° F and 180° F. The sequence of operation and wiring diagram are located in the weather housing on out door units and
burner compartments of indoor unit.

WARNING

Fire or Explosion hazard can cause property damage, severe injury or death. Ensure that all air taken into the unit is
free from the presence of:

a) Flammable solids, liquids and gases.
b) Explosive materials. Example: grain dust, coal dust, gun powder etc.
c) Substance which may be come toxic when exposed to heat or passing through a gas flame.

INSTALLATION AND SERVICE INSTRUCTIONS

The information provided is a guide to the proper installation, operation and troubleshooting of the unit. Retain the manual
as a reference for operation and maintenance personnel. Should contact with the factory be necessary, provide the unit model
number and serial number. Install and wire the equipment in accordance with the applicable national and local governing
bodies codes. Authorities having jurisdiction should be consulted before making the installation. Local codes may require
additional safety controls and/or interlocks.

UNIT LOCATION

Prior to locating the unit check with the authorities having jurisdiction. The unit should be located with clearance to open
access doors and remove filters. Ensure that the unit is installed level. Provide adequate clearance on either side of the unit
to service blower, bearings, motors, drives and filters. Ensure that the position of the heater relative to support beams is
correct so as to provide adequate support for the equipment. For roof mounted units, check the spacing of the roof structure
beams to avoid interference with air ducts.

LOCATION OF ACCESSORIES

The remote panel will be shipped as a separate package. Mount the panel and have an electrical contractor install wiring.

FACTORY TESTING & START UP CHECKLIST

All OSD series units are factory fired and tested prior to shipping. Each unit is shipped with the tester’s report and a start-up
checklist. Complete the start-up checklist and return one copy to the factory.

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INSPECTION OF EQUIPMENT

All shipments are made F.O.B. the factory. The unit is securely strapped or blocked to prevent shipping damage and each
shipment inspected prior to leaving the plant. All parts, where feasible, are strapped to or included in the unit. Upon receipt
of goods, check the shipment against the bill of lading to ensure all items have been received. Carefully check the unit for
physical damage in the presence of the carrier’s representative. Should parts be missing or damage noted, file a claim
immediately with the carrier. ICE does not assume responsibility for the handling of the goods in transit and is not
responsible for the initiation of freight claims.

INSTALLATION AND SERVICE INSTRUCTIONS

Direct Gas Fired Air Heaters

LOCATION OF UNIT AND DISTRIBUTION

Inlet

The intake shall be designed and located to prevent snow, rain, flammable gas, toxic gases and other deleterious materials
from entering the unit. (Less than 500 F.P.M. is an accepted velocity.)

INSTALLATION

Smaller models are shipped as one total unit. All other models are shipped in sections that are easily erected on the job site.
The main sections consist of a burner damper section that contains the motor, and a blower section. The secondary sections
are the filter, louver, mixing box etc., which are added in sections as required.

1. All sections are pre-drilled and are bolted together in the field (as per Figure 1).

2. Belts must be installed on the motor, and limit and discharge controls may have to be mounted and/or wired.

3. When clearance is not a factor, ensure that the unit is adequately protected from obstruction.

NOTE: On roof top units the joints will have to be caulked to prevent rain from entering the unit.

Indoor Suspension

On indoor models holes at the base of the units are provided for 5/8” suspension rods (see Figure 6). Unit must be lifted and
handled from the lifting holes provided at each end of the channel iron, when suspending from the ceiling. If units are to be
lifted from the bottom for mounting on a platform (as with a forklift), unit must be supported.

NOTE: DO NOT LIFT CABINET WITHOUT THIS SUPPORT.

Rooftop Installation

Support rails (minimum of 4” high) must be provided underneath the unit. In some cases, more height may be required when
installing the supply duct through the roof (see Figure 1) or if a unit is a bottom discharge (see Figure 2).

Minimum clearance from the unit, to combustible construction, is clearly marked on the rating plate attached to the unit.

No source of flammable vapors, gases or dust shall be with in 20’ horizontally of any unit unless that source is separated from
the unit by an enclosure of fire and vapor resistive materials.

On indoor suspended units, when necessary to provide working clearance beneath the unit, the installation shall be made at a
suitable height above the floor.

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CONNECT DUCTWORK

1. On indoor units, install fresh air duct to inlet of unit. Install intake hood or louvers with screen.

a) Make required opening in wall and line with angle frame inside. Should be completed before outside is started to

avoid crumbling.

b) Insert insulated fresh air “collar” through opening with flanges turned out to provide rigidity.

c) Anchor intake hood with birdscreen to wall.

d) Caulk perimeter of opening to make rain tight.

2. Connect discharge air duct or discharge grille to unit outlet. If unit is installed on a roof, be sure that the duct going

through the roof is adequately flashed and sealed to prevent leakage (see Figure 1).

3. Where a ductwork system or other enclosure is directly connected to the inlet or outlet of the heater is such a way as to

cause a possible gas trap and accumulation of a flammable mixture, a pre-purge cycle shall be incorporated to provide not
less than 4 complete air changes of the ductwork or enclosure by volume prior to an ignition.

4. Where additional automatically operated inlet or discharge air louvers are used, they shall be electric interlocked to

ensure the maximum designed opening before either starting or running circuits may be energized.

EXHAUST INTERLOCK

a) This unit shall be electrically interlocked so that it will operate only when the associated exhaust system(s) is

functioning. An exhaust airflow proving switch shall be used (Refer to sheet exhaust interlock). For typical
application, and (wiring diagram) for electric hookup.

b) The total air discharge capacity of the unit must not exceed by more than 10% the total discharge capacity of

the exhaust systems in conjunction with which it is used. Where the tempered air is discharged directly into a
booth, the total air discharge capacity of the booth.

c) The exhaust air proving switches should be set as to open when the volume of exhaust drops by more than

10% (dirty exhaust filters, etc.).

CONNECT GAS SUPPLY

a) Run correctly sized gas line to the unit. Install manual shut off valve plug-cock type approved for the application.

NOTE: Gas line pressure must be a least 7” W.C” when unit is operating at full input (Burner manifold pressure at full input
is from 4” to 4 ½” W.C.) Check rating plate on unit for maximum gas input.

b) Bleed and vent lines shall be installed in accordance with the applicable requirements.

COMPLETE WIRING

1. Install remote supervisor panel or if summer-off-winter switch (is used) in the desired location.

2. Complete wiring to supervisor panel or summer-off-winter switch as shown on wiring diagram.

3. Install fused disconnect switch (to be furnished by installer) and connect 3 phase power supply to disconnect

switch mounted on unit. Voltage must correspond to voltage marked on rating plate.

4. Complete all wiring to accessories (interlocks) as per wiring diagram provided on the unit.

NOTE: It is recommended that filters be removed during winter operation, if up stream from burner.

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WARNING

FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY, OR

DEATH.

Check for gas leaks with rich soap and water solution any time work is done on a gas control.

START-UP PROCEDURE

1. Remove shipping blocks from:

a) Blower if rubber or spring isolated.
b) Check to be sure that damper opens, if tied down, remove wire.
c) Check modulating discharge controller, on units, to ensure that it is in the blower air stream. On some units this

control may be mounted external from the unit. If so, check to see that the sensor installed is the discharge air stream
of the heater air and that the controller is wired to the modulating motor, regulating gas supply to burner.

2. Make sure that the main firing valve is closed, but that gas is available in the service line.

3. Check to ensure exhaust fans are wired into the control panel and that there is power to the exhaust starter relays.

Check to ensure exhaust fans interlock switches are installed and wired to the control panel.

4. Familiarize yourself with the sequence of operation and wiring diagrams this will give you information as to how the

unit operates in the paint and cure modes.

5. Check voltage to ensure it matches the voltage stamped on the unit rating plate, and all wires are connected between

unit and remote panel.

6. The timers TD-1 - TD-5 are factory set but you should check them to ensure they have not moved during transit to job

site.

a) Normal setting of high limits are paint mode -165°F cure mode -200°F auto reset.

7. Operate unit through paint mode by pushing in the system “on” push button. The unit should operate as per sequence

of operation.

a) Pilot

The Protector relay monitors the pilot flame through the flame rod. A minute current is sent from the relay through
the flame rod, and trough the pilot flame to “ground”. The relay detects the current flow and acts to open the safety
valve as required. When no flame exists, current cannot flow and the relay acts to close the valve. Current flow
depends only on flame contact on the rod: temperature of the rod is of no importance.

Since the flame rod is a current-carrying conductor, it must be free of any contact with conductive parts of the pilot
burner. Insulator must be clean, dry and free from cracks. While the flame rod is made of a heat resistant alloy it
may, after long service, deteriorate to the point of flame contact. Check for serious corrosion or loss of metal. It must
be tight enough in the insulator to maintain its position. Do not use too much force or the insulator may crack.

Proper operation of the flame rod can be checked by measuring the flame rod current; refer to flame safeguard
instruction sheet with unit. Lacking a micrometer, a check can be made with an operating burner through all its
normal phases. Relay response should be prompt with no chattering or drop out.

The spark rod (Midco Burner see Figure 5 for gap setting, Maxon Burner spark ignitor No. 18075) produces a high
tension arc at the correct location for lighting the pilot. Ignition transformer must be rated for 6000 Volts, 20
Milliampers secondary, minimum.

The spark rod or spark ignitor, must be free of contact with conductive parts of the pilot burner. Insulator must be
clean, dry and free of cracks. Check the spark rod for serious corrosion or loss of metal. It must be held tightly
enough is the insulator to maintain its position.

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Gap must be 1/16” to 3/32” (see Figure 5). Setting can also be checked by cycling the pilot. Ignition must be prompt
and positive. Do not allow careless positioning to cause arc of flame rod; serious relay damage would result.

The spark ignitor on Maxon burners, if ignitor shows deterioration of ignitor points the complete spark ignitor should
be replaced part No. 18075.

8. If pilot tries for ignition, but locks out, the air proving switches (high and low) that are mounted across the profile

plate, should be checked to make sure that the proper amount of air is flowing through the unit. Check to make sure
blowers are running in the proper direction. This can be checked by placing a differential gauge across the profile
plate of the burner section. If the pressure drop is between .30” W.C., and .95” W.C., these switches should be made,
then check pilot to ensure proper flame. Check instruction sheet for flame safeguard system.

Pilot adjustment screw is in the Thermax shut-off valve. When setting, adjust for the best reading, then open pilot set
screw slightly.

a) Main flame supervision: With units that have more than three feet of burner from point or supervision, a second

flame rod will be on the main burner. This switching is done with a time delay relay. See wiring diagram. This can
be disconnected for testing for pilot, or you have to ensure main flame by opening up the firing valve within 15
seconds after pilot solenoid is powered. As supervision will switch from pilot to main flame in that time. Check to
ensure that unit will lockout in the event of main flame failure on low-fire by closing main firing valve.

9. Gradually open firing valve to start main flame. Check for flame over entire burner length. Adjust the pressure

regulator to 4” or 4 ½ ” W.C. pressure or the amount of gas marked on the rating plate.

10. All OSD units may have Maxitrol modulation. Read over the Maxitrol literature for the high fire and low fire setting.

By removing the wire from #2 on the amplifier the unit will stay on low fire and allow you to set the by pass or low
fire setting to ensure that the flame is completely across burner and is between 1” and 1½ ” long (see literature
supplied with unit).

11. To set up high fire you will require spray test resistor 1.10K, dry (cure) test resistor 1.21K. These are attached to the

Maxitrol literature. These resistors should be placed across #3 and #4 of the amplifier on the unit (remove when test
is complete).

a) Check gas pressure switch setting.

High pressure gas switch …………………………………..…… 6” W.C.
Low pressure gas switch ………………………………….……. 2” W.C.

NOTE: The high and low gas pressure switches may be the manual reset type on some units.

FLAME SUPERVISION CHECK

a) The flame supervision should be checked periodically to insure that the controls are operational. With the unit

on full operation and firing, close the main manual firing valve and pilot manual firing valve. This should lock
out the unit.

b) The units with more than 3 feet of burner from the point of supervision have dual flame rod and a delay timer for

main flame supervision. Closing the main firing valve should lock out the safety relay and the unit should
shutdown.

c) The main safety valve should be checked for gas tightness by placing a manometer in the manifold between the

safety valve and the manual firing valve (a 1/8” plug is provided for this). If there is a build up of pressure with
the unit locked out and the manual valve closed, the safety valve should be replaced.

d) The complete gas line and manifold should be checked for gas tightness.

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C.F.M.

a) This unit depends upon an adequate supply of air for good combustion and operation. Care should be taken to

ensure that properly sized inlet hood and ductwork are installed and that the unit is discharging the right
amount of CFM.

TROUBLE SHOOTING GUIDE

On start up, the unit will not operate properly. It may be an electrical mix up in the wire from the unit to the control
panel (see wiring drawing).

The wire connector shown 12 are in the remote panel.
The wire connector shown E12 are on the unit.
It is recommended you have a volt meter AC/DC, and a differential pressure gauge 0” - 2”
(magnehelic) and a gas pressure gauge 0” - 12”.

SPRAY MODE

1. If inlet damper fails to open when system switch is pushed in.

a) Check to see if power is on #4. If no power supply starter overloads (1 OLS-1), may be open R1-1

normally closed contacts may be open. Main flame safe guard relay needs to be reset.

2. Fresh air damper open, but no power on #9.

a) Damper end switch open (DMES-1) reset.

3. High exhaust fan operating, no power on #13.

a) Check high exhaust fan inter lock switch.

4. If supply fan is not operating, check delay start timer (TD1) normally set at 3 seconds to allow for exhaust fan

to come up to speed to keep the booth from over pressure and blow the doors open.

a) Balance exhaust and supply fan.

5. No power on #40.

a) Check summer/winter switch.

b) Spray high limit (HL-S).

c) Check air flow across burner with a magnehelic gauge to ensure proper air flow. Should be a difference

between .45” and .65” W.C.

6. Power on #40, but burner will not come on.

a) Change flame safe guard relay.

7. Power on #40 burner tries to fire up but locks out.

a) Check pilot solenoid valve.

b) Check ignition transformer.

c) Check flame rod, if dirty clean, if cracked isolator replace.

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8.

Burner on low fire only.

a) Check TD2 timer low fire timer should be set at 20 seconds.

b) Check DC volts on #55 and #57, if above 5 V.D.C. modulation valve may be defective, replace.

9. See Maxitrol literature to trouble shoot the system.

NOTE: On custom built units the number designation may change.

Carefully check wire diagram supplied with unit.

BAKE MODE

1. Purge light “off”, dry cycle light not “on”.

a) Check and replace.

2. Burner not on, no power on #40.

a) Check dry high limit (HL-B).
b) Check low exhaust inter lock.
c) Check high and low profile air switches.
d) Check profile damper should be closed below burner.

3. Power on #40 burner not on. See instruction spray mode 5, 6, 7, and 8.

4. Burner on, but will not operate up to selector set point.

a) Check to see if temperature delay timer TD4 is powered and switch over from #12 to #11, on the

Maxitrol, amplifier is completed.

b) Check discharge sensor.
c) Refer to Maxitrol trouble shooting guide provided with this manual.

OPERATING PRINCIPLES OF THE RAW GAS BURNER

The raw gas burner is designed to operate in a duct of flowing fresh air. Fuel gas is fed directly to the burners; kinetic
energy of the air stream furnishes combustion air. The burner must be installed to fire with, and parallel to, the air
flow. By virtue of velocity impact and suction generated by the diverging shape of the combustion baffles, air is
induced into the air ports in the combustion zone. The air supply is constant though only that which mixes with the gas
flowing from the burner ports, takes part in combustion.

When a very small quantity of gas is admitted to the burner, sufficient mixing takes place in the low fire slot within the
burner, casting and combustion takes place in this zone. Since the low fire zone is contained within the burner casting
it is effectively shielded from fire disrupting uncontrolled air entry.

As the gas is increased the flame progresses into the intermediate fire zone where an additional supply of air is
available. High or full capacity, mixing occurs at the larger air ports of the high fire zone augmented by air spilling
over the end of the baffles.

On a reduction of gas supply the reverse sequence takes place. The flame receding to a location of lesser air supply
until the low fire zone is reached. The system above is suitable for a turn down range of approximately 30 to 1.

With the suction by the blower there is a pressure in the gas manifold of less that zero at low fire. Therefore, when
checking the manifold pressure you will find that the pressure will range from approximately 4” W.C. to less than
zero, when the unit is modulating from high to low fire.

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