Continental Girbau CG75-85 Installation Manual

Gas dsi/electric/steam

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Installation manual (120 pages)

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Page 1 For replacement parts, contact the distributor from which the dryer was purchased or ® Continental Girbau, Inc. 2500 State Road 44 Oshkosh WI 54904 Telephone: (920) 231-8222 / Fax: (920) 231-4666 www.cont-girbau.com 121600JEV/rar CGI Part No.
Page 2 ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Replacement parts can be obtained from your distributor or Continental Girbau, Inc. ® Please specify the dryer model number and serial number in addition to the description and part number, so that your order is processed accurately and promptly.
Page 3: For Your Safety
IMPORTANT YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) STANDARDS.
Page 4 WARNING The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJURY OR FIRE COULD RESULT. WARNING DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER/SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. IMPORTANT PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and/or specified in the installation manual included with the dryer.
Page 5: Table Of Contents
Table of Contents SECTION I IMPORTANT INFORMATION ................3 A. Receiving and Handling ....................... 3 B. Safety Precautions ........................4 SECTION II SPECIFICATIONS/COMPONENT IDENTIFICATION ........6 A. Specifications ..........................6 B. Component Identification ......................8 SECTION III INSTALLATION PROCEDURES ................. 10 A.
Page 6 SECTION VI ROUTINE MAINTENANCE .................. 41 A. Cleaning ........................... 41 B. Adjustments ..........................42 C. Lubrication ..........................42 D. Lint Drawer Removal ........................ 43 SECTION VII TROUBLESHOOTING ................... 44 Microprocessor Controller (Computer) Models ................44 Dual Timer Models ......................... 50 SECTION VIII DATA LABEL INFORMATION ................
Page 7: Section I
5. Freight claims are the responsibility of the consignee, and ALL claims must be filed at the receiving end. The manufacturer assumes no responsibility for freight claims or damages. ® 6. If you need assistance in handling the situation, please contact the Continental Girbau, Inc. Traffic Manager at (920) 231-8222 Ext. 16.
Page 8: Safety Precautions
B. SAFETY PRECAUTIONS WARNING: For your safety, the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury, or loss of life. WARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels removed.
Page 9 7. A program should be established for the inspection and cleaning of lint in the burner area, exhaust ductwork, and area around the back of the dryer. The frequency of inspection and cleaning can best be determined from experience at each location. WARNING: The collection of lint in the burner area and exhaust ductwork can create a potential fire hazard.
Page 10: Specifications/Component Identification
MS 041603 CG75-85 50 Hz single-phase (1ø) non-reversing dryers use a 1 HP (0.745 kw) motor. ALL CG75-85 reversing dryers are supplied with two (2) 3-phase (3ø) motors standard: a 1 HP (0.745 kw) blower motor and a 1/2 HP (0.37 kw) drive motor.
Page 11: Specifications
Specifications CG75-85 (Gas/Electric/Steam) NOTE: The manufacturer reserves the right to make changes in specifications at any time without notice or obligation.
Page 12: Component Identification
B. COMPONENT IDENTIFICATION 1. Dryer Front View Illus. No. Description Controls Control (top access) Door Assembly Main Door Assembly Lint Compartment Area (lint drawer) Data Label and Installation Label (affixed on the left side panel area behind the top control [access] door)
Page 13 2. Dryer Rear View Illus. No. Description Heating Unit Electric Service Relay Box Basket (tumbler) Bearing Mount Assembly Idler Bearing Mount Assembly Blower Motor Assembly (for reversing models only) Leveling Legs (rear) Basket (tumbler) (drive) Motor Assembly Dryer Exhaust...
Page 14: Installation Procedures
SECTION III INSTALLATION PROCEDURES Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installation must conform to applicable American National Standards: ANSI Z223.1- LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electrical Code) or in Canada, the installation must conform to applicable Canadian Standards: CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION (for General Installation and Gas Plumbing) or Canadian Electrical Codes Parts 1 &...
Page 15: Unpacking/Setting Up
10. The dryer must be installed with provisions for adequate combustion and make-up air supply. CAUTION: This dryer produces combustible lint and must be exhausted to the outdoors. Every 6 months, inspect the exhaust ducting and remove any lint build up. IMPORTANT: Dryer must be installed in a location/environment, which the ambient temperature remains between 40º...
Page 16: Dryer Enclosure Requirements
C. DRYER ENCLOSURE REQUIREMENTS Bulkheads and partitions should be made of noncombustible materials and must be located a minimum of 12-inches (30.48 cm), 18-inches (45.72 cm) or more is recommended for ease of installation, maintenance, and service above the dryer’s outer top, except along the front of the dryer which may be partially closed in if desired.
Page 17: Fresh Air Supply Requirements
D. FRESH AIR SUPPLY REQUIREMENTS When the dryer is operating, it draws in room air, heats it, passes this air through the basket (tumbler), and exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If the make-up air is inadequate, drying time and drying efficiency will be adversely affected.
Page 18: Exhaust Requirements
E. EXHAUST REQUIREMENTS 1. General Exhaust Ductwork Information Exhaust ductwork should be designed and installed by a qualified professional. Improperly sized ductwork will create excessive back pressure which results in slow drying, increased use of energy, overheating of the dryer, and shutdown of the burner by the airflow (sail) switches, burner hi-limits, or basket (tumbler) hi-limit thermostats.
Page 19 IMPORTANT: Exhaust back pressure measured by a manometer in the exhaust duct must be no less than 0 and must not exceed 0.3 inches (0.74 mb) of water column (W.C.). IMPORTANT: It is recommended that exhaust or booster fans not be used in the exhaust ductwork system.
Page 20 IMPORTANT: For extended ductwork runs, the cross section area of the ductwork can only be increased to an extent. When the ductwork approaches the maximum limits noted in this manual, a professional heating, venting, and air conditioning (HVAC) firm should be consulted for proper venting information.
Page 21 3. Multiple (Common) Dryer Venting IMPORTANT: For extended ductwork runs, the cross section area of the ductwork can only be increased to an extent. When the ductwork approaches the maximum limits noted in this manual, a professional heating, venting, and air conditioning (HVAC) firm should be consulted for proper venting information.
Page 22 IMPORTANT VENTING REMINDERS 1. Ductwork size and installation should be done by a qualified professional. 2. The dryer must be exhausted to the outdoors. 3. Ductwork should be routed as short as possible to the outdoors with as few elbows as possible. 4.
Page 23: Electrical Information
F. ELECTRICAL INFORMATION 1. Electrical Requirements It is your responsibility to have ALL electrical connections made by a properly licensed and competent electrician to assure that the electrical installation is adequate and conforms to local and state regulations or codes. In the absence of such codes, ALL electrical connections, materials, and workmanship must conform to the applicable requirements of the National Electrical Code ANSI/NFPA NO.
Page 24 2) Electric Models Only ALL electrically heated dryers must be connected to the electric service shown on the dryer’s data label, which is affixed to the left side panel area behind the top control (access) door. The connecting wires must be properly sized to handle the rated current. NOTE: Electrically heated service (amperage) specifications/requirements are not available at the time of printing.
Page 25 INGLE HASE Ø LECTRICAL ONNECTIONS EADS Black White Green White Neutral Ground If local codes permit, power to the dryer can be made by the use of a flexible U.L. listed power cord or pigtail (wire size must conform to rating of dryer), or the dryer can be hard wired directly to the service breaker panel.
Page 26 5. 3-Phase (3ø) Wiring Connections/Hookup (For Non-Reversing Models Only) The only electrical input connections to the dryer are the 3-phase (3ø) power leads (L1, L2, L3, and sometimes Neutral) and ground. Single-phase (1ø) power for the control circuit is done internally to the dryer.
Page 27 6. 3-Phase (3ø) Wiring Connections/Hookup (for Reversing Models Only) The electrical connections on ALL 3-phase (3ø) gas dryers and steam dryers are made into the rear service box located at the upper left area of the dryer. Electrical connections for electrically heated dryers are made in the electric oven area located at the upper rear area of the dryer.
Page 28 CAUTION: The dryer must be grounded. A ground lug has been provided for this purpose. IMPORTANT: A CIRCUIT SERVICING EACH DRYER MUST BE PROVIDED. The only electrical connections to the dryer are the 3-phase (3ø) leads (L1, L2, L3, and sometimes Neutral) and ground.
Page 29 CG75-85 (Gas/Steam) ELECTRICAL SERVICE SPECIFICATIONS (PER DRYER) IMPORTANT: 208 VAC AND 240 VAC ARE NOT THE SAME. When ordering, specify exact voltage. NOTES: When fuses are used they must be dual element, time delay, current limiting, class RK1 or RK5 ONLY. Calculate/determine correct fuse value, by applying either local and/or National Electrical Codes to listed appliance amp draw data.
Page 30: Gas Information
(610 meters) is made by changing each burner orifice. If this conversion is necessary, contact the distributor ® who sold the dryer or contact Continental Girbau, Inc. IMPORTANT: THIS GAS DRYER IS NOT PROVIDED WITH AN INTERNAL GAS SUPPLY SHUTOFF AND AN EXTERNAL GAS SUPPLY SHUTOFF MUST BE...
Page 31 NUMBER Rating Qty. D.M.S.* Qty. D.M.S.* Part Number Rating Number Number CG75-85 175,000 44,100 140819 140803 882935 Shaded area is stated in metric equivalent * Drill Measurement Size (D.M.S.) equivalents are as follows: Natural Gas ..... #30 = 0.1285” (3.2639 mm).
Page 32 3. Piping/Connections ALL components/materials must conform to National Fuel Gas Code Specifications ANSI Z223.1-LATEST EDITION, or in Canada, CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION (for General Installation and Gas Plumbing), as well as local codes and ordinances and must be done by a qualified professional.
Page 33 Consistent gas pressure is essential at ALL gas connections. It is recommended that a 3/4-inch (19.05 mm) pipe gas loop be installed in the supply line servicing a bank of dryers. An in-line pressure regulator must be installed in the gas supply line (header) if the (natural) gas pressure exceeds 12.0 inches (29.9 mb) of water column (W.C.) pressure.
Page 34: Steam Information
H. STEAM INFORMATION It is your responsibility to have ALL plumbing connections made by a qualified professional to assure that the steam plumbing installation is adequate and conforms with local and state regulations or codes. Care must be exercised when leveling steam dryers into final position. After leveling the dryer, check the downward pitch of the heat exchanger from front to rear with a level.
Page 35 IMPORTANT: Steam coil failure due to water hammer by wet steam will VOID THE WARRANTY. a. The pressure of the condensate in the steam supply line will cause water hammer and subsequent heat exchanger (steam coil) failure. The steam supply connection into the main supply line must be made with a minimum 10-inch (25.4 cm) riser.
Page 36 4. Steam Damper Air System Connections Steam models are manufactured with a pneumatic (piston) damper system, which requires an external supply of compressed air. The air connection is made to the steam damper solenoid valve, which is located at the rear inner top area of the dryer just in front of the electric service relay box. a.
Page 37 c. Air Regulation No air regulator or filtration is provided with the dryer. External regulation/filtration of 80 PSI (5.51 bar) must be provided. It is suggested that a regulator/filter gauge arrangement be added to the compressed air line just before the dryer connection. This is necessary to insure that correct and clean air pressure is achieved.
Page 38 6. Steam Damper Air Piston (Flow Control) Operation Adjustment Damper operation was tested and adjusted prior to shipping at 80 PSI (5.51 bar). If damper air adjustment is necessary, locate the flow control valve and make the necessary adjustments as noted below.
Page 39: Preparation For Operation/Start-Up
I. PREPARATION FOR OPERATION/START-UP The following items should be checked before attempting to operate the dryer: 1. Read ALL “CAUTION,” “WARNING,” and “DIRECTION” labels attached to the dryer. 2. Check incoming supply voltage to be sure that it is the same as indicated on the dryer data label affixed to the left side panel area behind the top control (access) door.
Page 40: Preoperational Tests
J. PREOPERATIONAL TESTS ALL dryers are thoroughly tested and inspected before leaving the factory. However, a preoperational test should be performed before the dryer is publicly used. It is possible that adjustments have changed in transit or due to marginal location (installation) conditions. 1.
Page 41 NOTE: To check for proper sail switch operation (for gas and electric models only), open the main door and while holding main door switch plunger in, start dryer. Dryer should start but heat circuit should not be activated (on). If the heat system is activated, the sail switch is improperly adjusted and must be adjusted by bending the actuator arm of the sail switch toward the burner box.
Page 42: Preoperational Instructions
K. PREOPERATIONAL INSTRUCTIONS OPL MODELS 1. To start the dryer: a. Microprocessor controller (computer) dryers 1) The light emitting diode (L.E.D.) display will read “FILL.” 2) Press the “E” on the keyboard (touch pad). 3) The L.E.D. display will quickly show “Ld30,” “LC04,” or “F180.” The dryer will start, and the L.E.D.
Page 43: Service/Parts Information
B. PARTS 1. Replacement parts should be purchased from the distributor from whom the equipment was purchased. If ® the distributor cannot be contacted or is unknown, contact the Continental Girbau, Inc. for a distributor near you please call (920) 231-8222.
Page 44: Warranty Information
9. ALL returns must be properly packaged to insure that they are not damaged in transit. Damage claims are the responsibility of the shipper. ® 10. ALL returns should be shipped to Continental Girbau, Inc. in such a manner that they are insured and a proof of delivery can be obtained by the sender.
Page 45: Routine Maintenance
SECTION VI ROUTINE MAINTENANCE A. CLEANING A program and/or schedule should be established for periodic inspection, cleaning, and removal of lint from various areas of the dryer, as well as throughout the ductwork system. The frequency of cleaning can best be determined from experience at each location.
Page 46: Adjustments
WARNING: When cleaning steam coil fins, be careful not to bend the fins. If fins are bent, straighten by using a fin comb, which is available from local air conditioning supply houses. 90 DAYS Inspect and remove lint accumulation in customer furnished exhaust ductwork system and from dryer’s internal exhaust ducting.
Page 47: Lint Drawer Removal
D. LINT DRAWER REMOVAL To remove the lint drawer from the dryer pull drawer out approximately halfway. Rotate/move lint drawer stop hinge (refer to the illustration below) downward and pull drawer out. IMPORTANT: After replacing the lint drawer back into the dryer, be sure to rotate/move hinge back to the upward stop position.
Page 48: Troubleshooting
SECTION VII TROUBLESHOOTING IMPORTANT: YOU MUST DISCONTINUE AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) STANDARDS.
Page 49 3. Failed drive motor. 4. Failed microprocessor controller (computer). C. Drive motor (reversing) operates in one (1) direction only, stops and restarts in same direction... 1. Failed drive motor contactor (relay). 2. Failed arc suppressor (A.S.) board (for reversing models only). 3.
Page 50 G. Both drive motor and blower motor are not operating (DO NOT start), microprocessor controller (computer) motor indicator dots are on... 1. Fault in main door switch circuit. 2. Blown fuse (2-Amp very fast acting fuse [if applicable]). 3. Failed arc suppressor (A.S.) board (for reversing models only). 4.
Page 51 1. Failed keyboard (touch pad) label assembly. 2. Failed microprocessor controller (computer). L. Microprocessor controller (computer) will only accept certain keyboard (touch pad) entries... 1. Failed keyboard (touch pad) label assembly. 2. Failed microprocessor controller (computer). M. Microprocessor controller (computer) locks up and light emitting diode (L.E.D.) display reads erroneous message(s) or only partial segments...
Page 52 GAS MODELS ONLY 1. Fault in sail switch circuit... a. Sail switch is out of adjustment or has failed. b. Sail switch damper is not closing or is fluttering... 1) Lint screen is dirty. 2) Restriction in exhaust ductwork. 2. Fault in burner hi-limit circuit or tripped manual reset hi-limit. 3.
Page 53 4. Failed steam damper 24 VAC pneumatic solenoid switch. 5. Failed piston. 6. Steam damper stuck closed. Q. Dryer operates but is taking too long to dry... 1. Exhaust ductwork run too long or is undersized, back pressure must be no less than 0 and cannot exceed 0.3 inches (0.74 mb) water column (W.C.).
Page 54: Dual Timer Models
2. Basket (tumbler) is out of proper alignment... a. Check both vertical and lateral alignment. b. Check gap between front panel and basket (tumbler) front, setscrews may have come loose and basket (tumbler) walked forward or backwards. 3. Loose basket (tumbler) tie rod. 4.
Page 55 2. Open at location, service main fuse or circuit breaker. 3. Failed push to start relay. 4. Failed door switch and/or circuit. 5. Failed heat timer. 6. Failed dual timer relay. B. Drive motor (only) is not operating... 1. Failed drive motor contactor. 2.
Page 56 1) Check blower (impellor/fan) motor and rotation direction. 2) Restriction in location exhaust system. 2. Tripped burner hi-limit circuit. 3. Tripped lint compartment manual reset (225º F [107º C]) safety thermostat circuit. 4. Failed heat selector switch. ELECTRIC MODELS ONLY 1.
Page 57 2. Steam damper binding in partially open position (for steam models only). 3. Lint and/or dust accumulation on steam coil fins (for steam models only). 4. Housekeeping... a. Lint screen and lint compartment are not being cleaned on a regular basis. b.
Page 58: Data Label Information
Continental Girbau, Inc. This information is on the data label located on the left side panel ® area behind the top control (access) door. When contacting Continental Girbau, Inc. please have the model number and serial number available.
Page 59 The model number is a manufacturer’s number, which describes the size of the dryer and the type of heat (gas, electric, or steam). 2. SERIAL NUMBER ® The serial number allows Continental Girbau, Inc. to gather information on your particular dryer. 3. MANUFACTURING CODE NUMBER The manufacturing code number is a number issued by the manufacturer, which describes ALL possible options on your particular model.
Page 60: Reversing Timer Spin/Dwell Adjustments
SECTION IX REVERSING TIMER SPIN/DWELL ADJUSTMENTS Dual timer models with “reversing option” have an electric reversing timer in the electric service box, which is located in the upper rear area of the dryer. Both the dwell (stop) time and basket (tumbler) spin time are adjustable by mode selection switches located on the electronic timer (as noted in the illustration below).
Page 61: Procedure For Functional Check Of Replacement Components
SECTION X PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor Controller (Computer) Board a. Upon completing installation of the replacement microprocessor controller (computer) board, reestablish power to the dryer. b. Start the drying cycle. c. Verify that the motor(s) and the heat indicator dots, in the microprocessor controller (computer) board’s light emitting diode (L.E.D.) display are on.
Page 62 e. Open main door. The dryer must stop and ALL indicator lights on the back side of the microprocessor controller (computer) board must go out. (Refer to the illustration on the previous page.) f. Try to restart the dryer with the main door open. g.
Page 63: Burner And Basket (Tumbler)/Lint Chamber Manual Reset Hi-Limit Instructions
SECTION XI BURNER AND BASKET (TUMBLER)/LINT CHAMBER MANUAL RESET HI-LIMIT INSTRUCTIONS I M P O R T A N T MANUAL RESET HI-LIMIT INSTRUCTIONS FOR DUAL TIMER OR PHASE 5 WITHOUT HEAT FAULT (GAS MODELS ONLY) This dryer was manufactured with a burner manual reset hi-limit and basket (tumbler)/lint chamber hi-limit thermostat.
Page 64: Electric Or Steam Models Only
I M P O R T A N T MANUAL RESET HI-LIMIT INSTRUCTIONS FOR DUAL TIMER OR PHASE 5 WITHOUT HEAT FAULT (ELECTRIC or STEAM MODELS ONLY) This dryer was manufactured with a manual reset basket (tumbler)/lint chamber hi-limit thermostat. If the manual reset thermostat is open prior to the start of the drying cycle, or during the cycle, the dryer will not recognize the open state of the hi-limit thermostat and will start or continue through the drying cycle with no heat.
Page 65 CGI A113302 1 - 12/22/00-2 2 * 01/03/01-50 3 * 01/05/01-26 4 - 01/23/01-100 5 * 04/20/01-100 6 - 09/19/01-100 7 - 02/14/02-100 8 - 06/20/01-100 9 - 10/09/02-100 10 * 04/16/03-25...

Continental Girbau CG75-85 Installation Manual

Section I

Important Information

Section II

Specifications/Component Identification

Section III

Installation Procedures

Section IV

Service/Parts Information

Section V

Warranty Information

Section VI

Routine Maintenance

Section VII

Troubleshooting

Section VIII

Data Label Information

Section IX

Reversing Timer Spin/Dwell Adjustments

Section X

Procedure for Functional Check of Replacement Components

Section XI

Burner and Basket (Tumbler)/Lint Chamber Manual Reset Hi-Limit Instructions

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