Urschel COMITROL 2100 Instruction Manual
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Urschel COMITROL 2100 Instruction Manual

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Instruction
Manual
SAFETY
GENERAL
INFORMATION
INSTALLATION
OPERATION
MAINTENANCE
PARTS
COMITROL ® PROCESSOR
MODEL 2100
LABORATORIES INCORPORATED

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Summary of Contents for Urschel COMITROL 2100

  • Page 1 COMITROL ® PROCESSOR Instruction MODEL 2100 Manual SAFETY GENERAL INFORMATION INSTALLATION OPERATION MAINTENANCE PARTS LABORATORIES INCORPORATED...
  • Page 3 COPYRIGHT© 2018 Urschel Laboratories, Inc., Chesterton, Indiana. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of Urschel Laboratories, Inc.
  • Page 4 Addendum Manual Page Number Revision 10-11 Safety, Protective Devices: Add the following. The emergency stop button (1) provides rapid access to shut down the machine in an emergency. The starting circuit will remain interrupted (open) until the button is reset; rotate and pull out to reset.
  • Page 5 Addendum Manual Page Number Revision General Information, Specifications: the variable speed motor for the feed screw shown in the manual is no longer available. A variable frequency drive (VFD) is used to control the speed of the feed screw motor (1). Feed screw speed is controlled by a potentiometer (2) located on the front of the electrical enclosure.
  • Page 6 Addendum Manual Page Number Revision 28-29 Operation, Start-up, Stopping and Feeding: The following applies to the current electrical system. If your machine is equipped with a previous version of the electrical system see the following pages or the machine manual. Start-up Procedure 1.
  • Page 7 Addendum Manual Page Number Revision 28-29 Operation, Start-up, Stopping and Feeding (continued): The following applies to the current electrical system. If your machine is equipped with a previous version of the electrical system see the following pages or the machine manual.
  • Page 8 Addendum Manual Page Number Revision 28-29 Operation, Start-up, Stopping and Feeding: The following applies to the electrical system supplied from approximately October 2009 until September 2018. See the previous pages for the starting and stopping procedures for the current electrical system. The top reset button is labeled MASTER RESET (1).
  • Page 9 Addendum Manual Page Number Revision Operation, Feeding: The following replaces the information in the machine manual. Feeding Method DANGER Never place hands into the feed opening! The feed area contains a rotating feed screw and a rotating agitator which can cause serious injury such as amputation! IMPORTANT Do not allow foreign material such as metal,...
  • Page 10 Addendum Manual Page Number Revision Operation, Machine Overload or Jam: The following applies to the current electrical system. If your machine is equipped with a previous version of the electrical system see the next page or the machine manual. Motor Overload If the machine shuts off during operation, one of the motors has likely been overloaded.
  • Page 11 Maintenance Cleaning: Add the following. Cleaning a New Machine and Parts Before Use Parts and equipment supplied by Urschel have not been sanitized. Urschel recommends that the supplied parts and equipment be properly cleaned and sanitized prior to use and in accordance with the requirements of this application.
  • Page 12 A.10 Addendum Manual Page Number Revision 46-47 Maintenance, Electrical Assembly: The current electrical enclosure is shown to the right. Note the variable frequency drive (1) for the feed screw motor, power line filter (2), and main circuit breaker with disconnect switch (3). The machine is supplied with a soft start controller (4).
  • Page 13 Addendum A.11 Manual Page Number Revision 46-47 Maintenance, Electrical Assembly (continued): The following applies to pages 46-47 in their entirety. For information on the function of specific electrical components, see the following pages. The electrical assembly was supplied with an amplifier (1) beginning in 1994 until 2018. The function of the amplifier is described in the Model 2100 manual L1954. The electrical assembly was redesigned and new machines were supplied with a safety monitor (2) beginning in 2018.
  • Page 14 A.12 Addendum Manual Page Number Revision 46-47 Maintenance, Electrical Assembly (continued): Add the following. Mini Circuit Breakers (MCBs) and Fuses The electrical enclosure is supplied with either mini circuit breakers (1) or fuses. The chart to the right shows which devices are supplied for a given voltage and power supply type.
  • Page 15 Only one of the K1 or K2 LEDs are lit: If both CH1 and CH2 are lit, but either the K1 or K2 LED is not lit, the safety relay has experienced a fault. Contact your Urschel service representative for further assistance.
  • Page 16 Maintenance, Electrical Assembly (continued): Add the following. Replacing the Circuit Breaker 1. Remove the rotary disconnect mechanism (1). To determine the Urschel part number of the circuit breaker, note the amperage rating (2) on the front and see the Current Transformer Windings Chart included in this addendum.
  • Page 17 Addendum A.15 Manual Page Number Revision 46-47 Maintenance, Electrical Assembly (continued): Add the following. Current Transformer and Motor Load Indicator The current transformer (1) measures the current being drawn by the motor. The transformer is connected to the motor load indicator (2) and must be properly configured for the electrical specifications of your machine.
  • Page 18 A.16 Addendum Manual Page Number Revision 46-47 Maintenance, Electrical Assembly (continued): Add the following. Testing the Motor Load Indicator Perform the following test if you suspect that the indicator is not functioning correctly or if the motor has been replaced. 1.
  • Page 19 Addendum A.17 Manual Page Number Revision 46-47 Maintenance, Electrical Assembly (continued): Add the following. Replacing the Motor Load Indicator 1. Disconnect the secondary wires from the back of the motor load indicator. 2. Remove the indicator. Remove the fasteners that secure the indicator to the bracket (1).
  • Page 20 A.18 Addendum Manual Page Number Revision 58-59 Parts, Frame Assembly: the current frame and related parts are shown below. 61453 Frame Assembly, 364 Frame Motor...
  • Page 21 Addendum A.19 Manual Page Number Revision 58-59 Parts, Frame Assembly, continued ITEM NO. PART NO. DESCRIPTION QTY. — 61452 Frame Assembly, 326 frame motor, (for 40 hp motor, includes items 1–5) . . — 61453 Frame Assembly, 364 frame motor, (for 60 hp motor, includes items 1, 4–6) 1 61454 Frame &...
  • Page 22 A.20 Addendum Manual Page Number Revision 60-61 Parts, Agitator & Feed Screw: the current agitator & feed screw and related parts are shown below.
  • Page 23 Addendum A.21 Manual Page Number Revision 60-61 Parts, Agitator & Feed Screw, continued ITEM NO. PART NO. DESCRIPTION QTY. 61521 Feed Adapter ......... . 61598 “O”...
  • Page 24 A.22 Addendum Manual Page Number Revision 68-69 Parts, Motor and Drive Parts: the current motors are listed on the following page. Note that item 3 variable speed motors shown in the manual are no longer available. This motor drives the feed screw, which is now controlled by a variable frequency drive.
  • Page 25 Addendum A.23 Manual Page Number Revision 68-69 Parts, Motor and Drive Parts, continued ITEM NO. PART NO. DESCRIPTION QTY. 61415 Motor, 40 hp, 220/380-240/415 volts, with brake ....Motor, 40 hp, 380-415 volts, Y-D, with brake .
  • Page 26 A.24 Addendum Manual Page Number Revision 68-69 Parts, Motor and Drive Parts: Motor Brake, Horizontal, Stearns 87000, REV B: See the picture below and the parts list on the following page for the current brake assemblies and related parts.
  • Page 27 2018 – 63926 - Brake Assembly, 50 lb/ft, 87000, REV B, horizontal * Contact your Urschel representative. NOTICE Check the information plate attached to the brake for the brake version. Earlier motors used the 87000 series brake. Parts are not interchangeable between the 87000 and the 87000 Rev B brakes. Verify brake series number before...
  • Page 28 A.26 Addendum This page intentionally left blank.
  • Page 29 Addendum A.27 Manual Page Number Revision 70–83 Parts, Electrical Assembly: Pages A.28-A.41 in this addendum contain the current electrical assemblies, wiring diagrams, VFD, Soft Start, and Current Transformer Winding Charts, and the switch assembly supplied on the machine. Pages A.42-A.76 in this addendum contain repair parts for previous electrical assemblies, wiring diagrams, switch assembly, and information on previous motor circuit protective devices and current transformer windings.
  • Page 30 A.28 Addendum Manual Page Number Revision 70–83 Parts, Electrical Assembly: The electrical assembly currently in use is shown below and on the following page. The electrical assembly is supplied with either mini circuit breakers or fuses.
  • Page 31 Addendum A.29 Item Quantity Part Number and Description – 64274 - Electrical Assembly, M2100 (includes items 1–19) – 64275 - Electrical Assembly, machine, M2100 11593 - Breather/Drain, 1/4" 13408 - Padlock With Chain 21499 - Split Ring, s.s. 21778 - Padlock Retainer - Overload Relay (OL1, use with Overload Base Adapter) - Control Circuit Transformer, 100 VA (T1) 10625 - Round Head Machine Screw, with washer, 10-32 x 1/2"...
  • Page 32 A.30 Addendum Manual Page Number Revision 70–83 Parts, Electrical Enclosure Assembly: The electrical enclosure assembly currently in use is shown below and on the following page. The electrical assembly is supplied with either mini circuit breakers or fuses.
  • Page 33 21861 - Terminal End Section, 2 circuit, 4 connection point (for 21673) 64271 - Electrical Enclosure Panel, M2100 64272 - Electrical Schematic, M2100 * Contact an Urschel representative. Optional Parts (An optional accessory which customers can use to track the operational hours of the machine.)
  • Page 34 A.32 Addendum Manual Page Number Revision 70–83 Parts, Electrical Enclosure Assembly (continued): The enclosure assembly door parts currently in use are shown below and on the following page.
  • Page 35 21749 - Potentiometer Body, 2500k Ohms 21862 - Legend Plate, potentiometer, 3" diameter 21924 - Pilot Light, yellow 21572 - Push Button Nut, metal 21432 - Latch, push button 21925 - Pilot Light, lamp, white, 24 VAC/VDC - Door Gasket (fitting and adhesive required) 21270 - Quarter Turn Latch Assembly (Industrial Enclosures) 21271 - Quarter Turn Latch Assembly (Hoffman Enclosures) * Contact your Urschel representative.
  • Page 36 A.34 Addendum Manual Page Number Revision 70–83 Parts, Electrical Schematic 64272: Use with the electrical assembly and electrical enclosure assembly shown on the previous pages.
  • Page 37 Addendum A.35 Manual Page Number Revision 70–83 Parts, Electrical Schematic 64272: Use with the electrical assembly and electrical enclosure assembly shown on the previous pages.
  • Page 38 A.36 Addendum Manual Page Number Revision 70–83 Parts, Electrical Schematic 64272: Use with the electrical assembly and electrical enclosure assembly shown on the previous pages.
  • Page 39 Addendum A.37 Manual Page Number Revision 70–83 Parts, Electrical Schematic 64272: Use with the electrical assembly and electrical enclosure assembly shown on the previous pages.
  • Page 40 A.38 Addendum Manual Page Number Revision 70–83 Parts, VFD Chart and Soft Start Chart 64273: Use with the electrical assembly shown on the previous pages.
  • Page 41 Addendum A.39 Manual Page Number Revision 70–83 Parts, Current Transformer Windings Chart: Use with the electrical assembly and electrical enclosure assembly shown on the previous pages. See Replacing the Circuit Breaker and Replacing the Current Transformer in this addendum for more information on replacing these components. Current Transformer Windings Chart Full Load MCCB1...
  • Page 42 A.40 Addendum Manual Page Number Revision 70–83 Parts, Electrical Assembly, Safety Sensors and Enclosure Fittings: safety sensors and enclosure fittings currently in use are shown below and on the following page. Agitator Impeller Motor Motor Feed Screw Motor Sensor 1 Sensor 2...
  • Page 43 Addendum A.41 Item Quantity Part Number and Description Electrical assemblies include the following parts: 63739 - Sensor, 12’ lead 63741 - Actuator 61914 - Bracket 10232 - Hex Head Cap Screw, 10-24 x 5/8", s.s. 12799 - Spacer, 1/16" (1.6 mm) 10351 - Hex Head Cap Screw, 10-24 x 7/8", s.s. 10231 - Hex Nut, 10-24, s.s., locking 10236 - Hex Head Cap Screw, 1/4-20 x 3/8", s.s.
  • Page 44 A.42 Addendum Electrical Assemblies, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical assembly, Y-D start, CE compliant.
  • Page 45 Addendum A.43 Electrical Assemblies, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical assembly, Y-D start, CE compliant. Item Quantity Part Number and Description – 64094* - Electrical Assembly, 40 hp, 380-415 volt, Y-D, CE (includes items 1–23) 64095* - Electrical Assembly, 60 hp, 380-415 volt, Y-D, CE (includes items 1–23) –...
  • Page 46 A.44 Addendum Electrical Enclosure, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical enclosure, Y-D start, CE compliant; use with 64094 and 64095 electrical assemblies.
  • Page 47 12763 - Fuse Terminal, 5 x 20mm, IEC (for FU4, includes item 26) 12781 - Transparent Cover 21438 - Terminal Block 21439 - End Anchor 21442 - Grounding Block, size 4 21443 - Grounding Block, size 10 * Not for sale; part number supplied for reference only. ** Contact an Urschel representative.
  • Page 48 A.46 Addendum Electrical Enclosure (Door Parts), previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical enclosure, Y-D start, CE compliant; use with 64094 and 64095 electrical assemblies.
  • Page 49 21436 - Reset Button Assembly (includes items 29–30) 21437 - Reset Button 21717 - Boot, push button, ABB - Door Gasket (fitting and adhesive required) 21270 - Quarter Turn Latch Assembly (Industrial Enclosures) 21271 - Quarter Turn Latch Assembly (Hoffman Enclosures) * Not for sale; part number supplied for reference only. ** Contact an Urschel representative.
  • Page 50 A.48 Addendum Electrical Schematic 64096 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical schematic for 64094 and 64095 electrical assemblies.
  • Page 51 A.49 Addendum Electrical Schematic Drive Constants Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous drive constants, use with 64096 schematic.
  • Page 52 A.50 Addendum Electrical Assembly, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical assemblies, across the line start.
  • Page 53 Addendum A.51 Electrical Assembly, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical assemblies, across the line start. Item Quantity Part Number and Description – - Electrical Assembly (includes items 1–28) § 13408 - Padlock With Chain 11593 - Breather/Drain, 1/4"...
  • Page 54 A.52 Addendum Electrical Enclosure, previous Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical enclosure, across the line start, use with 64099, 64100, 64098 and 64097 electrical assemblies.
  • Page 55 12763 - Fuse Terminal, 5 x 20mm, IEC (for FU4, includes item 17) 12781 - Transparent Cover 21438 - Terminal Block 21439 - End Anchor 21442 - Grounding Block, size 4 21443 - Grounding Block, size 10 * Not for sale; part number supplied for reference only. ** Contact an Urschel representative.
  • Page 56 A.54 Addendum Electrical Enclosure (Door Parts) Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical enclosure, across the line start, use with 64099, 64100, 64098 and 64097 electrical assemblies.
  • Page 57 21436 - Reset Button Assembly (includes items 29–30) 21437 - Reset Button 21717 - Boot, push button, ABB - Door Gasket (fitting and adhesive required) 21270 - Quarter Turn Latch Assembly (Industrial Enclosures) 21271 - Quarter Turn Latch Assembly (Hoffman Enclosures) * Not for sale; part number supplied for reference only. ** Contact an Urschel representative.
  • Page 58 A.56 Addendum Electrical Schematic 64101 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous electrical schematic for 64099, 64100, 64098 and 64097 electrical assemblies.
  • Page 59 Addendum A.57 Electrical Schematic Drive Constants and Overload Relay Charts Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: previous drive constants and overload relays, use with 64101 schematic. Chart 2, 30 hp Motor, 460V Chart 1, 30 hp Motor, 200-240V Overload CT Winding Overload...
  • Page 60 A.58 Addendum Safety Switches and Enclosure Fittings Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: safety switch and enclosure fittings for previous electrical assemblies. Agitator Impeller Motor Motor Feed Screw Motor Switch Number 1 Switch Number 2...
  • Page 61 Addendum A.59 Safety Switches and Enclosure Fittings Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: safety switch and enclosure fittings for previous electrical assemblies. Item Quantity Part Number and Description Electrical assemblies include the following parts: 63739 - Sensor, 12’ lead 63741 - Actuator 61914 - Bracket 10232 - Hex Head Cap Screw, 10-24 x 5/8", s.s.
  • Page 62 A.60 Addendum Repair Parts for Previous Electrical Assembly and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 63 Addendum A.61 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. ITEM NO. PART NO. DESCRIPTION QTY. — 61446* Electrical Assembly, 40 H.P., 220–240 volt, (includes items 1–21) ..Padlock, with chain .
  • Page 64 A.62 Addendum Repair Parts for Previous Electrical Assembly and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 65 Addendum A.63 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. (continued from the previous page) ITEM NO. PART NO. DESCRIPTION QTY. 21424 Push Button Assembly, start (includes item 49) ....Boot, push button .
  • Page 66 A.64 Addendum Repair Parts for Previous Electrical Assemblies and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 67 Addendum A.65 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. ITEM NO. PART NO. DESCRIPTION QTY. — 61448* Electrical Assembly, 30 H.P., 200–240 volt, (includes items 1–23) ..—...
  • Page 68 A.66 Addendum Repair Parts for Previous Electrical Assembly and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 69 Addendum A.67 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. (continued from the previous page) ITEM NO. PART NO. DESCRIPTION QTY. 21263 Start Button Assembly, (includes item 48) ..... Protective Cap, flush head, IEC .
  • Page 70 A.68 Addendum Repair Parts for Previous Electrical Assemblies and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 71 Addendum A.69 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. Manual Page Number Revision ITEM NO. PART NO. DESCRIPTION QTY. — 61476* Electrical Assembly, 40 H.P., 380–415 volt, Y-D, CE, (includes items 1–24) Electrical Assembly, 60 H.P., 380–415 volt, Y-D, CE, (includes items 1–24) —...
  • Page 72 A.70 Addendum Repair Parts for Previous Electrical Assemblies and Enclosure Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 73 Addendum A.71 Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. (continued from the previous page) ITEM NO. PART NO. DESCRIPTION QTY. 21263 Start Button Assembly, (includes item 51) ..... Protective Cap, flush head, IEC .
  • Page 74 A.72 Addendum Schematic for 61446, 61448, 61449 and 64445 Electrical Assemblies Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 75 Addendum A.73 Schematic for 61476 and 61477 Electrical Assemblies Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure.
  • Page 76 A.74 Addendum Motor and Circuit Protective Devices, Current Transformer Windings Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: repair parts for previous electrical assembly and enclosure. See Replacing the Current Transformer in this addendum for more information on replacing the current transformer. Feed Screw and Agitator Motor Current...
  • Page 77 Addendum A.75 Motor and Circuit Protective Devices Manual Page Number Revision 70–83 Parts, Electrical Assembly, continued: Impeller Motor Overload Relays repair parts for previous electrical for IEC contactors, Wye-Delta Start assembly and enclosure. The chart below shows the motor full load amps (first column) and the calculated value for Wye- Delta start (second column).
  • Page 78 A.76 Addendum Manual Page Number Revision 84–85 Parts, Safety Signs and Machine Labels: The chart below replaces the chart in the machine manual. The languages added are shown in bold: Part Number Language Item 1 Item 2 Item 3 Item 4 Item 5 Language* Code*...
  • Page 79 With subsidiaries and sales offices in principal cities worldwide. This instruction manual contains the most current information available at the time of publication. Urschel Laboratories reserves the right to make changes at any time without notice. This manual represents the machine as it is currently manufactured at the time of publication.
  • Page 80 4. Notify your supervisor of any machine condition which may create a hazard in its operation. 5. Notify Urschel Laboratories immediately of any accidents that have occurred on this machine. If there are any questions regarding the safe operation of this machine, contact Urschel Laboratories.

  • Page 81: Table Of Contents

    contents FOREWORD ......2 SAFETY and Safety Warning ....5 RULES FOR SAFE OPERATION .
  • Page 82 contents MAINTENANCE and Safety Warning ... 33 COVERS AND GUARDS ..... . . 34 Opening or Removing, Inspection, Installation .
  • Page 83 SAFETY WARNING: Any person who oper- ates, cleans, repairs, adjusts, installs or supervises the operation of or uses this machine in any way must know and follow all safety rules and operating principles set forth in this manual!
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  • Page 85: Safety

    See the Addendum for updated information SAFETY Rules for Safe Operation READ AND PRACTICE SAFETY RULES IN THIS MANUAL: DANGER! This machine contains sharp knives and rotating parts. Never operate this machine if any guard or safety device has been opened, removed, or modified;...

  • Page 86: Safety Signs

    SAFETY Safety Signs Safety signs and safety switches are placed on Urschel ® machines to help you avoid personal injury. They are there for your protection. If your machine does not have these signs or switches, you must not operate the machine. Notify your supervisor and contact Urschel Laboratories, Inc.
  • Page 87 SAFETY Safety Signs Danger labels (Figure 4) are visible DANGER when a protective cover or guard has MACHINE IS UNGUARDED. been opened or removed. This label REPLACE GUARD OR COVER. warns you that the machine is PELIGRO unguarded and must not be restarted LA MAQUINA ESTA SIN PROTECCION.

  • Page 88: Protective Devices

    See the Addendum for updated information SAFETY Protective Devices Safety switches (Figure 6) are pro- vided to prevent operation of the machine when certain protective covers or guards have been opened or removed. These switches must be checked before operating the machine and repaired or replaced if they do not work properly.
  • Page 89 Covers and guards, safety signs, safety switches, and brake motors are standard equipment on newly manufactured machines and are available for placement on older machines that may not have had them at the time of original manufacture. Contact Urschel Laboratories for complete information.

  • Page 90: Safety Switch System

    SAFETY Safety Switch System SAFETY SWITCH SYSTEM The safety switch system has an ampli- fier which utilizes prewired safety switches on certain covers and guards to prevent the machine from operating when these covers or guards are opened or removed. WARNING: A qualified trained person must check the safety switch...

  • Page 91: Amplifier

    See the Addendum for updated information SAFETY Safety Switch System AMPLIFIER The amplifier, viewed through the starter enclosure window, is an electronic device that processes the sensor signal (Figure 10). Based on the sensor signal, the amplifier will either allow or not allow the machine to start.

  • Page 92: Safety Switch System Test

    See the Addendum for updated information SAFETY Safety Switch System SAFETY SWITCH SYSTEM TEST 2. Remove the cutting enclosure. Turn power disconnect/lockout switch to “I” WARNING: A qualified trained (ON) and press the top reset button. person must check the safety switch Only the red “relay condition”...
  • Page 93 SAFETY Safety Switch System 117 V RELAY CONDITION LOGIC AMPLIFIER FYQLA1-140R-3 R W B Figure 11 — Amplifier and safety switches with corresponding covers and guards (1) Cutting Enclosure, (2) Feed Adapter, (3) Amplifier, (4) Green “Relay Condition” LEDs, (5) Red “Relay Condition” LEDs, (6) Red “Attention”...
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  • Page 95: General Information

    GENERAL INFORMATION...

  • Page 96: Specifications And Applications

    See the Addendum for updated information GENERAL INFORMATION Specifications and Applications SPECIFICATIONS PRODUCT LIMITATIONS The Comitrol Processor Model 2100 is THE MODEL 2100 IS NOT SUITED TO equipped with stainless steel product contact CUT HARD, FROZEN PRODUCT. Frozen parts. product should be tempered to approxi- mately 27–35°F (-2.8–1.7°C).

  • Page 97: Operating Principle

    GENERAL INFORMATION Operating Principle Figure 12 — Cutaway view of the feed and cutting assemblies. (1) Impeller (3600 RPM), (2) Cutting Head, (3) Feed Screw (15–75 RPM), (4) Agitator (34 RPM), (5) Product OPERATING PRINCIPLE Product is delivered by an agitator and feed screw to the cutting head and impeller (Figure 12).

  • Page 98: Sizes Of Cuts, Cutting Heads

    The cutting head is a ring of vertical knives and horizontal separators in a rigid, one piece unit (Figure 14). Cutting heads are identified by the Urschel 5-digit part number and a corresponding description number. The description number indicates the height of the head (3"), the pattern and...

  • Page 99: Types Of Cutting Head

    GENERAL INFORMATION Cutting Heads Fabricated cutting heads (Figure 15) with openings ranging from .010 to 1.500" are available in the following types: “K” (28 column) type cutting heads are the most popular and are capable of cutting many kinds of product. “J”...

  • Page 100: Speed Control

    See the Addendum for updated information GENERAL INFORMATION Impellers, Operating Speeds, Speed Control IMPELLERS Several different impellers are available for the Model 2100 (Figure 16). The Dio-Cut impeller, standard on the Model 2100, is designed to continually move product over all cutting edges of the cutting head to produce the longest possi- ble usage.

  • Page 101: Installation

    INSTALLATION...

  • Page 102: Shipment, Pre-Installation, Location, Lifting

    INSTALLATION Shipment, Pre-installation, Location, Lifting MACHINE SHIPMENT LIFTING THE MACHINE Every Urschel machine is fully inspected WARNING: Secure machine frame to and test-run before it is shipped. The Model lifting forks with a chain or strap to pre- 2100 is shipped completely assembled.

  • Page 103: Electrical Power

    INSTALLATION Electrical Power ELECTRICAL POWER The electrical installation must be per- formed by a qualified electrician in accor- dance with all applicable electrical codes. Refer to Figure 18 and proceed as follows: 1. Connect the outside power source to the terminals on top of the disconnect in the starter enclosure.
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  • Page 105: Operation

    OPERATION WARNING: This machine contains sharp knives and rotating parts. Only qualified trained personnel should operate this machine. Before opening or removing any cover or guard always turn the power disconnect/lockout switch to “O” (OFF) and lock out power source. After machine has come to a complete stop, press the “I”...

  • Page 106: Start-Up, Stopping And Feeding

    See the Addendum for updated information OPERATION Start-up, Stopping and Feeding DANGER: KEEP HANDS START-UP PROCEDURE AWAY FROM FEED OPENING CAUTION: Processing food prod- ucts can create hazardous floor condi- tions. Provisions must be made to help prevent the operator from slipping while moving around the machine.

  • Page 107: Stopping Procedure

    See the Addendum for updated information OPERATION Start-up, Stopping and Feeding STOPPING PROCEDURE WARNING: Never attempt to open or remove covers or guards while machine is running! Contact with exposed rotating parts may cause severe injury such as amputation! 1. Stop feeding product. This allows remaining product to be cut and dis- charged.

  • Page 108: Feeding

    See the Addendum for updated information OPERATION Feeding FEEDING METHOD achieved at 100% motor load. This will vary with the type of reduction head and product CAUTION: Do not allow foreign being run. Once the feed rate has been material such as tools, hardware, established, without overloading the motors stones, wood, bottles or cans to enter or cutting parts, the meter should be used as...

  • Page 109: Machine Overload Or Jam

    See the Addendum for updated information OPERATION Machine Overload or Jam MOTOR OVERLOAD If the motors shut off during operation, it is likely that they have been overloaded. After maintenance personnel have cor- rected the problem (allowing at least five minutes for thermal overloads to cool) machine may be restarted by first pressing the “RESET”...
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  • Page 111 MAINTENANCE WARNING: This machine contains sharp knives, rotating parts, and volt- ages dangerous to life. Only qualified trained personnel should perform maintenance duties on this machine. Before opening or removing any cover or guard always turn the power discon- nect/lockout switch to “O” (OFF) and lock out power source.

  • Page 112: Maintenance

    MAINTENANCE Covers and Guards OPENING OR REMOVING WARNING: Before opening or removing any cover or guard always turn the power disconnect/ lockout switch to “O” (OFF) and lock out power source. After machine has come to a complete stop, press the “I” (START) button to verify machine will not start.
  • Page 113 MAINTENANCE Covers and Guards Figure 22 — Covers and guards. (1) Belt Guard, Cover (2) Belt Guard, Back, (3) Cutting Enclosure, (4) Impeller Hub Guard (between motor and cutting enclosure)

  • Page 114: Cleaning

    See the Addendum for updated information MAINTENANCE Cleaning IMPORTANCE OF DAILY CLEANING DAILY CLEANING PROCEDURES Stainless steel parts will corrode if salty Only qualified trained personnel should and acidic product juices are not removed clean the machine. Consult your company completely.

  • Page 115: Cleaning And Safety Signs

    MAINTENANCE Cleaning and Safety Signs SAFETY SIGNS 3. Stop the machine. Turn power dis- connect/lockout switch to “O” (OFF) and lock out. After machine has come WARNING: Safety signs are placed to a complete stop, press the “I” on machines to help users avoid per- (IMPELLER START) button to verify sonal injury.

  • Page 116: Lubrication

    See the Addendum for updated information MAINTENANCE Lubrication RECOMMENDED LUBRICANT The Model 2100 requires periodic lubri- cation of the motors and speed reduction units. Speed reduction units, which drive the feed screw and agitator, are mounted on the end of the feed hopper (Figure 23). The units are filled with oil at the time of shipment and should be checked for correct level before starting the machine.

  • Page 117: Motor Lubrication

    See the Addendum for updated information MAINTENANCE Lubrication MOTOR LUBRICATION Lubricate according to the motor manu- facturer’s instructions which are supplied with this machine. NOTE: With the machine running, the variable speed motor should be cranked through the full range of speeds daily to keep internal parts lubricated.

  • Page 118: Cutting And Feed Assemblies

    MAINTENANCE Cutting and Feed Assemblies DISASSEMBLY Refer to Figure 25 below and proceed as follows: 1. Disconnect and lock out power source. Press the “IMPELLER START” button to verify machine will not start. 2. Remove cutting enclosure and feed adapter. Loosen two clamp screws and carefully slide adapter clear of feed screw (Figure 26).
  • Page 119 MAINTENANCE Cutting and Feed Assemblies 3. Remove feed screw and thrust bearing. Carefully pull feed screw forward through the housing (Figure 27). NOTE: Handle feed screw with care so as not to damage flights or bearing sur- faces. 4. Remove cutting head. Remove fasten- ers and carefully slide the cutting head over the impeller.

  • Page 120: Inspection

    MAINTENANCE Cutting and Feed Assemblies INSPECTION All parts should be cleaned, inspected for serviceability, and repaired or replaced if necessary. Cutting Head: Clean thoroughly with water or cleaning solution and a stiff brush. Use compressed air to remove any remain- ing product.

  • Page 121: Reassembly

    MAINTENANCE Cutting and Feed Assemblies REASSEMBLY 1. Install seal and seal cover. Make sure seal is properly oriented (tabs flush with seal surface facing out). See Figure 30. 2. Install impeller. All mating surfaces must be free from nicks or foreign mate- rial.

  • Page 122: Cutting Heads

    Cutting Heads IDENTIFYING CUTTING HEADS 3 K - 030 120 - Cutting heads are identified by the Urschel 5 digit part number and a corre- sponding description number stamped or embossed on the mounting lugs or columns (Figure 32). The first digit (3) in the sample descrip- tion number indicates the cutting head height (actual dimension is 3.390"...

  • Page 123: Resharpening Cutting Heads

    MAINTENANCE Cutting Heads RESHARPENING CUTTING HEADS To resharpen fabricated cutting heads: URSCHALLOY cutting heads may be 1. Remove cutting head from machine. returned to the factory for resharpening, pro- See “Disassembly”, page 40. vided a certain amount of increased cutting clearance is acceptable.

  • Page 124: Electrical Assembly

    See the Addendum for updated information MAINTENANCE Electrical Assembly INSPECTION WARNING: In the event of an electri- cal problem, only a qualified electrician should inspect or repair the fault. Volt- ages dangerous to life exist in the starter enclosure! The power discon- nect/lockout switch must be in the “O”...
  • Page 125 See the Addendum for updated information MAINTENANCE Electrical Assembly Fuses (NEMA & CE enclosures): Remove fuses and transformer fuses. Check with an ohmmeter. If one fuse is replaced, all others of that type fuse should also be replaced. Heaters (NEMA enclosure): If heaters (thermal overloads) have been tripped sever- al times they may fail to reset.
  • Page 126 (5 inch pounds or person must always perform the safety 0.56 newton-meters). Turn power discon- switch system test before operating the nect/lockout switch to “I” (ON). If LEDs machine. See “Safety Switch System remain lit, contact Urschel Laboratories. Test”, page 14.
  • Page 127 MAINTENANCE Electrical Assembly Resistors and sensor leads: Check dielectric grease coating on resistors, sensor leads and terminal strip. Dielectric grease provides a moisture barrier to reduce the potential for premature amplifier failure. If resistors, sensor leads and terminal strip need to be greased, use only dielectric tune- up grease.

  • Page 128: Troubleshooting

    Feed rate too high See “Feeding Method”, page 30. Loss of one phase of Perform complete electrical check on motor power starter. See “Wiring Diagram”, pages 80 & 81. Motor problem Contact Urschel Laboratories for location of nearest authorized motor service center.
  • Page 129 Dull blades or cutting See “Cutting Heads”, pages 44 & 45. edges in reduction head Incorrect impeller and Contact an Urschel representative to set up a reduction head combi- test to determine the correct impeller and nation reduction head combination.
  • Page 130 MAINTENANCE Troubleshooting PROBLEM CAUSE CORRECTION Feed Screw Cutting frozen or Frozen product should be tempered to Breaks or extremely hard product approximately 27—35°F (-2.8—1.7°C). See Cutting Head is page 18. Damaged Excessive Heat Insufficient lubrication Fill reduction units to correct level with rec- or Noise from ommended lubricant.

  • Page 131: Parts

    PARTS...
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  • Page 133: Ordering Information

    3. Include name and phone number of person to contact if further information is required by repair department. Customers in U.S.A.: It is not necessary to inform Urschel Laboratories, Inc. by phone that you are returning parts for repair as long as complete instructions are included in the package.

  • Page 134: Tools

    See the Addendum for updated information PARTS Tools...
  • Page 135 See the Addendum for updated information PARTS Tools ITEM NO. PART NO. DESCRIPTION QTY. 11053 Allen Wrench, 5/16" long ....... . . 11055 Allen Wrench, 3/8"...

  • Page 136: Frame Assembly

    See the Addendum for updated information PARTS Frame Assembly 61352 FRAME ASSEMBLY, 364 FRAME MOTOR...
  • Page 137 See the Addendum for updated information PARTS Frame Assembly ITEM NO. PART NO. DESCRIPTION QTY. — 61312 Frame Assembly, 324 frame motor, (for 30 H.P. motor, includes items 1–5) . — 61308 Frame Assembly, 326 frame motor, (for 40 H.P. motor, includes items 1–5) . —...

  • Page 138: Agitator And Feed Screw

    See the Addendum for updated information PARTS Agitator & Feed Screw...
  • Page 139 See the Addendum for updated information PARTS Agitator & Feed Screw ITEM NO. PART NO. DESCRIPTION QTY. 61521 Feed Adapter ........61598 “O”...

  • Page 140: Cutting Assembly

    PARTS Cutting Assembly...
  • Page 141 PARTS Cutting Assembly ITEM NO. PART NO. DESCRIPTION QTY. 61539 Mounting Plate ........10323 Hex Head Cap Screw, 3/4-10 x 2-1/4", s.s..

  • Page 142: Cutting Heads, Urschalloy

    PARTS Cutting Heads, Urschalloy * Actual dimension of cutting head is 3.390”. NOTE: See page 21 for a description of cutting head types. Use 5 digit part numbers when ordering. Consult Urschel Laboratories for specific cutting head applications.
  • Page 143 PARTS Cutting Heads, Urschalloy " CUTTING HEADS URSCHALLOY 3A-050080U 66855 3A-050100U 66856 3A-100100U 67061 3A-120120U 66753 3A-120360U 66824 3A-120840U 67065 3K-025040U 66844 3K-030060U 66774 3K-030090U 66770 3K-030120U 66754 3K-030165U 66765 3K-030180U 66750 3K-030210U 66784 3K-030240U 66755 3K-030270U 66948 3K-030300U 66756 3K-030340U 66938 3K-030400U...

  • Page 144: Cutting Heads, Fabricated

    PARTS Cutting Heads, (Fabricated) * Actual dimension of cutting head is 3.390”. NOTE: See page 21 for a description of cutting head types. Use 5 digit part numbers when ordering. Consult Urschel Laboratories for specific cutting head applications.
  • Page 145 PARTS Cutting Heads, (Fabricated) " " " CUTTING HEADS CUTTING HEADS CUTTING HEADS SPECIAL COLUMN 3A-060090 66857 3K-010010 66852 3-060180-10 67009 3A-090090 66651 3K-015015 66412 3-060240-10 67008 3A-120150 66601 3K-010020 66752 3-060300-10 66837 3A-120210 67151 3K-020020 66738 3-060390-14 66708 3A-090270 66891 3K-015025 66413...

  • Page 146: Motor And Drive Parts

    See the Addendum for updated information PARTS Motor and Drive Parts...
  • Page 147 See the Addendum for updated information PARTS Motor and Drive Parts ITEM NO. PART NO. DESCRIPTION QTY. 61909 Motor, with brake, 30 H.P., 230/460 volts ..... . . 61228 Motor, with brake, 40 H.P., 200-208-230/460 volts .

  • Page 148: Electrical Assembly (Nema)

    See the Addendum for updated information PARTS Electrical Assembly (NEMA)
  • Page 149 See the Addendum for updated information PARTS Electrical Assembly (NEMA) ITEM NO. PART NO. DESCRIPTION QTY. — Electrical Assembly, 2100, (includes items 1–67) ....Circuit Breaker or Motor Circuit Protector.
  • Page 150 See the Addendum for updated information PARTS Electrical Assembly (NEMA)
  • Page 151 See the Addendum for updated information PARTS Electrical Assembly (NEMA) (continued from page 71) The following items refer to the parts list on page 71. ITEM NO. PART NO. DESCRIPTION QTY. Circuit Breaker or Motor Circuit Protector ..... Control Circuit Transformer With Fuses, (includes items 15–17).

  • Page 152: Electrical Assembly (Ce Compliant)

    See the Addendum for updated information PARTS Electrical Assembly (CE compliant)
  • Page 153 See the Addendum for updated information PARTS Electrical Assembly (CE compliant) ITEM NO. PART NO. DESCRIPTION QTY. — 61424 Electrical Assembly, 2100, 60 H.P., 380/415 volts, YD, IEC (includes items 1–44 below and items 45–67 on page 77) ... —...
  • Page 154 See the Addendum for updated information PARTS Electrical Assembly (CE compliant) 2 5 5...
  • Page 155 Wiring Diagram........*** Consult Urschel Laboratories.

  • Page 156: Electrical Assembly, Switches

    See the Addendum for updated information PARTS Electrical Assembly, Switches...
  • Page 157 See the Addendum for updated information PARTS Electrical Assembly, Switches Electrical assemblies include the following items 1–29. ITEM NO. PART NO. DESCRIPTION QTY. 63741 Actuator ..........63739 Sensor, 12' lead .

  • Page 158: Wiring Diagram 61398

    See the Addendum for updated information PARTS Wiring Diagram 61398 IMPELLER MOTOR FEED SCREW MOTOR AGITATOR DOOR MOTOR 115 VOLTS 0 VOLTS GRD. RESET EMG. STOP T.C. OVERLOADS 1TR T.O. IMPELLER START STOP FEED SCREW 1 2 3 START STOP AGITATOR START STOP...

  • Page 159: Wiring Diagram 61425

    See the Addendum for updated information PARTS Wiring Diagram 61425 Motor Current Transformer Full Load Windings Amps (M1) Primary Secondary DOOR IMPELLER MOTOR FEED SCREW MOTOR AGITATOR MOTOR 115 VOLTS 0 VOLTS RESET EMG. STOP T.C. IMPELLER STOP START OFF DELAY T.O.

  • Page 160: Motor And Circuit Protective Devices, Nema

    See the Addendum for updated information PARTS Motor and Circuit Protective Devices, NEMA IMPELLER MOTOR Motor Heater Element Heater Element Motor Heater Element Full Settings HEATER ELEMENTS AND Full Size 3 Starter Size 4 Starter Size 3 Starter Load Load MOTOR CIRCUIT PROTECTOR Amps Trip Cam...

  • Page 161: Motor And Circuit Protective Devices, Ce

    See the Addendum for updated information PARTS Motor and Circuit Protective Devices, CE Compliant IMPELLER MOTOR FEED SCREW & AGITATOR MOTORS OVERLOAD RELAYS OVERLOAD RELAYS AND FUSES for CE compliant/IEC contactors, for CE compliant/IEC contactors Wye-Delta Start See the information plate on the motor and the schematic The chart below shows the motor full load amps inside the electrical enclosure.

  • Page 162: Safety Signs And Machine Labels

    See the Addendum for updated information PARTS Safety Signs and Machine Labels DANGER DO NOT PUT HANDS INTO OR OVER FEED HOPPER. PELIGRO NO PONER LAS MANOS DENTRO O ENCIMA DE LA TOLVA DE ALIMENTACION. 11664 DANGER DO NOT PUT HANDS INTO OR UNDER DISCHARGE CHUTE.
  • Page 163 Urschel Label ........

  • Page 164: Dimensional Drawing

    PARTS Dimensional Drawing 22 .42" (569mm) 44 .31" (1125mm) 30 .35" (771mm) NEMA TYPE 4 STAINLESS STEEL 35 .94" ELECTRICAL ENCLOSURE (913mm) 40 HP (29.8kW) MOTOR W/ BRAKE 69 .04" 65 .00" (1754mm) (1651mm) AGITATOR CUTTING ENCLOSURE 70 .24" (1784mm) 41 .87"...
  • Page 166 2503 Calumet Avenue 1200 Cutting Edge Drive Chesterton, Indiana 46304 U.S.A. P.O. Box 2200 Corporate: +1.219.464.4811 Fax: +1.219.462.3879 Valparaiso, IN 46384-2200 Toll Free: +1.844.URSCHEL (877.2435) tel: 219-464-4811 www.urschel.com fax: 219-462-3879 Technical Publication inquiries: techpubs@urschel.com e-mail: info@urschel.com Other inquiries: info@urschel.com web site: http: //www.urschel.com With subsidiaries and sales offices in principal cities worldwide.

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