Urschel COMITROL 2100 User manual

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

A.1
The addendum is placed in the front of
the manual to alert the user to revisions
in the manual’s contents. Addendum
page numbers have an “A” prex.
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.
Comitrol® Processor, Model 2100
Addendum to manual L1954
Publication Description: ADDENDUM TO L1954, ENGLISH, M2100 (SS L2756)
Publication Number: L3200
Date issued: September 2018
Supersedes publication L2756
URSCHEL
CORPORATE HEADQUARTERS
1200 Cutting Edge Drive
Chesterton, Indiana 46304 U.S.A.
Corporate: +1.219.464.4811 Fax: [phone]
Toll Free: +1.844.URSCHEL (877.2435)
www.urschel.com
Technical Publication inquiries: [email protected]
Other inquiries: [email protected]
7Safety, Rules for Safe Operation: Add the following.
Lockout Procedure
mWARNING
Always follow the lockout procedure
before opening any guard! Failure to lock
out the power disconnect switch could
result in accidental start-up and serious
injury!
1. If the machine is running, push the
impeller stop button (1).The impeller,
feed screw, and agitator motors will stop
immediately.
2. Turn the disconnect switch handle (2)
on the electrical enclosure o󰀨 and lock
out. Use the padlock (3) attached to the
enclosure to lock the switch, or lock the
switch according to your plant policy on
energy lockout procedures.
3. Verify that the machine will not start.
If the emergency stop button (4) was
pushed, rotate and pull out to reset. After
rotating parts have stopped, press the
impeller start button (5) and hold for 2
seconds. The impeller motor should not
start.
Press the feed screw start button (6)
and hold for 2 seconds. The feed screw
motor should not start.
Press the agitator start button (7)
and hold for 2 seconds. The agitator motor
should not start.
5
2
3
4
1
Manual Page Number Revision
6
7

A.2 Addendum
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. The button is monitored by a safety
relay which shuts down the machine if the
button fails.
13-14 Safety, Safety Switch System: A safety monitor (2) is supplied with
the current electrical system. See the entries for pages 46-47 for more
information on changes to the electrical system. The safety switch testing
procedure has not changed.
Manual Page Number Revision
1
Locations of Sensor Leads on the
Safety Monitor
Switch Number 1 2
Guard Cutting
Enclosure Feed Adapter
Switch Input IN1 IN2
2

A.3
Manual Page Number Revision
Addendum
18 GeneralInformation,Specications: 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.
22 General Information, Operating Speeds and Speed Control:
The potentiometer (see the photos above) for the feed screw can be set
from one (minimum) to 10 (maximum), for a speed range of 15.6–78.0 RPM.
1
2

AddendumA.4
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. All foreign objects and product must
be removed from the feed area (1). All
guards must be securely in place.
2. Unlock and remove the padlock (2)
from the disconnect switch handle
(3) located on the electrical enclosure.
If the emergency stop button (4) was
previously pushed, it must be reset; rotate
and pull out to reset.
3. Turn the disconnect switch handle on
(I).
4. Press the impeller start button (5).The
pilot light (6) will illuminate when the
impeller motor starts.
5. Let the impeller reach full operating
speed. Wait about 20 seconds.
NOTICE
The feed screw and agitator cannot be started
until the impeller has reached full operating
speed.
6. Press the feed screw start button (7)
and agitator start button (8).Begin
feeding product into the machine and use
the potentiometer dial (9) to adjust the
speed of the feed screw if necessary. See
the entry for page 30 in this addendum
and Operation, Feeding in the machine
manual for more information.
1
5
3
2
4
6
7
9
8

A.5Addendum
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.
Stopping Procedure
mWARNING
Never attempt to open or remove the
guards while the machine is running!
Contact with exposed rotating parts may
cause sever injury such as amputation!
1. When appropriate for the product, ush
the feed area thoroughly with a generous
amount of water before stopping the
machine.
2. Stop feeding product. Allow the product
inside the cutting chamber and hopper to
be cut and discharged. Push the agitator
stop button (1) and the feed screw
stop button (2) when there is no product
remaining in the machine.
3. Push the impeller stop button (3).The
impeller motor will stop.
4. Turn the disconnect switch handle o󰀨
(O). Lock out the handle with the padlock
or in accordance with your plant policy on
energy lock out procedures.
5. If the guards are to be opened, verify
that the machine will not start. Press
the impeller start button (4) and hold for
2 seconds. The impeller motor should not
start.
Press the feed screw start button (5)
and hold for 2 seconds. The feed motor
should not start.
Press the agitator start button (6)
and hold for 2 seconds. The agitator motor
should not start.
Use of the Emergency Stop Button
The emergency stop button (7) provides
rapid access to shut down the machine in an
emergency. It is not intended for use as the
routine stopping method. Stop the machine
with the procedure shown to the left.
If the emergency stop button is pressed,
it must be reset before the machine can be
restarted; rotate and pull out to reset.
1
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4
5
6
7

AddendumA.6
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). If the emergency
stop button (2) was previously pushed,
the button must be reset in order to start
the machine; rotate and pull out to reset.
Allow the machine to reach full
operating speed, approximately ten
seconds, before feeding product. This
allows the motor for the feed screw to
reach the full programmed speed.
1
2

A.7Addendum
Manual Page Number Revision
Feeding Method
mDANGER
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,
stone or wood to enter the feed area.
Parts will be damaged and the product
contaminated.
 Thefeedingmethoda󰀨ectsthequality
andcapacityofthenishedproduct.Asteady,
uniform ow of properly sized product from a
conveyor or similar feeding system yields the
best quality and greatest capacity. Dumping
large quantities of product into the feed
opening produces undesirable cuts and can
overload the motor, clog the feed opening, or
jam the cutting unit. Continuous overfeeding
or jamming will also cause premature damage
and failure of machine components.
The potentiometer dial (1) on the
electrical enclosure controls the speed of the
feed screw motor. To increase the feed rate,
turn the dial to the right. To reduce the feed
rate, turn the dial to the left. When the optimal
feed rate is found, look through the window
on the electrical enclosure door and note
the percentage displayed on the motor load
indicator (2). This percentage can be used as
a reference for setting feed rates in the future.
The optimal feed rate may be at less than
100% of full motor load.
Except for an emergency, never start or
stop the machine when the cutting unit is full
of product. This puts a tremendous strain
on the motor, bearings and cutting parts.
In addition, product that is cut before the
machine has reached full operating speed
may be of such poor quality that it must be
discarded.
30 Operation, Feeding: The following replaces the information in the machine
manual.
1
2

AddendumA.8
Manual Page Number Revision
31 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o󰀨duringoperation,
one of the motors has likely been overloaded.
Maintenancepersonnelshouldrstlocateand
correct the cause of the overload before the
machine is restarted.
If the machine stops, check the yellow
motor overload light (1) on the outside
of the electrical enclosure. The light will
illuminate if the impeller motor, feed screw
motor, or agitator motor has experienced an
overload. If the light is illuminated, press the
reset button (2) and hold for 4-5 seconds.
Start the machine in the normal manner. If the
machineshutso󰀨again,seeMaintenance:
Troubleshooting in the machine manual.
NOTICE
The variable frequency drive (VFD) will
display the error code oL1 or oL2 only if the
feed screw motor has overloaded.
(continued on the next page)
2 1

A.9Addendum
Manual Page Number Revision
31 Operation, Machine Overload or Jam (continued): The following applies
to the electrical system supplied from approximately October 2009 until
September 2018. See the previous page for motor overload information for
the current electrical system.
If the feed screw motor becomes overloaded causing the machine to
shuto󰀨,adisplaycodeof“oL1”willbedisplayedonthevariablefrequency
drive or VFD (1).Shouldthisoccur,turnthedisconnectswitcho󰀨andallow
at least 5 seconds for the fault
to clear. Contact maintenance
personnel to correct the cause of
the overload. Turn the disconnect
switchon.Pressthe“MASTER
RESET”button,thenstartinthe
manner described in the manual.
Refer to the variable frequency
drive manufacturer’s manual for the
procedure when the digital operator
displaysadi󰀨erenterrorcode.
If the impeller or agitator motors
haveoverloaded,rstpressthe
impeller reset (2) and agitator
reset (3)buttons.Allowve
minutes for the thermal overloads to
cool. Next, press the master reset
button, then start in the manner
described in the manual.
36 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.
38-39 Maintenance, Lubrication: An optional hour meter is available to track
machine operating time. See the entry for the Electrical Enclosure Assembly
for more information.
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3

AddendumA.10
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 lter (2), and main circuit breaker with disconnect switch (3).
The machine is supplied with a soft start controller (4). The soft start
controls the inrush of current to the impeller motor when the impeller start
button is pressed. This is intended to reduced stress on the motor and motor
shaft, and prevent a voltage dip in the power supply. See the soft start
manufacturer's information included with the machine for more information.
1
2
3
4

A.11Addendum
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specic
electrical components, see the following pages.
The electrical assembly was supplied with an amplier (1) beginning in
1994until2018.Thefunctionoftheamplier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. The monitor serves
afunctionsimilartothatoftheamplier,butisnot
a direct replacement and is not interchangeable.
See the following pages for more information on
the safety monitor.
The SCR-31-i Viper safety relay (3) was
added to the electrical assembly in conjunction
with the safety monitor. The safety relay monitors
the input from the safety monitor and the emergency
stop button. See the following pages for more
information.
NOTICE
Previously supplied electrical components are
available as repair parts unless otherwise noted in
this addendum.
1
2
3

AddendumA.12
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. If circuit breakers trip or fuses fail
frequently, investigate the cause.
Reading the Safety Monitor
The safety switches are connected to
the inputs (2) along the bottom of the safety
monitor. Each input has two input status
lights (3). A green status light means the
input circuit is closed. A red light means the
input circuit is open. All status lights must be
green (closed) for the machine to run.
When a guard is removed the
corresponding status light turns red. Remove
the cutting enclosure for example (see
Maintenance, Covers and Guards in the
machine manual) with the disconnect switch
handle on (I). The IN1 (4) input status light
turns red. The light turns green when the
cover is replaced. See the chart to the right for
the location of each switch or sensor.
The fault lights (5)ashredwhenthe
monitor detects an open safety circuit. If the
faultlightsareashingandnoneoftheinput
status lights are red, turn the disconnect
switchhandleo󰀨.Wait5secondsandthen
turn the handle back on.
The PWR (6) light is green when the
disconnect switch handle is on. Electrical
power is supplied to the machine.
Voltage Power
Supply
Type
Short Circuit Protective
Device (SCPD)
Circuit
Breaker
Fuse
240 and
lower
Wye 
Delta  
380 - 480 Wye  
Delta 
575 Wye 
Delta 
1
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3
4
5
6

A.13Addendum
Manual Page Number Revision
46-47 Maintenance, Electrical Assembly (continued): Add the following.
Safety Relay LEDs
The safety relay includes the following
LEDs. Various combinations of lit and unlit
LEDs help to indicate the status of the safety
system.
(1) Power
(2) Reset
(3) CH1
(4) CH2
(5) K1
(6) K2
The Power, CH1, CH2, K1 and K2
LEDs are lit: All guards are in place and the
emergency stop button is reset. The machine
is ready to start.
The Power and Reset LEDs are lit: A
guard(s) has been removed or the emergency
stop button has been pushed.
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.
1
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3
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6

AddendumA.14
Manual Page Number Revision
46-47 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. If the
circuit breaker is equipped with a magnetic
adjustment dial (3), note the setting.
2. Install the new circuit breaker and
replace the operating mechanism.
3. Adjust the instantaneous trip setting
with the magnetic adjustment dial. Refer
to the setting on the old breaker or see
the Current Transformer Windings Chart
included in this addendum. A small section
of the chart (4) is shown at the right. See
thecolumninthecharttitled“/mSetting”.
Circuit breakers with amperage ratings
below 150 amps do not have magnetic
adjustment dial.
4. If the motor has been replaced, check
the motor full load amperage rating on
the motor nameplate. Adjust the magnetic
adjustment dial if necessary. Also check the
windings on the current transformer (5).
See the information on the following page
and rewind the transformer if necessary.
1
3
Full Load
Amps
MCCB1
Size
MCCB1
Part Number
Im
Setting
CT WIND
PRI SEC
46
125 A 21932 5
2 -2
47 2 -2
48 2 -1
49 2 -1
50 2 0
5
4
2
2
(See page A.39: Current Transformer Windings
Chart for the complete chart.)

A.15Addendum
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congured
fortheelectricalspecicationsofyourmachine.
Replacing the Current Transformer
1. Disconnect the primary wire (3) from the
circuit breaker. Note the number of times
the wire is wound through the transformer.
The top illustration shows examples of
primary windings with values of 1 and 2.
2. Disconnect the secondary wires (4)
from the transformer terminals. Note the
number of times the wire is wound through
the transformer and to which terminals the
wires are connected (one secondary wire is
shown in color in the illustration for clarity;
both wires are black).
3. Install the replacement transformer with
the XI and HI marks (5) face up.
4. Wind the primary wire through the
transformer. Refer to your notes from
Step 1 or see the Current Transformer
Windings Chart included in this addendum.
A small section of the chart (6) is shown
at the right; see the columns indicated by
the arrows. See the motor name plate to
determine the full load amps or check the
amperage rating of the circuit breaker as
described on the previous page.
5. Wind the secondary wire through the
transformer. The wire wound through
the transformer connects to the positive
terminal (7) on the motor load indicator.
Refer to your notes from Step 2 or see the
Current Transformer Windings Chart in this
addendum for the number of windings. See
thecolumninthecharttitled“CTWIND”.
If the value from the chart is negative,
connect the wire to the XI terminal (8)
on the current transformer. If the value is
positive, connect the wire to the HI terminal
(9). Connect the remaining wire to the other
terminal.
(–) (+)
1
5
5
3
7
9
2
4
8
6
Full Load
Amps
MCCB1
Size
MCCB1
Part Number
Im
Setting
CT WIND
PRI SEC
46
125 A 21932 5
2 -2
47 2 -2
48 2 -1
49 2 -1
50 2 0
(See page A.39: Current Transformer Windings
Chart for the complete chart.)

AddendumA.16
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. Verify that the indicator is displaying
zero when the motor is not running. Turn
the adjustment screw (1) to set the
needle to zero if necessary.
2. Attach an amperage clamp to the
primary wire (2) that passes through
the current transformer (3). Start the
machine and measure the amperage.
3. Divide the measured amperage by
the motor full load amperage (full
load amperage is found on the motor
name plate). Multiply this value by 100
to determine the percentage of full motor
load. Compare the measured percentage
to the percent shown on the indicator.
They must be within ±2%. Continue to
Step 4 if the indicator is not displaying the
correct percentage.
4. Verify that the current transformer
windings are correct. See Steps 5 and 6
under Replacing the Current Transformer
in this addendum. If the windings are
correct, the motor load indicator has likely
failed and must be replaced.
1
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3

A.17Addendum
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). The fasteners are located on
the backside of the bracket.
3. Install the replacement indicator. Install
the fasteners that secure the indicator to
the bracket.
4. Locate the wire that is wound through
the current transformer (2).Connect this
wire to the positive terminal on the back of
the indicator. Connect the remaining wire
to the negative terminal.
5. Test the indicator. See the instructions in
this addendum.
1
2
Manual Page Number Revision
56-57 Parts, Tools: Items 1 and 2 have been replaced by:
98137 - Wrench,13 piece. set, chrome plated, ball end
98163-Screwdriver,athead,1/4"atx6"
Items 4 and 6 have been replaced by:
98130-Wrench,combination,1/2",chromeplated
98131-Wrench,combination,7/16",chromeplated

AddendumA.18
58-59 Parts, Frame Assembly: the current frame and related parts are shown below.
Manual Page Number Revision
61453 Frame
Assembly,
364 Frame
Motor