Urschel COMITROL 3600 SLANT User manual

Instruction
Manual
COMITROL®PROCESSOR
MODEL 3600 SLANT
SAFETY
GENERAL
INFORMATION
INSTALLATION
OPERATION
MAINTENANCE
PARTS
LABORATORIES
INCORPORATED

1
COMITROL PROCESSOR
MODEL 3600 SLANT
Instruction Manual
1781 OCT01
(supersedes 1134 APR 84)
rschel Laboratories, Inc.
2503 Calumet Ave., P.O. Bo 2200
Valparaiso, Indiana 46384-2200 U.S.A.
219/464-4811 fa : 219/462-3879
e-mail: [email protected]
web site: http://www.urschel.com
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. If your machine contains parts not shown, or if there
are any questions regarding the safe operation of this machine, contact Urschel Laboratories.
COPYRIGHT© 2001 Urschel Laboratories, Inc., Valparaiso, Indiana. All rights reserved. No part of this manual
may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy-
ing and recording, for any purpose without the e press written permission of Urschel Laboratories, Inc.
® Urschel, ® Comitrol and ® Urschalloy are registered trademarks of Urschel Laboratories, Inc.

2
FOREWORD
This manual must be read by or to each person before that person operates, cleans,
repairs, adjusts, installs, supervises the operation of, or uses this machine in any way.
You must learn and follow all the safety rules and operating principles set forth in this
manual. This means:
1. Follow all warnings, cautions, and other safety messages in this manual and on the
machine. Recognize the safety alert symbol , which indicates a potential personal
safety hazard.
2. Never work beyond defined safety skills.
3. Insist on thorough and proper safety training.
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.

3
FOREWORD .............................2
SAFETY and Safety Warning .................5
R LES FOR SAFE OPERATION ...................7
SAFETY SIGNS ..............................8
PROTECTIVE DEVICES ........................10
SAFETY SWITCH SYSTEM......................12
Safety Switch System, Safety Switch ...............12
Amplifier .................................13
Safety Switch System Test ......................14
GENERAL INFORMATION ................17
SPECIFICATIONS ............................18
Specifications, Product Limitations, Noise Emission ......18
Applications, Operating Principle ..................19
C TTING HEADS AND IMPELLERS................20
Cutting Heads, Impellers .......................20
Urschalloy Cutting Heads, Fabricated Cutting Heads .....21
INSTALLATION ..........................23
SHIPMENT, PRE-INSTALLATION, LOCATION, LIFTING ...24
Machine Shipment, Pre-installation Plan, Location,
Lifting the Machine ..........................24
ELECTRICAL POWER .........................25
Electrical Power.............................25
OPERATION and Safety Warning ............27
START- P, STOPPING AND FEEDING ..............28
Start-up Procedure ...........................29
Stopping Procedure, Feeding Method ...............29
MACHINE OVERLOAD OR JAM ..................30
Motor Overload, Correcting Machine Overload or Jam ....30
(continued)
contents

4
contents
MAINTENANCE and Safety Warning .........31
COVERS AND G ARDS .......................32
Opening or Removing, Inspection, Installation .........32
CLEANING ................................34
Importance of Daily Cleaning, Cleaning Agents & Daily
Cleaning Procedures ........................34
L BRICATION ..............................35
Lubrication ................................35
SAFETY SIGNS .............................35
Safety Signs, Inspection, Installation ...............35
FEED ASSEMBLY & C TTING HEADS..............36
Disassembly ...............................36
Inspection, Reassembly .......................37
C TTING HEADS ............................38
Resharpening Cutting Heads ....................38
ELECTRICAL ASSEMBLY ......................40
Inspection ................................40
TRO BLESHOOTING .........................44
PARTS..................................47
ORDERING INFORMATION .....................49
Ordering Parts, Returning Parts for Repair............49
TOOLS ...................................50
SLANT MACHINE ............................52
C TTING HEADS ( RSCHALLOY) ................54
C TTING HEADS (FABRICATED) .................56
15 LB-FT STEARNS 56200 BRAKE ASSEMBLY........58
ELECTRICAL ASSEMBLY ......................60
ELECTRICAL ASSEMBLY (CE compliant)............62
ELECTRICAL SCHEMATIC (NEMA) ................66
ELECTRICAL SCHEMATIC (CE compliant) ...........67
SAFETY SIGNS & MACHINE LABELS ..............68
OPTIONAL PARTS ...........................70
DIMENSIONAL DRAWING ......................72

SAFETY
5
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!

6
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7
SAFETY
Rules for Safe Operation
READ AND PRACTICE SAFETY R LES IN THIS MAN AL:
1. DANGER! This machine contains sharp knives and rotating parts. Never
operate this machine if any cover, guard or safety device has been opened,
removed, or modified; doing so can result in serious injury or amputation.
2. When covers or guards are opened or removed, sharp edges and pinch
points are e posed. Use e treme caution to avoid touching or striking these
areas with your hands or body.
3. Always disconnect and lock out the power source, push the “I” (START)
button and verify machine does not start before doing any work on this
machine.
4. DANGER! Never put your hand or any foreign object into the feed opening
or discharge area. Serious personal injury and/or damage to the machine
may result.
5. NEVER attempt to assist the feeding or discharging of product with your
hands.
6. Only qualified trained personnel should attempt to clean, adjust, repair or
maintain the machine. Proper cleaning and maintenance procedures are
found in the maintenance section of this manual.
7. This machine contains protective covers and guards equipped with safety
switches. If the machine operates with any of these protective covers or
guards opened, removed or modified, this machine is not safe to operate.
Call a qualified electrician immediately to locate and repair the fault. Prior to
operating the machine, the safety switches must be checked by qualified
trained personnel. Complete information on checking safety switches is
found in the safety section of this manual.
8. Should the machine become overloaded or jammed, DO NOT attempt to
correct the problem with the power source on. Disconnect and lock out
the power source. Detailed instructions for correcting product jamming are
found in the operation section of this manual and should be read and under-
stood by all maintenance, service, or operation personnel.
9. The sound pressure level produced by this machine is likely to e ceed 85
dB(A). Use adequate hearing protection.


8
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 aboratories, Inc. For the part numbers, languages and locations of
safety signs, see “Safety Signs and Machine abels” in the parts section of this manual.
A caution label (Figure 1) is provided
to remind you of safety rules which
must be followed to avoid personal
injury.
Danger labels (Figure 2) are placed at
or near the feed opening to warn you
and anyone near the machine that this
opening is an access to sharp rotating
parts and pinch points which can cause
serious injury. Never insert your hand, a
tool, or any foreign object into the feed
opening.
Danger labels (Figure 3) are placed on
or near the discharge chute to warn you
and anyone near the machine that this
opening is an access to sharp rotating
parts and pinch points which can cause
serious injury. Never insert your hand, a
tool, or any foreign object into the dis-
charge chute.

11666
PRECAUCION
CAUTION
MACHINE CONTAINS ROTATING PARTS SUCH AS SHARP KNIVES, PULLEYS, BELTS OR GEARS.
NEVER RUN MACHINE WITH ANY GUARD OR COVER REMOVED, EVEN FOR CLEANING.
TURN THE MACHINE OFF, DISCONNECT AND LOCK OUT POWER SOURCE BEFORE
ATTEMPTING TO SERVICE OR REMOVE OBSTRUCTION.
RUNNING MACHINE WITH ANY GUARD OR COVER REMOVED MAY RESULT IN SERIOUS INJURY
OR AMPUTATION.
READ AND UNDERSTAND INSTRUCTION MANUAL.
LA MAQUINA CONTIENE PIEZAS GIRATORIAS TALES COMO CUCHILLAS AFILADAS, POLEAS,
CORREAS O ENGRANAJES.
NUNCA HACER FUNCIONAR LA MAQUINA CON CUALQUIERA DE LOS PROTECTORES O
CUBIERTAS RETIRADOS, INCLUSO PARA LIMPIARLA.
APAGAR LA MAQUINA, DESCONECTAR Y BLOQUEAR EL SUMINISTRO ELECTRICO ANTES DE
INTENTAR HACER UNA REPARACION O QUITAR UNA OBSTRUCCION.
SE CORRE EL RIESGO DE SUFRIR GRAVES LESIONES O AMPUTACION SI SE HACE FUNCIONAR
LA MAQUINA CON CUALQUIERA DE LOS PROTECTORES O CUBIERTAS FUERA DE SU LUGAR.
LEER Y ENTENDER EL MANUAL DE INSTRUCCIONES.
Figure 1 — Caution abel
Figure 2 — Danger abel, Feed Opening
Figure 3 — Danger abel, Discharge Chute
11662
DO NOT PUT HANDS INTO FEED OPENING.
NO PONER LA MANO DENTRO DE LA
ABERTURA DE ALIMENTACION.
DANGER
PELIGRO
11663
DANGER
PELIGRO
DO NOT PUT HANDS INTO OR UNDER
DISCHARGE CHUTE.
NO PONER LA MANO DENTRO O BAJO
EL CONDUCTO DE DESCARGA.

9
SAFETY
Safety Signs
Figure 4 — Danger abel, Removed Guard
Figure 5 — Danger and Hazard Alert abels
11667
DANGER
PELIGRO
MUST BE OPENED AND SERVICED BY
QUALIFIED ELECTRICIAN ONLY. INSTALL
TO MEET APPLICABLE CODES.
DEBE SER ABIERTO Y REPARADO POR UN
ELECTRICISTA CALIFICADO SOLAMENTE.
INSTALAR DE ACUERDO A LOS CODIGOS
CORRESPONDIENTES. 220 VOLTS ~
12716
11665
MACHINE IS UNGUARDED.
REPLACE GUARD OR COVER.
LA MAQUINA ESTA SIN PROTECCION.
VOLVER A COLOCAR EL PROTECTOR
O CUBIERTA.
DANGER
PELIGRO
Danger labels (Figure 4) are visible
when a protective cover or guard has
been opened or removed. This label
warns you that the machine is
unguarded and must not be restarted
until all covers and guards are
replaced.
A danger label and a hazard alert
label (Figure 5) are placed on the
starter enclosure to warn you that this
is a source of electrical hazard. The
enclosure must be opened and serviced
by a qualified electrician only and the
installation must meet applicable codes.
The number on the hazard alert label
indicates the voltage requirements of
the machine.

10
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. Never rely solely on
these safety switches. Always push the
“O” (STOP) button then disconnect
and lock out the power source. When
machine has come to a complete stop,
push the “I” (START) button to verify
that the machine will not start before
removing any part from the machine.
Power disconnect/lockout switch
(Figure 7), located on the starter enclo-
sure, is intended to eliminate the
danger of accidental start-up when
locked in the “O” (OFF) position.
Figure 6 — Safety Switch
Figure 7 — Power Disconnect/ ockout Switch

A brake motor (Figure 8) is provided
to reduce “coasting” stops of potentially
dangerous parts of the machine.
Covers and guards enclose poten-
tially dangerous machine areas. These
covers and guards are of utmost impor-
tance to safe machine operation. Never
attempt to operate the machine with a
cover or guard opened, removed or
modified Serious personal injury
may occur!
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 com-
plete information.
11
SAFETY
Protective Devices
Figure 8 — Brake Motor

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
system for proper function before oper-
ating the machine There is a problem
with the safety switch system if the
machine can be started while any cover
or guard that is equipped with a safety
switch is opened or removed DO NOT
operate the machine in this condition!
Serious injury such as amputation
could result!
SAFETY SWITCH
The safety switch consists of two parts,
the sensor and the actuator (Figure 9).
The sensor is attached to certain fi ed
components on the machine and sends a
signal to the amplifier. The actuator is
attached to certain covers and guards and
must be aligned and within 1/16" (1.6 mm)
of the sensor.
12
SAFETY
Safety Switch System
2
1
Figure 9 — Safety Switch. (1) Sensor, (2) Actuator

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. The amplifier’s LEDs
help identify possible problems with the
safety switches.
Function of the amplifier’s LEDs is as
follows: when the green “relay condition”
LEDs are illuminated, the guards and
covers equipped with switches are in
place and properly aligned. When one or
both of the red “relay condition” LEDs are
illuminated, a safety switch circuit is open.
When the red “switch output” LEDs are
illuminated, they indicate which correspon-
ding safety switch is open.
When the red “attention” LED is flash-
ing, the amplifier has gone into a reset
condition. With all sensors and actuators
properly aligned, the power to the machine
must be turned off and then on again to
reset the amplifier. If the amplifier will not
reset, call a qualified electrician to locate
and repair the fault (see “Amplifier”, page 42).
13
SAFETY
Safety Switch System
3
12
4
Figure 10 — Amplifier. (1) Green “Relay Condition”
EDs, (2) Red “Relay Condition” EDs, (3) Red
“Attention” ED, (4) Red “Switch Output” EDs

SAFETY SWITCH SYSTEM TEST
WARNING: A qualified trained
person must check the safety switch
system for proper function before oper-
ating the machine There is a problem
in the safety switch circuit if the LEDs
are not lit as indicated or, if having
opened or removed a cover or guard
equipped with switch, the machine can
be started DO NOT operate the machine
in this condition! Operating the machine
in this condition could result in serious
injury such as amputation! Call a quali-
fied electrician to locate and repair the
fault See “Electrical Assembly”, page 40
1. With all covers and guards in place,
turn the power disconnect/lockout
switch to “I” (ON). Only the green “relay
condition” LEDs on the amplifier should
be lit (Figure 11, page 15). Push the “I”
(START) button. Machine should start.
(See “Troubleshooting”, page 44 if
machine does not start.) Push the “O”
(STOP) button and turn power discon-
nect/lockout switch to “O” (OFF). Visu-
ally verify machine has come to a
complete stop.
WARNING: Be careful to avoid
contact with cutting parts and sharp
edges exposed during the safety switch
system test Contact with cutting parts
and sharp edges could result in serious
injury such as amputation
2. Remove or open one cover or guard
equipped with switch. Turn power
disconnect/lockout switch to “I” (ON).
Only the red “relay condition” LEDs and
the red “switch output” LEDs corre-
sponding to the switch on the removed
or opened cover or guard should be lit
on the amplifier. If LEDs are lit cor-
rectly, push the “I” (START) button. The
safety switch circuit has been inter-
rupted and machine should NOT start.
If the machine does start, that safety
circuit has failed. Push the “O” (STOP)
button, then disconnect and lock out
power source. Call a qualified electri-
cian to locate and repair the fault
immediately.
3. Turn the power disconnect/lockout
switch to “O” (OFF) and replace or
close the cover or guard.
4. Individually remove or open each
additional cover or guard equipped
with switch and repeat steps 2 and 3.
Make sure all covers and guards are
securely in place after safety switch
system has been tested.
14
SAFETY
Safety Switch System

15
SAFETY
Safety Switch System
RELAY
CONDITION
C
2
LOGIC AMPLIFIER
FYQLA1-140R-3
D
E
S
O
L
N
E
P
O
117 V
6
OBWR
5
OBWR
4
OBWR
3
OBWROBWRO
R2R1L2L1
RW B
1
3
6
7
5
4
1
2
9
8
Figure 11 — Amplifier and safety switches with corresponding covers and guards. (1) Cutting Enclosure,
(2) Front Cover with Feed Hopper, (3) Amplifier, (4) Green “Relay Condition” EDs, (5) Red “Relay Condi-
tion” EDs, (6) Red “Attention” ED, (7) Red “Switch Output” EDs, (8) Sensor, (9) Actuator

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17
GENERAL INFORMATION

SPECIFICATIONS
The Model 3600 comes equipped with
stainless steel and rschalloy®product
contact parts.
WARNING: Do not modify this
machine! Any modification or omission
of parts could compromise the safety
and sanitation of this machine
Length: ...........................35.69" (906 mm)
Width:.............................29.21" (742 mm)
Height: ...........................38.64" (981 mm)
(See “Dimensional Drawing”, page 72.)
Net Weight:.....................390 lbs. (177 kg)
Gross Weight Crated:......490 lbs. (222 kg)
Impeller Drive Motor: 10 H.P. (7.5 kW),
totally enclosed, fan-cooled, with brake.
Motors set at 60 hertz run 3600 RPM. For
motors set at different hertz, see page 53.
See motor specifications plate and
motor manufacturer’s instructions for more
information.
PROD CT LIMITATIONS
MAXIMUM INPUT PRODUCT SIZE, in
general, should not e ceed 2-1/2" (63.5 mm)
in any dimension.
PRODUCTS WHICH ARE EXPLOSIVE
or create a potentially e plosive atmos-
phere should not be processed by this
machine. A potentially e plosive atmos-
phere could be created if processing your
product creates fumes or dust in sufficient
concentrations.
GENERAL INFORMATION
Specifications
18