CC700 DIGITAL PULSE TACHOMETER

INSTALLATION INSTRUCTIONS

WARRANTY STATEMENT

General

Adjustment of the centering and alignment flange is a one-time adjustment performed at initial installation. This unique shaft-mounted device yields the highest accuracy tachometer feedback. All errors associated with couplings and foot mounted tachs are eliminated. The tachometer can be replaced with a spare in a matter of minutes without any adjustment..

1. ADAPTER PLATE INSTALLATION

1.1 Prepare motor shaft by removing any dirt, debris, burrs, or other protrusions from the area where the adapter plate surfaces will come in contact with the motor shaft. A wire wheel, wire brush, sandpaper, and files are tools needed for this procedure.

1.2 Using 1/4" hex key, remove adapter plate from Centering & Alignment Flange (Drawings 700A7521 and 7007524)

1.3 Clean the surface of the adapter plate to be mounted to the motor shaft.

1.4 Mount the adapter plate to the motor shaft with the hardware provided. Make sure the pilot and counterbore fits, and that the surface with the mounting screw holes is flush with the mounting surface. If the mounting holes are outside of the pilot or counterbore, the plate should be flush with the motor shaft. If the mounting holes are inside the pilot or counterbore, they should contact the motor shaft leaving a small gap between the motor shaft and the adapter plate outside the pilot or counterbore area.

2.REMOVING CC700 TACHOMETER FROM CENTERING & ALIGNMENT FLANGE

Tools required: 1 1/8" Socket, 3/16" hex key and optional pencil magnet

With overspeed switch: 3/8" hex key, 3mm long arm hex key, and pocket flashlight

With analog tach: 3/8" hex key, 5/16" hex key and 5/32" balldriver

With analog tach and overspeed switch: same as with analog tach

2.1 Tachometer -- Reference Drawings 700A7521 sh1, 700A7521 sh2

2.1.1 With 3/16" hex key remove the (4) 1/4-20 x 5/8" socket head cap screws (SHCS) and the shaft thimble cover.

2.1.2 With 1 1/8" socket remove the 3/4-10 faced nut** from the mandrel shaft.

**The nut provided has been machined on both sides so that flatness will be maintained when installed. DO NOT use a nut that has not been machined. This can cause misalignment of the tach.

2.1.3 With the pencil magnet, remove the flat washer from the mandrel shaft.

2.1.4 Because of the tapered mandrel shaft, the tach may need to be loosened from the taper. Between the screw head of the torque arm and the Centering and Alignment Flange put a piece of wood, wrench, etc., as shown and apply pressure to free the tachometer from the mandrel. It will now slide freely off the mandrel shaft.

2.2 Tachometer with Overspeed Switch

"Reference Drawings 700A7522 sh1, 700A7522 sh2, 700A7522 sh3

2.2.1 With 3/8" hex key, remove 1/2" brass NPT plug.

2.2.2 With 3mm hex key loosen bellows coupling clamp screw. Use pocket flashlight to aid in seeing screw. Do not remove coupling from the overspeed switch unless replacing it.

2.2.3 With 3/16" hex key remove the (4) 1/4-20 x 3/4 SHCS holding the overspeed switch to the mounting spacer. Pull the overspeed switch away from the mounting spacer, turn gently while pulling.

2.3 Tachometer with CC290AT Analog Tachometer

Reference Drawings 700A7523 sh1, 700A7523 sh2, 700A7523 sh3

2.3.1 With 3/8" hex key, remove 1/2" brass NPT plug.

2.3.2 Take the pocket flashlight and locate the socket head screws of the coupling.

2.3.3 With the 5/32" balldriver loosen the coupling screw closest to the tach. This is the side clamped to the Centering and Alignment Flange mandrel shaft.

2.3.4 With the 5/16" hex key, remove the (4) 3/8-16 x 1" SHCS holding the CC290AT to the Nema 56C Flange, and gently pull the CC290AT from the 56C Flange. Note the coupling should be attached to the CC290AT.

2.3.5 Continue to remove tach per above instructions 2.1.2 through 2.1.4.

2.4 Tachometer with CC290AT Analog Tachometer and Overspeed Switch

2.4.1 Use removal instructions 2.3.1. through 2.3.5. Removing overspeed switch is not necessary for mounting and centering procedure. If overspeed switch does need to be removed, use removal instructions 2.2.1. through 2.2.4

Tools required: 1/4" hex key

3.1 Clean the mounting surfaces of the adapter plate and the Centering and Alignment Flange.

3.2 Mount the Centering and Alignment Flange with the (3) 5/16-18 SHCS provided and torque 20-25 ft-lbs. The Centering and Alignment Flange should be flush with the adapter plate. If not, remove the Centering and Alignment Flange, clean again and remount flange.

4. CENTERING AND ALIGNMENT PROCEDURE

Tools required: 3/16" long arm hex key, 1/4" hex key, and 1" dial indicator* scaled by 0.001" with magnetic stand

Dial indicators scaled by 0.0001" can be used, but it is best to start with above indicator until concentricity is roughed to approximately 0.01"

Objective: To align the mandrel shaft to +/- 0.001" of the motor shaft.

4.1.1 Note: The Centering and Alignment Flange vernier alignment screws are marked 1, 2, 3, and 4. The 1 and 3 axes will be referred to as the odd, and the 2 and 4 axes as the even.

4.1.2 Set dial indicator on mandrel shaft, see drawing 700A7525 Note: Indicator is shown at the 12 o'clock position, but any accessible position to the shaft is acceptable. Pull out the dial indicator post. The direction in which the dial moves will be the high.

4.1.2.1 The dial indicator should be secured from vibration as much as possible. Mounting to the motor housing is not acceptable. Mounting could be on

4.1.3 Rotate the motor shaft identifying the spot by the number** on the Centering and Alignment Flange that is the highest reading on the dial indicator. Have the motor stopped as close to where the number and the dial indicator are parallel. Set the dial indicator to zero. For this instruction let the high be on #3.

**Stay as close as possible to the axis. If the highest variance is between the

4.1.4 Rotate the motor and record the difference between #3 (the high) and #1 (the low). Ex. The difference is 0.020". To remove any misalignment, adjust half of the difference to achieve alignment. If it is off 0.020" when aligning, move the axis 0.010".

4.1.5 Stop the motor as close as possible to where the dial indicator and the high reading are parallel, as in 4.1.3. The #3 should be even with the dial indicator.

4.1.6 Take the 3/16" hex key and loosen the screw opposite the dial indicator, in this case the #1screw. Note: One complete revolution of the screw is approximately 0.042" of linear movement, 1 degree is approx. 0.0001" and 10 degrees approx. 0.001", and only adjust for half of the difference. If the difference is 0.020", loosen the #1 screw approximately 100 degrees, then tighten down on the #3 screw. The dial indicator should move in the direction of #1. Note: Some torque is required to drive the #3 screw. Drive the screw as far as it will go.

4.1.7 Set dial indicator to zero and rotate motor shaft.

4.1.8 Record difference between the adjusted axes, in this case #1& #3. If greater than 0.003" repeat aligning procedure. If less than 0.003" continue same procedure with the other axes. If less than 0.003" cannot be achieved, the other axes may be misaligned. If this is the case, continue procedure with the other axis. As the other axis is aligned the difference in the first axis aligned will either decrease or be able to be aligned to a closer difference.

4.1.9 Continue alignment procedure above for the other axes.

4.1.10 Now that the alignment is roughed in, continue this procedure adjusting from axis to axis to get the concentricity to +/- 0.001". In this case, if a screw needs to be loosened, just breaking the tension is enough, and then driving the opposite screw with a little extra torque can achieve the needed 0.001" alignment in the mandrel shaft.

Objective: To align the mandrel shaft +/- 0.001" perpendicular to the motor shaft.

4.2.1 Note: The Centering and Alignment Flange adjusting tilt screws are marked 5, 6, & 7.

4.2.2 Set the dial indicator on the mandrel, see Drawing 700A7526.

4.2.3 Rotate the motor shaft identifying the highest reading on the dial indicator. Because of the three tilt adjusting screws, the high reading for this alignment can be located between two numbers.

4.2.4 Stop the motor shaft as close as possible to the dial indicator high reading. Set the dial indicator to zero. If this is in between two numbers, mark the location with a magic marker.

4.2.5 Rotate the motor and record the difference between the high and the low readings.

4.2.6 Stop the motor as close as possible to dial indicator and the high reading as in 4.2.4.

4.2.7 Take the 3/16" hex key and screw in on the high area. The dial indicator should move in the direction of the low. As with the concentricity, adjust half the difference.

4.2.8 Adjust using the screw points as close as possible. If tilt adjustment is acceptable (+/- 0.001"); proceed to section 5; if not acceptable, continue with 4.2.8.1 for fine adjustment to acceptable tolerances.

4.2.8.1The high point may be located at a screw, or between two screws. In order to bring the tilt into acceptable tolerance it is most likely the case where two screws will need to be adjusted independently, but in combination with each other. This procedure will be trial and error. First make an adjustment with the screw that is the highest, then adjust the other screw. Set dial indicator to zero, rotate the motor and record the amount difference. Going through the process of tightening, loosening, rotating and recording, will bring the tilt into acceptable tolerances.

NOTE 1:	The Centering and Alignment Flange tilt adjustment screws are not flush with the adapter plate at time of shipment. It will take several turns of the tilt screw before coming in contact with the adapter plate. These screws have a nylon insert and will require more torque to screw into the Centering and Alignment base plate.

NOTE 2: In rare cases where the tilt adjustment screws have been screwed in as tight as possible, but still more adjustment is needed, take the 1/4" hex key and break the 5/16-18 SHCS mounting the Centering and Alignment Flange to the adapter plate, see Drawings 700A7524 & 700A7526. Only break the screw or screws where adjustment is needed, (high) do not break the low screw(s). Break is defined as turning a fraction of a turn, where the relief of stress due to the force exerted on the screw is removed. Because of this force in order to break the screw sometimes the screw(s) are loosened too much. Just snug the screw(s), not applying more than 20 in-lbs. of torque to the screw. Continue to adjust. If more adjustment is needed, repeat this process. Continue until tilt adjustment is acceptable.

Tooling required: Refer to Section 2

5.1 Tachometer - Drawings 700A7521 sh1, 700A7521 sh2

5.1.1 Clean the mandrel shaft and the tach hollow shaft and spray with a lubricant such as WD-40.

5.1.2 Slide the tach on the mandrel shaft. The tach should freely and easily slide all the way on the mandrel to the taper.

NOTE: If the tach does not slide freely, DO NOT force the tach onto the mandrel shaft. Repeat steps 5.1. and 5.2. If tach still does not slide freely onto the mandrel, contact Carlen Controls Inc. immediately.

5.1.3 Put flat washer and nut on mandrel shaft and tighten 20-25 ft-lbs.

5.1.4 Install shaft thimble cover and tighten 10-15 ft-lbs.

Mount Tachometer following steps 5.1.1 through 5.1.3. and then proceed with Overpseed Switch Installation.

5.2.1 Mount the overspeed switch on to the coupling extension with (4) 1/4-20 x 7/8" socket head cap screws.

5.2.1.1 With the pocket flashlight, check the gap between the coupling and the 3/4-16 nut, they should not touch. If coupling is touching, remove the overspeed switch and adjust coupling on overspeed switch shaft.

5.2.1.2 With the 3mm hex key torque coupling clamp screw 18-24 in-lbs.

5.2.2 Torque 1/2" NPT brass plug 10-15 ft-lbs.

5.3.1 Mount CC290AT to the coupling extension and tighten 15-20 ft-lbs.

5.3.2 Torque coupling screw 5-8 ft-lbs.

5.3.3 Torque 1/2" NPT brass plug 10-15 ft-lbs.

700A7522 sh1, 700A7522 sh2, 700A7527

5.4.1 Refer to section 5.3. If overspeed was removed, refer to section 5.2.

6.1 Mount stabilizer bar to CC700 torque arm making sure that the insulated spacers provided are mounted on each side of the torque arm as shown in Figure 6. Torque 10-15 ft-lbs.

6.2 Mount stabilizer bar to angle bracket, not provided, with the insulated spacers mounted as shown in Drawing 700A7509.

7.1 Tachometer Supplied with Mating Connector Only

7.1.1 Reference MS connector wiring drawings72325B005 without a Z pulse, or 72325B006 with a Z pulse for wiring to MS connector mating socket, provided.

7.1.2 Screw mating connector onto bulk head connector so that approximately two threads remain visible on the bulk head connector, as shown in Drawing 700A7510.

7.2 Tachometer Supplied with Mating Connector and Cable or (JB)Junction Box Option

7.2.1 Reference 7.1.2 for proper connector mounting.

NOTE: If Tach is a (2T), (3T), or a (4T) with multiple outputs, it is extremely important to correctly identify tach bulk head connector with appropriate mating connector. Reference outline drawings that are provided with each tach.

Carlen Controls, Inc. warrants its products to be free from defects caused by faulty materials or poor workmanship for a minimum period of one year from the date of shipment from Carlen Controls.

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