CC770R (TOP HAT) SENSOR
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Section 1 Received Condition
Section 2 Delivered Assembly
Section 3 Moving the CC770R unit while on skid
Section 4 Moving the CC770R unit off the skid
Section 5 Adapter Plate and C & A Coupling Installation
Section 6 Centering of the C & A Coupling
Section 7 Installation of the CC770R Top Hat Sensor and Connection of the Spline Shaft to the C & A Coupling.
Section 8 Setting Limit Switch
Section 9 Electrical Connections
Section 10 Maintenance
Section 11 Spline Shaft and Component Installation
With prior arrangement after hour phone numbers can be provided for your convenience to assist with CC770R Installation.
1. RECEIVED CONDITION
The shipping package should be examined for damage and any damage found should be promptly reported to the shipping company.
2. DELIVERED ASSEMBLY
The Model CC770R unit will be shipped entirely assembled, with the exception of the Centering and Alignment coupling (C & A coupling) assembly and the mounting hardware. The C & A coupling will be labeled and individually packaged. Also included in a marked package are these instructions and all necessary drawings for installation. Keep all information with the units until completely installed.
3. MOVING MODEL CC770R UNIT WHILE ON SKID
3.1 Before packing material is removed, skid can be moved with a forklift or crane. Make sure that the spline shaft has not come loose during shipment because it can be damaged when moving by one of these methods.
3.2 If packing material and banding material have been removed, the skid can only be moved by a forklift - DO NOT LIFT BY CRANE. Use extra care in moving the Model CC770R unit after the protective packing materials have been removed.
4. MOVING MODEL CC770R UNIT OFF OF SKID
4.1 Completely remove all packing materials, wooden crate, styrofoam, banding straps, etc., but DO NOT remove spline shaft shipping cover from either end of spline shaft until the unit is on the mill.
4.2 Remove the C & A coupling assembly and hardware from the box strapped to the pallet. Separate the CC770R from the mill plate if applicable or remove the (4) lag screws holding the unit to the skid.
Note: The mill plate is an optional item. If applicable, reference included drawings. The mill plate(s) may be shipped on a separate skid.
4.3 Using chain(s) and the two eyebolts on the top of the CC770R unit, lift unit onto the mill stand.
NEVER move the CC770R unit by the eyebolts with the mill plate attached.
To lift the unit with the mill plate, if applicable, mount chain(s) using the mill plate through holes.
Special care is required to protect the spline from damage. As noted above, DO NOT remove the spline shaft shipping cover until on the mill stand ready for installation. If covering is removed, DO NOT remove spline shaft from the unit. Have someone watch the spline as the unit is moved to prevent spline from being caught on anything. If the unit has to be set down before moving to the mill stand, elevate the unit, for example on wooden blocks.
5. MODEL CC770R ADAPTER PLATE and C & A COUPLING INSTALLATION
Reference drawing 770A1021 dwg. 1, and 770A1021 dwg. 2
5.1 Preparation for installation.
5.1.1 Move mill screw to upper maximum stroke position.
5.1.2 Remove existing mill plate (mill screw cover plate).
5.1.3 Prepare the mill screw by removing any dirt, debris, burrs or other protrusions from the area where the adapter plate will come in contact with the mill screw. A wire wheel, wire brush, sandpaper, and files are tools needed for this procedure.
5.2 Adapter plate with C & A coupling installation
5.2.1 Using 1/4" hex key, remove the (4) 5/16-18 socket head cap screws that mount the C & A coupling base plate to the adapter plate.
5.2.2 Locate the adapter plate on the center of the mill screw, and mount with the hardware provided.
Note: For center hole single bolt mounted adapter plates continue with section 5.2.3 for dowel pin installation. For multi-screw adapter plates, dowel pins are optional. If not using dowel pins continue with section 5.2.5.
5.2.3 The following method is suggested for installing dowel pins to insure proper alignment during future assembly. Drill (2) holes progressively to 3/8" diameter, reference applicable drawing provided for the (2) holes factory drilled in the adapter plate. Progressively drill - start with 1/4" diameter drill and drill hole. Then use 5/16" diameter drill and repeat. Then use 3/8" diameter drill and repeat. This will give the 3/8" diameter dowel pin a tight fit. Reaming is acceptable, but not necessary because it is not required that the dowel pins have a press fit, just a snug fit.
Note: With a magnet or vacuum immediately remove from the mill screw all metal chips. DO NOT LET ANY CHIPS FALL INTO MILL SCREW AREA.
5.2.4 Insert the 3/8" x 1" dowel pins (provided) into each hole. Tap firmly in, but do not mushroom or flatten the end of the dowel pin. The dowel pins must be flush or below the adapter plate surface. A rod or center punch can be used to push the dowel pins below the surface. If dowel pins are NOT flush or below the surface, remove and repeat section 5.2.3.
5.2.5 Locate the C & A base plate with coupling counterbore onto the adapter plate pilot. Using 1/4" hex key, mount (4) 5/16-18 socket head cap screws, torque 10-15 ft-lbs.
6. C & A COUPLING CENTERING
6.1 C & A coupling preparation
6.1.1 Using 3/16" hex key, loosen the coupling collar clamp.
6.1.2 Install 1/2" diameter centering rod (provided) into C & A coupling. Push rod through coupling into hole drilled in mounting plate, reference drawing770A1022 and 770A1022Jiggling the rod while pushing will aid engagement into the hole. Note the rod only needs to be engaged into the mounting plate hole; it does not need to be completely through the mounting plate. This will for alignment purposes, eliminate the flexibility of the coupling. The rod should be rigid. Check by trying to move the rod from side to side. If rod is not rigid repeat procedure.
6.1.3 Using 3/16" hex key, lightly tighten the coupling collar clamp.
6.1.4 Lower mill screw approximately 2" to 3" from upper position.
6.1.5 Put dial indicator about 1/2" to 1" from the top of the rod, reference drawing770A1023 Set the indicator to zero and mark the end of the rod with a marker at the point of contact with the indicator.
6.1.6 Rotate the screw 1 turn (360 degrees) up. Note the indicator readings at 90, 180, 270 and 360 degrees. Note (+/-) for these reading. For the alignment procedure, section 6.3, identify (+) as the centering rod moving towards the dial indicator, reference drawing770A1023.
6.1.7 Then rotate the screw 1 turn (360 degrees) down. Note the indicator readings at positions relative to the first set of readings. Note (+/-) for these readings.
6.2 Alignment tolerances and screw float defined
6.2.1 The objective is to align the C & A coupling to an acceptable tolerance of +/- 0.020"(0.51mm). However, because of screw wear and design, there is a screw float condition that has to be figured into the alignment procedure. The following are some screw float conditions and how these affect centering. Please address any questions or problems immediately to CCI before continuing with installation.
6.2.2 If initial set of readings when rotating the screw up are the same as when rotated back down, there is no apparent screw float. If readings are no greater than +/- 0.020"(51mm), then alignment is acceptable continue with section 7, but if alignment is required continue with section 6.3.
6.2.3 If when rotated up 360 degrees the indicator is different from the initial zero reading, but when rotated back down 360 degrees the reading returns to zero, there is screw float. For example, if the initial reading is zero, but when rotated 360 degrees the reading is (+ or -) 0.016"(0.40mm), the screw float is 0.016"(0.40mm). The acceptable tolerance with allowance for screw float is +/-0.020"(0.51mm) plus half of the screw float 0.008"(0.20mm) which equals +/- 0.028"(0.71mm). If after determining screw float the alignment is acceptable, continue with section 7, but if alignment is required, continue with section 6.3.
6.2.4 If when rotated up 360 degrees the indicator is different from the initial zero reading, and when rotated back down 360 degrees the reading is different than the initial zero reading, there is screw float. For example, if the initial reading is zero, but when rotated 360 degrees the reading is +0.008"(0.20mm), and when returned to the initial position the reading is (-) 0.010"(0.25mm), the screw float is 0.008"(0.20mm) plus 0.010"(0.25mm) which equals 0.018"(0.45mm). The amended acceptable tolerance is +/- 0.020"(0.51mm) plus half of the screw float 0.009"(0.23mm) = +/- 0.029"(0.74mm). Or if the readings were (+) 0.016"(40mm) and (+)0.008"(0.20mm), the screw float would be 0.016"(0.40mm) minus 0.008"(0.20mm) = 0.008"(0.20mm). The amended acceptable tolerance would be +/- 0.024"(0.61mm). If after determining the screw float alignment is acceptable, continue with section 7, but if alignment is required, continue with section 6.3.
Note: Screw float is very difficult to work with because the screw position varies from rotation to rotation, and therefore the dial indicator readings keep varying during the alignment procedure. It is important to do the best possible alignment within the tolerances specified. Because of the nature of all screws to be different, CCI continues to accumulate data on mill screws. If there are any questions or concerns with the installation, please contact Carlen Controls, Monday through Friday from 8:00am to 5:00pm at (540) 772-1736, or fax at (540) 7720-1737 or e-mail at email@example.com. With prior arrangement after hour phone numbers can be provided for your convenience.
6.3 C & A coupling alignment procedure
6.3.1 Rotate the screw one turn up and determine the greatest high or the (+), as defined in section 6.1.5.
Note: One complete revolution, 360 degrees, of the adjusting vernier set screw is approximately 0.042"(1.1mm) of linear movement, with 10 degrees approx. 0.001"(0.03mm).
Note: The adjusting vernier set screws have a nylox insert, so it will require some torque to loosen or drive the screws.
6.3.2 Using 3/16" hex key, loosen the adjusting vernier set screw opposite the high (+). If this is between (2) set screws, adjust the axis with the greatest difference first then continue with the other axis. Only loosen the set screw for half of the total difference. Then drive the high (+) side set screw as far as it will go.
Note: Make sure when complete that all set screws are screwed in as far as possible. If not, misalignment can occur.
6.3.3 Continue alignment procedure for each axis until acceptable tolerances specified in section 6.2 is attained.
6.3.4 Using 3/16" hex key, loosen collar clamp and remove centering rod.
7. Installation of the CC770R Top Hat Assembly and Connection of the Spline Shaft to the C & A Coupling. Reference drawings 770A1020 dwg.1, 770A1024, & 770A1025
7.1 Clean mill stand and new or modified mill plate surfaces mounting.
7.1.1 Bolt mill plate to mill stand, hardware not provided.
7.1.2 Clean mill plate and removable assembly (RA) surfaces for mounting.
7.2 Move the CC770R assembly onto the mill plate.
7.2.1 Bolt the RA stationary half, the one with the junction box, to the mill plate with 1/2-13 bolts (B-2) provided. Leave bolts 1-2 turns from tight.
7.2.2 Remove the (4) bolts (A) and (3) bolts (B-1) from the RA removable half, and slide this half out for access to the mill screw. If there is trouble removing the removable half, push on the top hat cover. If still unable to move half, loosen the (3) bolts (B-2) and push on cover until able to remove half.
7.2.3 Using 5/16" hex key, remove the (6) 3/8-16 socket head cap screws (E) and remove the top hat cover. Take care not to strike the spline shaft, sensor or limit switch.
7.3 Connecting spline shaft to C & A coupling.
7.3.1 Remove upper and lower spline shaft traveling cover.
7.3.2 Push spline shaft down into the C & A coupling. Spline shaft should go into the coupling so that there is no gap between coupling hub and spline shaft. Do Not ever use anything to hit the spline shaft.
Note: Do Not force the shaft into the coupling hub. If the spline shaft does not align with the coupling hub, move the RA fixed half loosely mounted on the mill plate until spline shaft can freely be pushed into hub. The (3) bolts (B-2) should be loose allowing movement of the unit.
7.3.3 Torque C & A coupling collar clamp 12-16 ft-lbs. Do Not push down on the spline shaft when tightening.
7.3.4 Reassemble the RA removable half back into place, mount the hardware, and torque to a minimum of 25 ft-lbs.
7.4 Gear box location.
7.4.1 Using 5/16" hex key, loosen the (8) 3/8-16 socket head cap screws (F) that mount the gear box to the RA cover plate, and return to finger tight, so gear box can move.
7.4.2 Rotate the mill screw to lower maximum stroke, then back to upper maximum stroke. This will center the gear.
7.4.3 Progressively tighten the (8) (F) screws. Go around the rectangular pattern tightening each a little at a time until finally torqued to 20-25 ft-lbs.
7.5 If limit switch is not included continue with section 9.
8. SETTING LIMIT SWITCHES - Reference:
For (2) CAM Limit Switch drawings 770A1026
For (3) CAM Limit Switch drawings 770A1027
For (4) CAM Limit Switch drawings 770A1028
8.1 Rotate mill screw to upper or lower limit.
8.2 For NEMA 11 limit switch remove (4) slotted screws or for NEMA 4 limit switch use 3/16" hex key and remove (4) socket head cap screws and remove limit switch cover.
8.3 For (2) CAM limit switch attach OHM-meter between COMM and NORM OPEN of micro switch "1", or to designated terminals in the junction box reference outline drawings supplied with sensor. For (3) and (4) CAM limit switches attach OHM-meter between the N.O. and N.O. points of micro switch "1", or to designated terminals in the junction box reference outline drawings supplied with sensor.
8.4 Pull out hex key that is inserted into the limit switch rear wall next to the micro switch. This hex key is to adjust the cams.
8.5 Insert the hex key into hole "B" in cam hub and loosen the screw. This will release CAM "A" to rotate for adjustment.
8.6 Rotate CAM "B" by hand until OHM-meter reads "0.00." This should be accompanied by a click that indicates the switch is closed.
8.7 Tighten screw "B".
8.8 Lower and raise screw. Make sure that OHM-meter goes to "0.00" at required position.
8.9 Continue to set remaining switches per section 8.1 through 8.8.
8.10 Return hex hey inside limit switch.
8.11 Install cover onto limit switch.
8.12 Place the top hat cover over unit, reference dwg.770A1020 dwg. 1. Be careful not to hit spline shaft. If the spline shaft is hit, remove cover and inspect shaft for damage. If damaged, replace with spare shaft, reference section 11.1 for spline shaft replacement.
8.13 Using 5/16" hex key, mount top hat cover with (6) 3/8-16 socket head cap screws (E), reference dwg770A1020 dwg. 2. Torque 20-25 ft-lbs.
9. ELECTRICAL CONNECTIONS
9.1 Wires are factory installed from the junction box to the CC3820R resolver and, if applicable, to the limit switch. The type of connections for the CC3820R are specified by customer requirements. The standard types of connections are conduit connection or sealed MS connector, reference CC3820R drawings provided. The (2) and (3) CAM limit switches use a sealed MS connector, and the (4) CAM limit switch is wired from junction box directly to micro switches.
The following electrical connections drawings have been included, also for reference are the CC3820R outline drawings provided in the parts box, reference section 2, and limit switch drawings reference section 9.
72325B019- CC3820R Dual Resolver Conduit Wiring
72325B023 - CC3820R Dual Resolver MS Connector Wiring for CC770R
72325B024 - Limit Switch terminations for (2) CAM with MS Connector
72325B025 - Limit Switch terminations for (3) CAM with MS Connector
IMPORTANT LUBRICATION INFORMATION - PLEASE READ
LUBRICATION FOR THE SPLINE SHAFT MUST BE INSTALLED AT TIME OF INSTALLATION OF THE CC770R TOP HAT SENSOR.
10.1 Spline Shaft Lubrication - reference drawing 770A0020-E
10.1.1 In the center of the RA assembly fixed half there is a 1/4" NPT female fitting with a square head plug. Remove the plug.
10.1.2 Connect this 1/4" female NPT to an automatic Grease or Oil system at the time of installation. The grease or oil that is being used to lubricate the mill screw is acceptable for the spline shaft.
Grease flow rate is approximately 1 oz./hr. or 30 cm3/hr.
Oil should be a continuous flow
Note: An excess of grease or oil is not damaging to the CC770R sensor.
If there are any questions or problems completing this requirement, please contact CCI immediately.
10.2 Manual lubrication of upper chamber of the antibacklash spline coupling - Reference drawing 770A0020-E
10.2.1 On removing the RA assembly removable half there is the union and tubing for the automatic lubrication system and above this towards the RA cover plate there is a standard grease fitting. The upper chamber has been filled with grease prior to shipment, unless specifically requested by the customer. This is a preventative action to stop moisture from getting into the gear box area of the sensor. It is not absolutely necessary to have grease in this chamber, but is recommended. The initial grease used by CCI is a AP-5, NLGI Grade 2 water resistant, non-melting, high temperature grease containing microfine molybdeenum disulfide, but mill screw grease is acceptable. As a minimum, this chamber should be filled yearly, but can be filled more often as needed on a regular maintenance schedule. The upper chamber can be connected to the automatic lubrication system.
10.3 Manual lubrication of the gear box - reference drawing 770A0020-E
10.3.1 The gear box has been filled with grease prior to shipment. This is a necessary action which helps seal the gear box from outside contaminants. It is recommended as a minimum this chamber should be filled yearly, but can be filled as often as needed on a regular maintenance schedule. The initial grease used by CCI with the unit is a AP-5, NLGI Grade 2 water resistant, non-melting, high temperature grease containing microfine molybdeenum disulfide, but mill screw grease is acceptable. The standard grease fitting is located on the side of the gear box. Pump grease into gear box until the grease starts coming out through the spline shaft exit. Grease is acceptable in this area, and does not need to be removed.
10.4 Protecting machined and non- machined surfaces
10.4.1 The CC770R although ruggedly designed for mill duty is a sensitive measuring instrument. To maintain accuracy, there are parts of the sensor that have been machined to close tolerance and are not protected by paint. These surfaces have been coated with a layer of grease prior to shipment. In most cases these surfaces are in contact with other machined surfaces and rusting is prevented.
The CC770R while undergoing regular maintenance, ie. 10.3, should be examined. If rust is present, an application of grease or alternative substance can be used on the parts. Do Not paint machined areas.
10.4.2 The spline shaft is stainless steel, but may react to certain chemicals in the milling process. Within the working range and below the shaft is protected by the automatic lubrication system, but above this the shaft is exposed. This is a section of the shaft that does not get used, and it 's protection is important, but not critical to the function of the sensor. The spline shaft has been lubricated both with a penetrating molykote oil and coated with grease. If at regular maintenance the shaft is showing signs of chemical damage, apply grease or alternative substance to the shaft, and institute this procedure at standard regular maintenance.
10.4.3 The painted areas of the CC770R sensor can be painted as needed. Do not paint any surface that was not originally painted.
11. SPLINE SHAFT and COMPONENT INSTALLATION
11.1 Spline shaft installation - reference drawing 770A1029
The spline shaft is factory installed and should not be removed from the sensor except to be replaced.
Note: Installing the spline shaft can be done with one person, but is easier for two people.
11.1.1 Insert the spline shaft through the gear box shaft and mesh with internal spline nut of the anti-backlash spline coupling (ABS coupling.) The spline shaft may needed to be rotated slight to align the grooves of the splines together, and may need to be gently pushed through into the spline nut. The spline will not go complete through the ABS coupling, so DO NOT force, hammer or bang spline shaft.
11.1.2 Insert the spline shaft piece, approximately 4" to 6" long, provided by CCI through the grease ring, if mounted on removable assembly or in the ABS coupling if not mounted. Mesh the spline shaft piece into the internal spline nut of the ABS coupling, approximately 1.65"- 42mm from the grease ring.
11.1.3 Rotate the spline shaft piece with the pliers and gently push down on the spline shaft through the gear box. When the two internal spline nuts of the ABS coupling mate, the spline shaft will slide through, and the piece being rotated will push out. This rotation will be approximately 5 to 15 degrees. DO NOT force, hammer or bang the spline shaft. If there is a problem inserting the spline shaft, call CCI.
11.1.4 After inserting spline shaft continue to connect to C & A coupling per section 7.3
11.2 Limit switch and CC3820R resolver installation to or removal from gear box - reference drawing 770A1030 dwg. 1 and 770A1030 dwg. 2
Note: For more information on CC3820R installation to or removal from gear box reference CC45P flange installation instruction (R106).
11.2.1 With 3/8" hex key, remove one or both of the 1/2" NPT brass socket plugs.
11.2.2 With 3mm hex key or ball driver, loosen the coupling collar closest to the gear box. Do Not remove the coupling screw.
11.2.3 With 3/16" hex key, remove the (4) 1/4-20 socket head cap screws mounting the flange to the gear box.
Note: Drawing 770A1030 sheet 2 and R106 for alternative CC3820R installation to or removal from gear box.
11.2.4 Gently pull the device from the gear box turning slightly.
11.2.5 To install limit switch or CC3820R reverse above steps following torque requirements of R106.
11.3 Gear box component installation to or removal from removable assembly (RA) cover plate box - reference drawings 770A1025 , 770A1031 dwg. 1 & 770A1031 dwg. 2
Note: The gear box can be removed from the RA cover with or without CC3820R and limit switch mounted to the gear box and the spline shaft installed. If shipping to CCI, only ship the gear box.
11.3.1 Using 3/16" hex key, loosen the C & A coupling collar clamp screw. Do not remove the screw from the collar.
11.3.2 Remove the spline shaft from the coupling by holding down on coupling and pulling up gently and turning on the spline shaft.
Note: The spline shaft can be removed prior to removing the gear box. It should be wrapped in a clean towel and placed in an area to prevent any damage.
11.3.3 Using 5/16" hex key, remove the (8) 3/8 socket head cap screws mounting the gear box to the RA cover plate.
11.3.4 Pull the gear box straight up from the RA cover plate. The gear box and the anti-backlash spline coupling will come up as one part. They are an integral component and should not be separated.
11.3.5 A new gear box can be installed. Install the spline shaft prior to installing gear box reference section 11.1.
11.3.6 Install the gear box with ABS coupling onto RA cover plate.
11.3.7 Using 5/16" hex key loosely mount the (8) 3/8 socket head cap screws mounting the gear box to the RA cover plate
11.3.8 Mount the spline shaft to the C & A coupling per section 7.3.
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.
This warranty does not cover defects or damages caused by service or repair performed by anyone other than Carlen Controls. Do not attempt to open covers or housings where fasteners have been sealed.
Carlen Controls’ liability is limited to replacing, repairing or issuing credit at its option, for any products which are returned by the original purchaser during the warranty period. Carlen Controls makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, whether or not such use or purpose has been disclosed to Carlen Controls in specifications or drawings previously or subsequently provided, or whether or not Carlen Controls’ products are specifically designed and/or manufactured for the buyer’s use or purpose. Carlen Controls’ liability on any claim for loss or damage arising out of the sale, resale or use of any of its products shall in no event exceed the selling price of the unit.
Carlen Controls warranty covers only products manufactured by Carlen Controls. Products used in conjunction with Carlen Controls products but supplied by another manufacturer; such as Inland Motors’ tachometer and Hubbell overspeed switches, are covered by original manufacturer’s warranty.
Return Products Procedure
No products may be returned, whether in warranty or out of warranty, without first obtaining approval from Carlen Controls. Any returned product (s) must be accompanied by a return authorization number. Products must be returned, prepaid, to Carlen Controls (no COD or Collect Freight accepted). The status of any product returned later than (3) days after the issuance of a return authorization number will be subject to review.
Returned Product Warranty Determination
After Carlen Controls’ examination, warranty or out-of-warranty status will be determined. If upon examination a warranted defect exists, then the product (s) will be repaired at no charge and shipped, prepaid, back to the buyer.
Return Product Non-Warranty Determination
After Carlen Controls’ examination, the buyer shall be notified of the repair cost. At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight, or authorize the product (s) to be shipped back as is, at the buyer’s expense. Failure to obtain a purchase order number or approval within (30) days of the notification will result in the product(s) being returned as is, at the buyer’s expense.
At times, the buyer may desire to expedite a repair. Regardless of warranty or out-of-warranty status, the buyer must issue a valid purchase order to cover the added rush cost service. Rush service is subject to Carlen Controls’ approval.
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