CC1500L LINEAR POSITON (CYLINDER) TRANSDUCER

ELECTRONICS MOUDULE

Section 1 Received Condition

Section 2 Delivered Assembly

Section 3 Model CC1500L Disassembly Instructions

Section 4 Removing & Installation of Electronics Module

Section 5 Assembly of Model CC1500L

Note: It is advised that the CC1500L be returned for repair. Once the seals of the sensor are broken CCI is no longer responsible for warranty of the unit. CCI can guarantee it's own work, but can not be held responsible for others work. Therefore, the option to change out the electronics module is available with the understanding that the party doing the work becomes totally responsible for the sensor.

1. RECEIVED CONDITION

The Electronics Module for the CC1500L is shipped packaged with an outer and inner packaging material. The packaging should be examined for damage and any damage found should be promptly reported to the shipping company. The outer material can be removed, but DO NOT remove the module from the inner protective packaging until ready to install into the cylinder.

The CC1500L sensor should only be disassembled in a CLEAN environment. After removing the CC1500L sensor from the machine, the cylinder is to be taken to a clean room where cylinder can be disassembled and new electronics module installed. A clean room is defined as an area away from dirt, grease, and other contaminants that can damage the sensor. Disassembling the sensor at the machine or in area with contaminants can cause irreparable damage.

MODEL CC1500L DISASSEMBLY INSTRUCTIONS

Reference drawings 1500A0100 sh.1, 1500A0100 sh.2, 1500A0101, 1500A0102 & 72325B029P

Note: It is advised that the CC1500L be returned for repair. Once the seals of the sensor are broken CCI is no longer responsible for warranty of the unit. CCI can guarantee it's own work, but can not be held responsible for others work. Therefore, the option to change out the electronics module is available with the understanding that the party doing the work becomes totally responsible for the sensor.

3.1 Using 3/16" hex key, remove the (3) 1/4-20 socket head cap screws and remove the CC1500L cover plate, reference drawings 1500A0100 sh.1, & 1500A0100 sh.2

Note: Visually one will see wires loosely wrapped around the electronics module connected to the HAN 10A connector and (3) 1/4-20 socket head cap screws which mount the electronics module to the cylinder flange.

3.2 Using a screwdriver, loosen the (4) screws of the HAN 10A connector insert and gently pull the insert out from the panel guiding the wiring from inside the tubing housing, reference drawing 1500A0101.

3.3 Using a screwdriver, loosen the HAN 10A connector's wire locking screws and gently pull the wires and ferrules out from the insert, reference drawing 72325B029P.

Note: It is important when installing the wires back into the connector that new ferrules be used. The ferrules will decrease the chance for loose wires. If not supplied, use adequate ferrules for 24 AWG wires.

3.4 After removing wires from the connector, slide them back into the cylinder tubing body.

3.5 Using 3/16" hex key, remove the (3) 1/4-20 socket head cap screws and remove the CC1500L tubing body from the cylinder flange, reference drawing 1500A0102.

REMOVING and INSTALLATION of CC1500L ELECTRONICS MODULE

Reference drawings 1500A0100 sh.1, 1500A0100 sh.2, 1500A0103 & 1500A0104

Note: DO NOT remove new electronics module from protective packing material until ready to mount to cylinder.

4.1 Using 3/16" hex key, remove the (3) 1/4-20 socket head cap screws with high collar lock washer holding the electronics module mounting plate to the cylinder flange.

Note: There are (3) 1/4-20 tapped holes in the mounting plate. If the electronics module sticks in the counter bore, use these holes with the (3) socket head screws just removed as jacking screws to free the mounting plate.

4.2 Gently slide the module out of the cylinder. DO NOT BANG, PRY, or BEND the module as this can cause irreparable damage.

Note: There is protective tubing mounted in the cylinder push rod. This is just placed in the push rod and can slide freely in and out. It needs to remain in the push rod, but may and can slide out of the push rod when removing the module. If it comes out, just slide it back into the push rod. DO NOT remove the tubing from the CC1500L.

4.3 Immediately after removing the electronics module from the cylinder place in a protective cover for example a clean towel or something to protect the reading rod. After installing the new module, the removed module can be packaged in that same protective packaging.

4.4 Remove the electronics module mounting plate by using a 1.75" wrench or adjustable wrench to hold the module and with a 1.125" wrench or adjustable wrench remove the 3/4-16 nut. Carefully slide the nut and the mounting plate over the reading rod.

4.5 Remove the new electronics module from the packaging material.

4.6 Carefully slide the mounting plate and the 3/4-16 nut into position.

Note: When mounting the 3/4-16 nut, use an anti-vibration, removable adhesive such as Loctite 290 or equivalent.

4.7 Tighten the 3/4-16 nut against the mounting plate.

4.8 Clean the cylinder flange counter bore surface and the electronic module mounting plate.

4.9 Carefully slide the electronics module with mounting plate into the nylon tubing and the cylinder.

4.10 Using 3/16" hex key mount the mounting plate to the cylinder flange with (3) 1/4-20 socket head cap screws and high collar lock washers, torque to 8 ft-lbs.

5. ASSEMBLY of MODEL CC1500L

Reference drawings 1500A0100 sh.1, 1500A0100 sh.2, 1500A0101, 1500A0102 & 72325B029P

5.1 Clean the cylinder flange and the tubing body mating surfaces.

5.2 Using 3/16" hex key mount the tubing body cylinder flange with (3) 1/4-20 socket head cap screws, torque to 8 ft-lbs.

5.3 Connect wires from the electronics module to the HAN 10A connector with new ferrules, reference drawing 72325B029P. Tighten the locking screws, and give a gentle pull on each wire.

Note: It is important when installing the wires into the connector that new ferrules be used. The ferrules will decrease the chance for loose wires. If not supplied, use adequate ferrules for 24 AWG wires.

5.4 Using screwdriver mount insert into the HAN 10A panel make sure to wrap the wires gently around the electronics module in the same way as the module that was removed.

5.5 Clean the cover plate and the tubing body mating surfaces.

5.6 Using 3/16" hex key mount the cover plate to the tubing body with (3) 1/4-20 socket head cap screws, torque to 8 ft-lbs.

5.7 CC1500L Linear Position Transducer is now ready to mount on the machine. Reference proper installation instruction for application.

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.

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.

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.

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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