Section 1 Received Condition

Section 2 Delivered Assembly

Section 3 Moving the CC770L unit while on skid

Section 4 Moving the CC770L 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 CC770L Top Hat Sensor and Connection of the CC1500L Shaft to the C & A Coupling.

Section 8 Setting Limit Switch

Section 9 Electrical Connections

Section 10 Maintenance

Section 11 Component Installation

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) 772-1737 or e-mail at carlen9.aol.com. With prior arrangements, after hour phone numbers can be provided for your convenience to assist with CC770L Installation.

The shipping package should be examined for damage and any damage found should be promptly reported to the shipping company.

The Model CC770L 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.

3.1 Before packing material is removed, skid can be moved with a forklift or crane. Make sure that the CC1500L 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 CC770L unit, after the protective packing materials have been removed.

4.1 Completely remove all packing materials, wooden crate, styrofoam, banding straps, etc., but DO NOT remove CC1500L shaft shipping cover from the end of 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 CC770L 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 CC770L unit, lift unit onto the mill stand.

NEVER move the CC770L 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.

Although the CC1500L Shaft is very resistant to damage, special care should be taken to protect the shaft from damage when moving unit to the mill stand. As noted above, DO NOT remove the shaft shipping cover until on the mill stand ready for installation. If covering is removed, DO NOT pull the shaft out from the unit. Have someone watch the shaft as the unit is moved to prevent shaft 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.

5.1 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, a 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 14 ft-lbs.

6.1 C & A coupling preparation

6.1.1 Using 1/4" hex key, loosen the coupling pressure clamp.

6.1.2 Install 3/4" diameter centering rod (provided) into C & A coupling. Push rod through coupling into coupling at least 3/4"-(19mm) reference drawing 770A1036. Jiggling the rod while pushing will aid engagement. Note the rod does not need to be completely through 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 1/4" 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 drawing 770A1036. 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 drawing 770A1037.

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) 772-1737 or e-mail at Carlen9.aol.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 CC770L Top Hat Assembly and Connection of the CC1500L Linear Transducer Shaft to the C & A Coupling. Reference Drawing 770A1020 sh.1, 770A1020 sh.2, 770A1038 sh.1 & 770A1038 sh.2

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 CC770L 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 limit switch(s).

7.3 Connecting CC1500L shaft to C & A coupling.

7.3.1 Remove the CC1500L shaft traveling cover.

7.3.2 Pull the shaft down into the C & A coupling. The shaft should go into the coupling so that there is no gap between coupling hub and the shaft. Do Not ever use anything to hit or pull on the shaft.

Note: Do Not force the shaft into the coupling hub. If the shaft does not align with the coupling hub, move the RA fixed half loosely mounted on the mill plate until the shaft can freely be pushed into hub. The (3) bolts (B-2) should be loose allowing movement of the unit.

Using 1/4" hex key, tighten both of the C & A coupling pressure clamp screws torque to 14 ft-lbs. It may be necessary to pull down or hold the shaft into position 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.

8. SETTING LIMIT SWITCHES Reference: For Limit Switch drawings 770A1040 & 770A1041

Note: The adjustments for extreme up or down limits are identical with the exception of the mill screw location for adjustments.

8.1 Rotate mill screw to lower limit and then back up to the upper limit.

8.2 Check and see that the adjustment of the main and secondary driving plate will adequately cover the range of travel for up and/or down extreme limits or both extreme limits. If no adjustment is needed continue with section 8.3

8.2.1 To adjust main and secondary drive plates, using 3/16" hex key loosen the secondary drive plate in the direction of the needed move.

8.2.2 Move the secondary plate into position and tighten screw to hold plate into position.

8.2.3 Using the 1/4" hex key, loosen the main drive plate pressure clamp and slide the plate into position and tighten the plate.

8.2.4 Using the 3/16" hex key, loosen the other secondary drive plate and move it into position.

8.2.5 Run the screw to lower limit and then back up to upper limit. Adjust plates more if needed. If plates are acceptable, torque main drive plate screw t0 14 ft-lbs, and the secondary screws to 8 ft-lbs.

8.3 Attach OHM-meter between the Common and the Normally Open contacts of the limit switch being adjusted at the terminals in the junction box., reference outline drawings supplied with the sensor.

8.4 To adjust the limit switch, use 3/16" hex key, loosen the (2) 1/4-20 socket head cap screws of the limit switch mounting plate, only 2 or 3 turns just enough so the plate can slide up and down the mounting bracket.

8.5 Move the limit switch up or down by hand until OHM-meter reads "0.00." This indicates the switch is closed.

8.6 Tighten the screws and repeat procedure for all the limit switches.

8.7 Lower and raise screw. Make sure that OHM-meter goes to "0.00" at required position.

8.8 Adjust switches if needed. If acceptable, torque screws 8 ft-lbs.

8.9 Place the top hat cover over the unit, Reference Drawings 770A1020 sh.1 & 770A1020 sh.2.

8.10 Using 5/16" hex key mount the top hat cover with (6) 3/8-16 socket head cap screws with high collar lock washers and SAE flat washers, Reference Drawings 770A1020 sh.1 & 770A1020 sh.2. Torque 20 ft-lbs.

8.11 To install a new limit switch, remove the top hat cover and using 3/16 "hex key, remove the (2) 1/4-20 screws from the limit switch mounting plate. The limit switch and the limit switch mounting plate are an integral piece, but the locking plate can be used with new limit switch.

8.11.1 Disconnect the limit switch wires from the junction box terminals.

8.11.2 Using 3/8" socket wrench loosen and remove the (4) 10-32 elastic stop nuts holding the panel to the junction box.

8.11.3 Gently pull the panel with the other wires attached to the terminals. Be careful not to damage or pull out any of the wires. It may be helpful to push on the wires from inside the RA assembly to aid in removing the panel.

8.11.4 Remove the old limit switch wires that have been disconnected by pulling them out of the junction box from inside the RA assembly and up through the RA cover plate.

8.11.5 Run the wires not striped down through the RA cover and through the conduit into the junction box and arrange the wires in a similar way as they were removed.

8.11.6 Strip the wires and connect them to the terminals.

8.11.7 Slide the panel back into the junction box by gently pulling on the wires from inside the RA assembly be careful not to damage any of the wires.

8.11.8 With socket, mount the panel into the junction box with (4) 10-32 elastic stop nuts, and tighten panel into the junction box.

8.11.9 Gently pull on the wires in the junction box to make sure they are all tight.

8.12 Readjust the limit switch per section 8.

9.1 Wires are factory installed from the junction box to the CC1500L Linear Transducer and if applicable, to the limit switch(s). The standard type of connection for the CC1500L is a sealed connector, reference CC1500L and wiring drawing provided. The CC1500L connector has a liquid tight cord connector mounted to the mating connector, which is wired to the junction box. The limit switch(s) has an integral cable molded into the switch that connects to terminals in the junction box.

The following electrical connection drawing has been included, also for reference are the CC1500L outline drawing(s) provided in the parts box, reference section 2, and limit switch drawings reference section 8.

Reference Drawing 72325B029 - CC1500L Linear Transducer HAN 10A Connector wiring

10.1 Protecting machined and non- machined surfaces

10.1.1 The CC770L 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 CC770L should be visually examined, as a minimum yearly, during regular mill maintenance inspections. If rust is present, an application of grease or alternative substance that does not affect the accuracy of the machined surfaces can be used on the parts. Do Not paint machined areas.

10.1.2 The painted areas of the CC770L sensor can be painted as needed. Do not paint any surface that was not originally painted.

11.1 CC1500L Installation - Reference Drawings 770A1042 sh.1, 770A1042 sh.2, 770A1042 sh.3 & 770A1042 sh.4

The CC1500L is factory installed and should not be removed from the sensor CC770L except to be replaced.

Note: Installing the CC1500L requires two people.

11.1.1 Raise the screw to upper maximum travel.

11.1.2 Remove the mating connector from the CC1500L.

11.1.3 Remove the removable half of the RA assembly.

11.1.4 Using 1/4" hex key loosen the (2) 5/16-18 C & A Coupling pressure clamp screws.

11.1.5 Pull out the 1.5"-(38mm) diameter CC1500L shaft from the coupling and slide it up into the CC1500L as far as it will go, but at no time FORCE or STRIKE shaft with any foreign object or tool.

11.1.6 After removing the CC1500L shaft from the coupling lower the screw at least 2"-(51mm) from the maximum up position.

11.1.7 With a screwdriver loosen the hose clamp which attaches the bellows to the CC1500L making sure bellows is loose from the CC1500L tubing.

11.1.8 Using a 3/16" hex key, loosen and remove the lower secondary drive plate.

11.1.9 Using a 1/4" hex key, loosen and remove the main drive plate from the CC1500L shaft.

11.1.10 With someone holding onto the CC1500L sensor use a 1/4" hex key and loosen the (2) 5/16 mounting stand pressure clamp screws, and gently pull the CC1500L from the coupling.

11.1.11 Slide the CC1500L down towards the mill screw. After lowering, angle the sensor to the connector side to clear the mounting stand and pull it up and out from the mounting stand. As one person pulls the sensor out the other can make sure the bellows comes off the CC1500L tubing.

11.1.12 To install the new CC1500L follow the removal instructions in reverse from 11.1.11 to 11.1.1. Torque 5/16-18 mounting stand pressure clamp and main drive plate clamp to 14 ft-lbs, and the secondary drive plates 1/4-20 hardware to 8 ft-lbs, and follow instruction in section 7 for mounting to C & A Coupling, and section 8 for limit switch(s)

11.1.13 Connect mating connector to CC1500L

11.1.14 Install RA assembly removable half per section 7 and top hat cover per section 8.

Note: After removing CC1500L from the mill stand, the inside electronics can be replaced. For this operation, reference CC1500L Electronics Module Replacement Instructions. It is advised that the CC1500L be returned to CCI 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 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.

11.2 Limit Switch Mounting Bracket Installation - reference drawing 770A1044

11.2.1 Using 3/16'" hex key remove the limit switch(s).

11.2.2 Using (2) 7/16" wrenches or adjustable wrenches remove the (5) hex bolts and elastic stop nuts and remove the bracket.

Note: There will be only one bracket if there are only one or two limit switches and two brackets with three or four limit switches. Both left and right side brackets are the same.

11.2.3 Put new bracket into place and mount with all (5) bolts.

11.2.4 Install and adjust limit switches per section 8.

11.3 Limit Switch Strike Plate Rod Installation - reference drawing 770A1044

11.3.1 Raise mill screw to approximately maximum up position.

11.3.2 Remove the RA assembly removable half and top hat cover per section 7 reference drawings 770A1020 sh.1 & 770A1020 sh.2.

11.3.3 Using 3/16" hex key, loosen both of the secondary drive plates and remove the lower plate from the rod reference drawing 770A1041.

11.3.4 Using 3/16" hex key remove the limit switch striker plate reference drawing 770A1040.

11.3.5 With someone holding onto the upper secondary drive plate to make sure the striker rod slides freely through and to remove the plate when it becomes unattached from the rod, pull the striker rod straight up through the linear bearing.

11.3.6 Gently push the new rod down through the linear bearing and slide the upper secondary drive plate onto the shaft through the linear bearing and the lower plate when rod is past the main drive plate.

11.3.7 Install the limit switch striker plate and adjust limit switch per section 8.

11.3.8 Install RA assembly removable half and top hat cover.

11.4 Linear Bearing Installation - reference drawing 770A1044

11.4.1 Follow instruction 11.3.1 through 11.3.5.

11.4.2 Using (2) 7/16" wrenches or adjustable wrenches remove the (4) hex bolts and elastic stop nuts and remove the linear bearing.

11.4.3 Mount the new linear bearing with all (4) bolts.

11.4.4 Follow instruction 11.3.6 through 11.3.8.

11.5 Mounting Stand Installation - reference drawing 770A1039

Note: The CC1500L should be removed before removing the mounting stand. To remove the CC1500L reference section 11.1.

11.5.1 Remove the CC1500L from the mill screw and the mounting stand per section 11.1.

11.5.2 Remove the limit switch(s) from the limit switch mounting bracket per section 8.11.

11.5.3 Using 1/4" hex key remove the (8) screws (F) attaching the mounting stand to the RA assembly cover plate and remove the mounting stand.

11.5.4 Put the new mounting stand into position and torque the (8) screws to 20 ft-lbs.

11.5.5 Install the CC1500L per section 11.1 and mounting and adjust the limit switch(s) per section 8.

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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