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Summary of Contents for Aerotech CCS Series
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Page 1: Ccs Hardware Manual
CCS Hardware Manual Revision: 1.03.00... - Page 2 This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies.
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Page 3: Table Of Contents
4.3.2. Ringseal O-Ring Replacement (CCS130DR-160 with -WCUT option only) 4.3.3. Wet Cut Rotary Union Seal Replacement (CCS130DR-160 with -WCUT option only) 4.4. Wet Cut Rotary Union Removal 4.5. Wet Cut Maintenance (CCS190DR-240-3C and CCS190DR-260-5C) 4.6. Troubleshooting Appendix A: Warranty and Field Service Appendix B: Revision History Index www.aerotech.com... -
Page 4: List Of Figures
Table of Contents CCS Hardware Manual List of Figures Figure 1-1: CCS Series Rotary Stage Figure 2-1: CCS130DR-160 Dimensions Figure 2-2: CCS190DR-240-3C Dimensions Figure 2-3: CCS190DR-260-5C Dimensions Figure 2-4: Mounting Hole Locations Figure 2-5: CCS130DR-160 Wet Cut Rotary Union Location... -
Page 5: List Of Tables
Table 1-1: CCS130 Model Numbering System Table 1-2: CCS190 Model Numbering System Table 1-3: Environmental Specifications Table 1-4: CCS Series Specifications Table 2-1: Stage to Mounting Surface Hardware Table 3-1: Motor Connector Pinout Table 3-2: Feedback Connector Pinout Table 3-3:... -
Page 6: Safety Procedures And Warnings
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual’s release. -
Page 7: Eu Declaration Of Incorporation
CCS Hardware Manual Table of Contents EU Declaration of Incorporation Manufacturer: Aerotech, Inc. 101 Zeta Drive Pittsburgh, PA 15238-2811 herewith declares that the product: CCS Stage is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006/42/EC as amended;... - Page 8 Table of Contents CCS Hardware Manual This page intentionally left blank. www.aerotech.com...
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Page 9: Chapter 1: Overview
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual’s release. -
Page 10: Table 1-1: Ccs130 Model Numbering System
Note: -WCUT option requires a wet-cut seal with O-ring matched to a specific tube diameter Accessories (To be Ordered as a Separate Line Item) Collet-D-CLTxxx Collet, Type-D; consult Aerotech for available sizes RingSeal-D-RSxx Ring seal; Type-D collet chuck Collet and gripper filtration kit... -
Page 11: Environmental Specifications
Indoor use only 1.2. Accuracy and Temperature Effects Aerotech products are designed for and built in a 20°C (68°F) environment. Extreme temperature changes could cause a decrease in performance or permanent damage to the CCS. At a minimum, the environmental temperature must be controlled to within 0.25ºC per 24 hours to ensure the CCS specifications are... -
Page 12: Basic Specifications
3. Dry-Cutting (no ring seal installed) on a system with the -WCUT option limits tube size to 6.7 mm. Wet-cutting (ring-seal required and installed) on a system with the -WCUT option limits tube size to 3.0 mm. 4. Maximum loads are mutually exclusive. Loading limits are due to the collet chuck mechanism. Contact Aerotech directly if part load requirement exceeds specifications. -
Page 13: Chapter 2: Mechanical Specifications And Installation
Aerotech. Use compressed nitrogen or clean, dry, oil-less air to remove any dust or debris that has collected during shipping. -
Page 14: Dimensions
CCS Hardware Manual 2.2. Dimensions N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual’s release. -
Page 15: Figure 2-2: Ccs190Dr-240-3C Dimensions
CCS Hardware Manual Assembly and Installation Figure 2-2: CCS190DR-240-3C Dimensions www.aerotech.com Chapter 2... -
Page 16: Figure 2-3: Ccs190Dr-260-5C Dimensions
Assembly and Installation CCS Hardware Manual Figure 2-3: CCS190DR-260-5C Dimensions Chapter 2 www.aerotech.com... -
Page 17: Securing The Stage To The Mounting Surface
N O T E : To maintain accuracy, the mounting surface must be flat to within 1 µm per 50 mm. CCS series stages have a fixed mounting pattern (as shown in Figure 2-4). -
Page 18: Figure 2-4: Mounting Hole Locations
Assembly and Installation CCS Hardware Manual Figure 2-4: Mounting Hole Locations Chapter 2 www.aerotech.com... -
Page 19: Load Capability
To prevent damage or performance degradation of the stage, the unsupported length and weight of the attached pressure vessel is limited. N O T E : Aerotech recommends the following limitations on the size and weight of an unsupported pressure vessel: Length past end of rotary union (L): <200 mm... -
Page 20: Air Requirements
The supply pressure for all three stages can be regulated to control the grip force on the workpiece material. Aerotech recommends using the minimum pressure required for the application that securely clamps the workpiece. Lower pressures reduce the possibility of damage to the workpiece, ensures the highest system performance, and increases the longevity of the system. -
Page 21: Mechanical Setup
With these stages, air pressure must be independently supplied to the "Collet Chuck Open" air input or "Collet Chuck Close" air input to actuate the collet chuck. Using Aerotech's solenoid valve setup supplied in the pneumatics kit or by alternatively supplying/removing air pressure to each air input, check for proper operation of the collet chuck. -
Page 22: Changing The Workholding Devices
Levin Type D precision collets and Hardinge 3C/5C Special Accuracy collets must be used to guarantee the collet runout specifications. Contact the factory for more details. N O T E : Various grip diameters are commonly available and can be interchanged. Chapter 2 www.aerotech.com... -
Page 23: Collet Installation And Removal Procedure For The Ccs130Dr-160 And Ccs190Dr-240-3C
Insert the desired workpiece into the collet. Actuate the collet to the closed position to verify that the workpiece is clamped in the collet. Adjust the collet depth and/or air pressure as required. Step 6: Restore power to the stage. Figure 2-6: Collet Installation www.aerotech.com Chapter 2... -
Page 24: Collet Installation And Removal Procedure For The Ccs190Dr-260-5C
CCS stages have integrated collet retention features. The CCS190DR-260-5C stage has a positive retention system that consists of a collet retention screw, which fits directly into the collet’s keyway and prevents the collet from unthreading. Figure 2-7: CCS190DR-260-5C Collet Retention System Components Chapter 2 www.aerotech.com... -
Page 25: Figure 2-8: Ccs190Dr-260-5C Alignment Scribe Marks
Remove the collet by turning it counter-clockwise. Store the collet in a safe location so it will not be damaged. If the collet is going to be stored for an extended period of time or where moisture is present, it should be coated with a thin layer of rust preventative oil. www.aerotech.com Chapter 2... - Page 26 Insert the desired material workpiece into the collet. Actuate the collet to the closed position to verify the material workpiece is clamped in the collet. Adjust the collet depth and/or air pressure as required. Step 10: Restore power to the stage. Chapter 2 www.aerotech.com...
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Page 27: Chapter 3: Electrical Specifications And Installation
Electrical installation requirements will vary depending on product options. Installation instructions in this section are for stages equipped with standard Aerotech motors intended for use with an Aerotech motion control system. Contact Aerotech for further information regarding products that are otherwise configured. -
Page 28: Motor And Feedback Connectors
N O T E : Refer to the other documentation accompanying your Aerotech equipment. Call your Aerotech representative if there are any questions on system configuration. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. -
Page 29: Table 3-1: Motor Connector Pinout
Motor Phase A Motor Phase B Motor Phase C Reserved Reserved Reserved Reserved Reserved Frame Ground (motor protective ground) Mating Connector Aerotech P/N Third Party P/N Backshell ECK00656 Amphenol #17E-1726-2 Sockets [QTY. 4] ECK00659 ITT Cannon #DM53744-6 Connector ECK00657 ITT Cannon #DBM9W4SA197 www.aerotech.com... -
Page 30: Table 3-2: Feedback Connector Pinout
Limit Common (internally connected to Pin 21) Encoder Common (internally connected to Pin 20) Reserved Reserved Reserved Reserved Case Signal shield connection (to case) Mating Connector Aerotech P/N Third Party P/N Backshell ECK00656 Amphenol #17E-1726-2 Connector ECK00300 FCI DB25S064TLF Chapter 3... -
Page 31: Motor And Feedback Wiring
All motor and controller manufacturers have their own designations for motor phases A/B/C and Hall signals A/B/C (refer to Section 3.5. for motor phasing). Shielded cables are required for the motor and feedback connections. Figure 3-1: Motor and Feedback Wiring www.aerotech.com Chapter 3... -
Page 32: Motor And Feedback Specifications
600 rpm N O T E : The encoders used on all CCS series stages come standard with a MHz clock rate. Aerotech can provide slower or faster clock rates to match the controller being used. Consult Aerotech for more information. -
Page 33: Table 3-6: Rotary Motor Specifications For The Ccs130Dr-160
6. Specifications given are for the motor only. When integrated into a housing with bearings additional losses should be considered. 7. Maximum winding temperature is 100 °C (thermistor trips at 100 °C) 8. Ambient operating temperature range 0 °C - 25 °C; consult Aerotech for performance in elevated ambient temperatures 9. All Aerotech amplifiers are rated A ;... -
Page 34: Table 3-7: Rotary Motor Specifications For The Ccs190Dr-240-3C And Ccs190Dr-260-5C
6. Specifications given are for the motor only. When integrated into a housing with bearings additional losses should be considered. 7. Maximum winding temperature is 100 °C (thermistor trips at 100 °C) 8. Ambient operating temperature range 0 °C - 25 °C; consult Aerotech for performance in elevated ambient temperatures 9. All Aerotech amplifiers are rated A ;... -
Page 35: Limits, Marker, And Machine Direction
Electrical Specifications and Installation 3.4. Limits, Marker, and Machine Direction Aerotech stages are configured to have positive and negative "machine" directions. The machine direction defines the phasing of the feedback and motor signals and is dictated by the stage wiring (refer to Section 3.5. -
Page 36: Motor And Feedback Phasing
Electrical Specifications and Installation CCS Hardware Manual 3.5. Motor and Feedback Phasing Motor phase voltage is measured relative to the virtual wye common point. Figure 3-3: Hall Phasing Chapter 3 www.aerotech.com... -
Page 37: Figure 3-4: Analog Encoder Phasing Reference Diagram
CCS Hardware Manual Electrical Specifications and Installation Figure 3-4: Analog Encoder Phasing Reference Diagram Figure 3-5: Encoder Phasing Reference Diagram (Standard) www.aerotech.com Chapter 3... - Page 38 Electrical Specifications and Installation CCS Hardware Manual This page intentionally left blank. Chapter 3 www.aerotech.com...
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Page 39: Chapter 4: Maintenance
4.1. Service and Inspection Schedule A frequent inspection and cleaning interval of the CCS series stages is recommended until a trend develops for the application. The inspection and cleaning interval depends on application conditions such as duty cycle, speed, and environment. -
Page 40: Cleaning And Lubrication
If the wear marks are large, or excessive polishing is required to remove these marks, the collet chuck and collet may need to be replaced. Contact Aerotech Technical Support for more information. Wear and fretting can be prevented with proper lubrication and maintenance intervals. -
Page 41: Figure 4-1: Collet And Collet Chuck Tapered Surfaces
It is also recommended that the collet and chuck interface surfaces be cleaned, inspected, and relubricated every time the collet is removed. Figure 4-1: Collet and Collet Chuck Tapered Surfaces www.aerotech.com Chapter 4... -
Page 42: Seal Replacement
4.3.1. Piston Seal Change Procedure The collet chuck and actuation mechanism on the CCS series stages are equipped with o-ring seals that are designed to last many collet chuck (open/close) cycles. However, due to regular wear, the seals may require replacement during the lifetime of the product. -
Page 43: Figure 4-4: Cross-Section View Of Ringseal Showing O-Rings
Step 5: Wrap the ringseal threads with Teflon thread seal tape [PTFE tape] in preparation for installation. Step 6: Re-insert the ringseal into the inner collet housing and tighten into position. Step 7: Re-insert the collet. Figure 4-4: Cross-section View of Ringseal Showing O-Rings www.aerotech.com Chapter 4... -
Page 44: Wet Cut Rotary Union Seal Replacement (Ccs130Dr-160 With -Wcut Option Only)
CCS Hardware Manual 4.3.3. Wet Cut Rotary Union Seal Replacement (CCS130DR-160 with -WCUT option only) The rotary seal in the wet cut rotary union requires periodic replacement. Contact Aerotech for obtaining appropriate replacement seals. Figure 4-5 shows a cross section of the rotary union assembly. -
Page 45: Figure 4-6: Rear Carriage Cover W/ Wet Cut Rotary Union
4-8). Small wear marks are normal. If the shaft is undamaged, clean both the shaft and seal end cap surfaces with a lint-free rag and isopropyl alcohol. If the shaft is scratched (you can feel it with your fingernail), contact Aerotech Technical Support. -
Page 46: Figure 4-8: Wet Cut Rotary Union Shaft Inspection
Step 9: Tighten the end cap screws and reconnect water supply. Step 10: Leak test stage prior to restoring stage power. Chapter 4 www.aerotech.com... -
Page 47: Wet Cut Rotary Union Removal
Also remove [QTY. 4] M5 rear housing cover screws along with cover (see Figure 4-6). Step 4: Remove the shoulder bolts and bushings (see Figure 4-10). Figure 4-10: Housing Assembly Showing Rotary Union www.aerotech.com Chapter 4... -
Page 48: Figure 4-11: Rotary Union Removal
Step 6: Install a new rotary union assembly by attaching it to the rear of the CCS shaft. Tighten to 10 ft·lbs. Step 7: Reinstall shoulder bolts and bushings. Step 8: Reattach cover and end cap. Step 9: Leak test stage prior to restoring stage power. Chapter 4 www.aerotech.com... -
Page 49: Wet Cut Maintenance (Ccs190Dr-240-3C And Ccs190Dr-260-5C)
Step 5: Remove and dry the rear cover and/or any wet-cut accessories on the rear of the stage. The rear cover can be removed by using a 2 mm allen wrench to loosen and remove the [QTY. 6] fasteners holding it on. Store the rear cover and fasteners together, in a safe location for later re-assembly. www.aerotech.com Chapter 4... -
Page 50: Figure 4-12: Rear Cover Removal
There may be o-ring lubricant present on some of the surfaces. The lubrication should be left if possible, but removing it will not cause harm to the system's operation. Figure 4-13: Collet-Chuck Piston and Piston Housing Cleaning Chapter 4 www.aerotech.com... -
Page 51: Figure 4-14: Front Cover And Labyrinth Seal Removal
The grease nipple on the front face supplies the grease to the labyrinth seal, which acts as a fluid barrier during stage operation. N O T E : Do not add excessive amounts of grease to the labyrinth seal. Figure 4-15: Front of Stage Cleaning www.aerotech.com Chapter 4... -
Page 52: Figure 4-16: Front Cover Installation
5. Orient the rear cover such that the integral drain is located at the lowest point of the stage. Tighten the fasteners to 1.0 N·m (8.7 in·lb). Step 12: Reinstall the collet. Follow all of the steps in Section 2.8. including cleaning, inspection, and relubrication. Step 13: Reconnect stage cables and restore power to the stage. Chapter 4 www.aerotech.com... -
Page 53: Troubleshooting
Air supplied to both "Collet Chuck Open" and "Collet Chuck Closed" open inputs. Supply to only one input at a time The collet has not been lubricated properly or the lubrication needs to be replenished (refer to Section 4.2.1.). www.aerotech.com Chapter 4... - Page 54 Maintenance CCS Hardware Manual This page intentionally left blank. Chapter 4 www.aerotech.com...
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Page 55: Appendix A: Warranty And Field Service
Aerotech 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 Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech’s... - Page 56 Aerotech's approval. On-site Warranty Repair If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for repair, and if Aerotech determines the problem could be warranty-related, then the following policy applies:...
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Page 57: Appendix B: Revision History
CCS Hardware Manual Revision History Appendix B: Revision History Revision General Information 1.03.00 Update air filtration specification from 0.25 microns to 1 micron (Section 2.5.) 1.02.00 General revision / Product update 1.01.00 New drain design 1.00.00 New manual www.aerotech.com Appendix B... - Page 58 Revision History CCS Hardware Manual This page intentionally left blank. Appendix B www.aerotech.com...
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Page 59: Index
Directive 2006/42/EC Performance Specifications S-130 Electrical Specifications S-76 S-130 piston seal replacement S-76 pressure vessel length/weight limits EN 60204-1 2010 Protection Rating EN ISO 12100 2010 protective ground connection Encoder Specifications ringseal o-ring replacement field service www.aerotech.com Index... - Page 60 S-76-35 seal replacement serial number service schedule shimming stabilizing stage stage distortion stabilizing Support Technical Support Thermistor Specifications Vibration Warranty and Field Service Wet Cut Fluid Requirements wet cut rotary union removal wet cut rotary union seal replacement Index www.aerotech.com...
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