Aerotech CCS Series User manual

Revision: 1.03.00
CCS Hardware Manual

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101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
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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.
Copyright © 2014-2019, Aerotech, Inc., All rights reserved.

CCS Hardware Manual Table of Contents
Table of Contents
CCS Hardware Manual 1
Table of Contents 3
List of Figures 4
List of Tables 5
Safety Procedures and Warnings 6
EU Declaration of Incorporation 7
Chapter 1: Overview 9
1.1. Environmental Specifications 11
1.2. Accuracy and Temperature Effects 11
1.3. Basic Specifications 12
Chapter 2: Mechanical Specifications and Installation 13
2.1. Unpacking and Handling the Stage 13
2.2. Dimensions 14
2.3. Securing the Stage to the Mounting Surface 17
2.4. Load Capability 19
2.5. Air Requirements 20
2.6. Wet Cut Fluid Requirements 20
2.7. Mechanical Setup 21
2.8. Changing the Workholding Devices 22
2.8.1. Collet Installation and Removal Procedure for the CCS130DR-160 and
CCS190DR-240-3C 23
2.8.2. Collet Installation and Removal Procedure for the CCS190DR-260-5C 24
Chapter 3: Electrical Specifications and Installation 27
3.1. Motor and Feedback Connectors 28
3.2. Motor and Feedback Wiring 31
3.3. Motor and Feedback Specifications 32
3.4. Limits, Marker, and Machine Direction 35
3.5. Motor and Feedback Phasing 36
Chapter 4: Maintenance 39
4.1. Service and Inspection Schedule 39
4.2. Cleaning and Lubrication 40
4.2.1. Collet & Collet Chuck Lubrication and Cleaning 40
4.3. Seal Replacement 42
4.3.1. Piston Seal Change Procedure 42
4.3.2. Ringseal O-Ring Replacement (CCS130DR-160 with -WCUToption only) 42
4.3.3. Wet Cut Rotary Union Seal Replacement (CCS130DR-160 with -WCUToption
only) 44
4.4. Wet Cut Rotary Union Removal 47
4.5. WetCutMaintenance (CCS190DR-240-3C and CCS190DR-260-5C) 49
4.6. Troubleshooting 53
Appendix A: Warranty and Field Service 55
Appendix B: Revision History 57
Index 59
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Table of Contents CCS Hardware Manual
List of Figures
Figure 1-1: CCS Series Rotary Stage 9
Figure 2-1: CCS130DR-160 Dimensions 14
Figure 2-2: CCS190DR-240-3C Dimensions 15
Figure 2-3: CCS190DR-260-5C Dimensions 16
Figure 2-4: Mounting Hole Locations 18
Figure 2-5: CCS130DR-160 Wet Cut Rotary Union Location 19
Figure 2-6: Collet Installation 23
Figure 2-7: CCS190DR-260-5C Collet Retention System Components 24
Figure 2-8: CCS190DR-260-5C Alignment Scribe Marks 25
Figure 3-1: Motor and Feedback Wiring 31
Figure 3-2: Machine Direction 35
Figure 3-3: Hall Phasing 36
Figure 3-4: Analog Encoder Phasing Reference Diagram 37
Figure 3-5: Encoder Phasing Reference Diagram (Standard) 37
Figure 4-1: Collet and Collet Chuck Tapered Surfaces 41
Figure 4-2: Typical Ringseal 42
Figure 4-3: Typical Ringseal Removal 42
Figure 4-4: Cross-section View of Ringseal Showing O-Rings 43
Figure 4-5: Cross-Section View of Wet Cut Rotary Union 44
Figure 4-6: Rear Carriage Cover w/ Wet Cut Rotary Union 45
Figure 4-7: Seal Location 45
Figure 4-8: Wet Cut Rotary Union Shaft Inspection 46
Figure 4-9: Wet Cut Rotary Union 47
Figure 4-10: Housing Assembly Showing Rotary Union 47
Figure 4-11: Rotary Union Removal 48
Figure 4-12: Rear Cover Removal 50
Figure 4-13: Collet-Chuck Piston and Piston Housing Cleaning 50
Figure 4-14: Front Cover and Labyrinth Seal Removal 51
Figure 4-15: Front of Stage Cleaning 51
Figure 4-16: Front Cover Installation 52
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CCS Hardware Manual Table of Contents
List of Tables
Table 1-1: CCS130 Model Numbering System 10
Table 1-2: CCS190 Model Numbering System 10
Table 1-3: Environmental Specifications 11
Table 1-4: CCS Series Specifications 12
Table 2-1: Stage to Mounting Surface Hardware 17
Table 3-1: Motor Connector Pinout 29
Table 3-2: Feedback Connector Pinout 30
Table 3-3: Feedback Specifications 32
Table 3-4: Encoder Lines Per Revolution 32
Table 3-5: Maximum Speed (rpm) 32
Table 3-6: Rotary Motor Specifications for the CCS130DR-160 33
Table 3-7: Rotary Motor Specifications for the CCS190DR-240-3C and CCS190DR-260-5C 34
Table 4-1: Recommended Lubricants 41
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Table of Contents CCS Hardware Manual
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the CCS. Read all parts of this manual
before you install or operate the CCS or before you do maintenance to your system. To prevent injury to you
and damage to the equipment, obey the precautions in this manual. The precautions that follow apply when
you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury to you or
damage to the equipment can occur. If you do not understand the information in this manual, contact
Aerotech Global Technical Support.
This product has been designed for light industrial manufacturing or laboratory environments. The protection
provided by the equipment could be impaired if the product is used in a manner not specified by the
manufacturer.
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. Refer to www.aerotech.com for the most up-to-date information.
D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of
electrical shock, bodily injury, or death the following precautions must be followed.
1. Access to the CCS and component parts must be restricted while connected to a power
source.
2. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
3. Disconnect electrical power before servicing equipment.
4. All components must be properly grounded in accordance with local electrical safety
requirements.
5. Operator safeguarding requirements must be addressed during final integration of the
product.
W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the
following precautions must be followed.
1. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source.
2. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid
potential hazards.
3. Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
4. The CCS stage must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
5. Use care when moving the CCS stage. Lifting or transporting the CCS stage improperly
can result in injury or damage to the CCS.
6. This product is intended for light industrial manufacturing or laboratory use. Use of this
product for unintended applications can result in injury and damage to the equipment.
7. If the product is used in a manner not specified by the manufacturer, the protection
provided by the product can be impaired and result in damage, shock, injury, or death.
8. Operators must be trained before operating this equipment.
9. All service and maintenance must be performed by qualified personnel.
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CCS Hardware Manual Table of Contents
EU Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
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;
and that the following harmonized European standards have been applied:
EN ISO 12100:2010
Safety of machinery - Basic concepts, general principles for design
EN 60204-1:2010
Safety of machinery - Electrical equipment of machines - Part 1:General requirements
and further more declares that
it is not allowed to put the equipment into service until the machinery into which it is to be
incorporated or of which it is to be a component has been found and declared to be in
conformity with the provisions of the Directive 2006/42/EC and with national
implementing legislation, for example, as a whole, including the equipment referred to in
this Declaration.
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2011/65/EU RoHS2 Directive
Authorized Representative: Simon Smith, European Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 10/14/2019
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Table of Contents CCS Hardware Manual
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CCS Hardware Manual Overview
Chapter 1: Overview
Aerotech’s CCS series rotary stages (patent pending) with integrated captured collet chucks provide
automated material handling capability for a wide range of materials and applications.
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. Refer to www.aerotech.com for the most up-to-date information.
Figure 1-1: CCS Series Rotary Stage
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Overview CCS Hardware Manual
Table 1-1: CCS130 Model Numbering System
CCS130DR Mechanical-Bearing Direct Drive Rotary Collet Stage
Stage Size (Required)
-160 160 mm stage height
Cutting Configuration (Required)
-DCUT Dry cutting configuration
-WCUT Wet cutting configuration with fluid rotary union
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
CGF Collet and gripper filtration kit
Table 1-2: CCS190 Model Numbering System
CCS190DR Mechanical-Bearing Direct Drive Rotary Collet Stage
Stage Size (Required)
-240-3C 240 mm stage height with 3C collet
-260-5C 260 mm stage height with 5C collet
Wrench (Optional
-WR Wrench for changing collet
Accessories (To be Ordered as a Separate Line Item)
Collet-3C-CLTxxx Collet, 3C; consult Aerotech for available sizes
Collet-5C-CLTxxx Collet, 5C; consult Aerotech for available sizes
CGF Collet and gripper filtration kit
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CCS Hardware Manual Overview
1.1. Environmental Specifications
W A R N I N G : Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to the
equipment.
Table 1-3: Environmental Specifications
Ambient
Temperature
Operating:
The optimal operating temperature is 20° C ±2° C (68° F ±4° F). If at any time the
operating temperature deviates from 20° C, degradation in performance could occur.
Storage: 0° to 40° C (32° to 104° F) in original shipping packaging
Humidity Operating: 20% to 60% RH
Storage: 10% to 70% RH, non-condensing in original packaging.
Altitude
Operating: 0 m to 2,000 m (0 ft to 6,562 ft) above sea level
Contact Aerotech if your specific application involves use above 2,000 m or below sea
level.
Vibration
Use the system in a low vibration environment. Excessive floor or acoustical vibration
can affect system performance. Contact Aerotech for information regarding your spe-
cific application.
Protection
Rating
The CCS stages have limited protection against particles but not liquids. This equates
to an ingress protection rating of IP50.
Use 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
repeatable over an extended period of time. The severity of temperature effects on all specifications depends
on many different environmental conditions, including how the CCS is mounted. Contact the factory for more
details.
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Overview CCS Hardware Manual
1.3. Basic Specifications
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. Refer to www.aerotech.com for the most up-to-date information.
Table 1-4: CCS Series Specifications
CCS130DR-160 CCS190DR-240-3C CCS190DR-260-5C
Travel 360° Continuous
Accuracy(1) 5 arc sec
Bidirectional Repeatability 2 arc sec
Maximum Speed(2) 1000 rpm 600 rpm 600 rpm
Aperture(3) 7.9 mm (Dry);
3 mm (Wet) 13 mm 26.5 mm
Maximum Torque
(Continuous) 0.48 N·m 2.85 N·m 5.06 N·m
Load Capacity(4)
Axial 2 kg 10 kg 15 kg
Radial 0.5 kg 5 kg 10 kg
Moment 0.75 N·m 6 N·m 12 N·m
Rotor Inertia (Unloaded) 0.0004 kg·m20.0039 kg·m20.0051 kg·m2
Stage Mass 3.1 kg 12.0 kg 14.1 kg
Material Hardcoat/Anodized Aluminum;
Hardened Stainless Steel (Collet Chuck)
Mean Time Between
Failure (MTBF) 10,000 Hours
Collet Type Type D (Louis Levin &
SonsTM)3C 5C
Collet Runout(5) <30 µm <25 µm <20 µm
System Air Pressure(6)(7)
(8) 100 psig 20-100 psig 20-80 psig
1. Calibrated accuracy requires the use of Aerotech controls and angular programming units.
2. Maximum speed listed is stage and motor dependent (assuming a 340 V bus). Actual speed may be lower due to motor back emf.
Consult Aerotech for more details.
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.
5. Measured TIR of a precision gage pin with an ultra precision collet (DIN6499) 3 mm away from the collet face at 80 psig applied
air pressure and no load. Measured 6 mm away from collet face at 40 psig applied air pressure for CCS190DR.
6. The CCS190DR-240-3C and CCS190DR-260-5C contain a double-acting collet mechanism that requires air to open and close
the collet chuck. Aerotech recommends compressed air filtered to 0.25 micron particle size or better.
7. Collet chuck mechanism is normally-open (CCS130DR-160). Collet mechanism requires air to close collet chuck. Air supply must
be dry (0º F dew point) oil-less air OR 99.99% pure nitrogen. Air or nitrogen must be filtered to 1 micron particle size or better.
8. Exceeding the maximum system air pressure on the CCS190 stages is not recommended and could cause damage and/or
performance degradation.
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CCS Hardware Manual Assembly and Installation
Chapter 2: Mechanical Specifications and Installation
W A R N I N G : CCS installation must be in accordance to instructions provided by this manual
and any accompanying documentation. Failure to follow these instructions could result in injury
or damage to the equipment.
2.1. Unpacking and Handling the Stage
N O T E : If any damage has occurred during shipping, report it immediately.
W A R N I N G : It is the customer's responsibility to safely and carefully lift the stage.
lMake sure that all moving parts are secure before moving the CCS. Unsecured moving
parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the CCS. Use care when
moving the CCS.
lLift only by the base. Do not use the tabletop or cables as lifting points.
Carefully remove the CCSfrom its protective shipping container. Gently set the CCS on a smooth, flat, and
clean surface.
Before operating the CCS, it is important to let it stabilize at room temperature for at least 12 hours. Allowing
it to stabilize to room temperature will ensure that all of the alignments, preloads, and tolerances are the
same as they were when tested at Aerotech. Use compressed nitrogen or clean, dry, oil-less air to remove
any dust or debris that has collected during shipping.
Each CCS has a label listing the system part number and serial number. These numbers contain information
necessary for maintaining or updating system hardware and software. Locate this label and record the
information for later reference.
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Assembly and Installation 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. Refer to www.aerotech.com for the most up-to-date information.
Figure 2-1: CCS130DR-160 Dimensions
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CCS Hardware Manual Assembly and Installation
Figure 2-2: CCS190DR-240-3C Dimensions
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Assembly and Installation CCS Hardware Manual
Figure 2-3: CCS190DR-260-5C Dimensions
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CCS Hardware Manual Assembly and Installation
2.3. Securing the Stage to the Mounting Surface
W A R N I N G : The CCS must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
W A R N I N G : Make sure that all moving parts are secure before moving the CCS. Unsecured
moving parts may shift and cause bodily injury.
W A R N I N G : Do not attempt to manually move the CCS if it is connected to a power source.
D A N G E R : PINCHPOINT! Keep Hands Clear while the stage is in motion.
The mounting surface must be flat and have adequate stiffness to achieve the maximum performance from
the CCS stage. When it is mounted to a non-flat surface, the stage can be distorted while the mounting
screws are tightened. This distortion will decrease overall accuracy. Adjustments to the mounting surface
must be done before the stage is secured.
Inspect the mounting surface for dirt or unwanted residue and clean if necessary. Use precision flatstones
on the mounting surface to remove any burrs or high spots. Clean the mounting surface with a lint-free cloth
and acetone or isopropyl alcohol and allow the cleaning solvent to completely dry. Gently place the stage on
the mounting surface.
N O T E : The CCS is precision machined and verified for flatness prior to product assembly at the factory.
If machining is required to achieve the desired flatness, it should be performed on the mounting surface
rather than the CCS. Shimming should be avoided if possible. If shimming is required, it should be
minimized to retain maximum rigidity of the system.
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).
Tightening torque values for the mounting hardware are dependent on the properties of the surface to which
the stage is being mounted. Values provided in Table 2-1 are typical values and may not be accurate for your
mounting surface. Refer to Section 2.2. for specific model mounting locations and dimensions.
Table 2-1: Stage to Mounting Surface Hardware
Mounting Hardware Typical Screw
Torque
CCS130DR-160 M5x0.8x14mm long [10-32x1/2 in long] SHCS 4.7 N·m
CCS190DR-240-3C and
CCS190DR-260-5C M6x1.0x25mm long [1/4-20x1 in long] SHCS 8 N·m
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Assembly and Installation CCS Hardware Manual
Figure 2-4: Mounting Hole Locations
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CCS Hardware Manual Assembly and Installation
2.4. Load Capability
The CCS is designed for tubular manufacturing applications. With this in mind, the tubes loaded into the
collet chuck of the rotary axis must fall within the maximum load parameters in Section 1.3.
N O T E : Maximum loads are mutually exclusive. Loading limits are due to the collet chuck mechanism.
Contact Aerotech directly if part load requirement exceeds specifications.
If the CCS130DR-160 is configured for wet cut, it will have a rotary union attached to the end of the rotary
shaft (Figure 2-5). A 1/8 in NPT tapped hole is provided on the end of the rotary union shaft to allow for
connecting a pressure vessel or extension tube. 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:
lLength past end of rotary union (L): <200 mm
lMoment about end of rotary union (M): <0.75 N-m
If these limits are exceeded, it is recommended that an external steady-rest or support be implemented.
Figure 2-5: CCS130DR-160 Wet Cut Rotary Union Location
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Assembly and Installation CCS Hardware Manual
2.5. Air Requirements
The air pressure supplied to the collet chuck is important in ensuring that the material or tool is released
properly.
lIf compressed air is used, it must be filtered to 1 micron, dry to 0º F dew point (CCS130DR-160 only),
and oil free.
lIf nitrogen is used, it must be 99.99% pure and filtered to 1 micron.
On the CCS130DR-160, the chuck becomes fully closed at approximately 4-7 bar (60-100 psig) depending
on the collet size. Higher pressures will not cause damage to the rotary union.
The collet chucks for the CCS190DR-240-3C and CCS190DR-260-5C close at approximately 1.7 bar (25
psi) depending on collet size. The maximum pressure that should be used on each stage is 6.9 bar (100 psi)
and 5.5 bar (80 psi) respectively. Higher pressures are not recommended and could cause damage and/or
performance degradation.
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.
2.6. Wet Cut Fluid Requirements
Water or cutting fluid used during wet cut operations must be conditioned to meet certain requirements
ensuring seal functionality and service life of the wet cut rotary union.
lWater or cutting fluid must be filtered to 5 microns or better.
lA fluid filter must be installed upstream of the rotary union between the pump outlet and the rotary union
inlet.
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