Related Manuals for Ingersoll-Rand Zero ZG Series
Summary of Contents for Ingersoll-Rand Zero ZG Series
- Page 1 47804819 Edition 3 May 2023 Zero Gravity Air Balancer 2.0 ZG Series User Manual Save these Instructions...
- Page 2 When tool life has expired, it is recommended to: • disassemble the tool. • degrease the tool. • separate tool parts by material for correct recycling. Tool repair and maintenance should be conducted by an Authorized Service Center. Refer all communications to the nearest Ingersoll Rand office or distributor. Manuals are available at ingersollrand.com Table 1.
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Page 3: Product Description
Product Description This control kit is designed for use with an air balancer. It provides the ability to electronically move loads up and down using the handle actuators or apply force directly to a lifted load. WARNING ● Controller must be used by a single operator. Simultaneous command inputs may result in hazardous movements. ●... -
Page 4: Handle Installation
4. Connect power cord to the controller. Note: Power supply 100-150 V AC, 50-400Hz. Fig. B Handle Installation NOTICE ● For load hook installation and lash up instructions, refer to the balancer Installation Manual 47646669001. ● Install the control handle inline with the wire rope and the load (Fig. C) or mount the control handle in a remote location using mounting brackets (Fig. -
Page 5: Standard Operation
Fig. F Deflate the Chamber 8. Three yellow lights indicate completion of initialization of the controller. When lit, pull down sleeve of the handle to deflate the chamber. Fig. G Operation WARNING ● Press Emergency Stop button to stop movement in case of an emergency. ●... -
Page 6: Float Mode
Float Mode Engage Float Mode To engage float mode, release the handle. Float mode will be triggered by lack of contact with the handle. While float mode is engaging, red light will appear on the ZG balancer. Do not touch the handle while the controller is calculating load. Float mode is engaged and calculation completes when three yellow lights appear on the controller. - Page 7 ● To enable no load balancing feature, click the option “Set new no load balancing weight”, and save this setting to the controller by clicking on “Write settings“ button. Configuration tool will indicate the status of write operation with a write successful message box. ●...
- Page 8 Interlock The interlock feature will not allow the handling device to open while it is suspended. This feature can be enabled using the configuration tool. Once enabled, the yellow lights indicate the user the state of interlocking operation as below: ●...
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Page 9: Speed Settings
Max Weight/Over Pressure Controlled pressure within the chamber will prevent fast upward movement if there is a blockage of the load or gripper, or sudden release of the load. Use this feature to prevent from such occurrence or limit the ZG balancer capacity. Use this field in configuration tool to set the maximum weight. -
Page 10: Interlock Wiring
Interlock Wiring NOTICE The interlock activates an available output on the I/O plug at the back of the handle. Connect the handling device to the controller as follow: - Pin J and K: Clamp control actuator. - Pin J and L: Release control actuator. - Pin J and M: Ready to release information. - Page 11 Zero Gravity Handle Review Refer to Fig. K. Fig. K Item Number Part Description Power Button (green) De-Clamp Button (orange) Clamp Button (blue) Handle Sleeve Top Eyelet Bottom Hook Block Main Plug: to Zero Gravity Control Box Extension Plug: Connection to Input or Output Emergency Stop 47804819_ed3 EN-10...
- Page 12 Zero Gravity Control Box Review Refer to Fig. L. Fig. L Item Number Part Description Power Supply 85-250 V AC Fuse Power Switch USB Connection Power ON Indicator Light Balancing Mode or Part Released Indicator Light Error Indicator Light Balancing Mode or Ready to Release Signal Indicator Light Balancing Mode or Part Clamped Indicator Light Main Plug: to Zero Gravity...
- Page 13 Software Communication Section Reload Internal Software of the Zero Gravity What is needed: Equipment Tool - Computer - AVRDudeSS Software To do: ● Install Arduino software rev 1.8.x ● Unzip the AVRDudeSS software folder to C:\Program Files\ ● Create a shortcut of AVRDudeSS.exe file to the local drive. ●...
- Page 14 ● A message pops out on the screen as in image below: Note: The software is loaded in the control box. Maintenance Electronics Steady red light on the controller box indicates run error. Restart system to troubleshoot errors. If problem recurs, system will switch to safe mode and red light remains constant.
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Page 15: Maintenance Schedule
Maintenance Schedule WARNING Disconnect the power supply before working on the equipment. The unit must be repaired by qualified personnel, risk of electric shock. Frequent Periodic Component Inspection Criteria for operation Daily (6 months) (1 year) Damages No visible damage on entire length or on plugs. Spiral Wire Kinks No visible kinks on entire length. - Page 16 Note: Max weight must not exceed 80% of the ZG balancer capacity. 4. Load is moving up and down but sometimes it’s a jerky motion or not working or a red light is blinking in the Control Box. ● This will occur when the operator is moving the load in the handle mode up and down in faster rate. ●...
- Page 17 Zero Gravity 2.0 (Bullard Hook) - Parts List Balancer Model Driver Description Suspension Balancer Prop 65 Label Zero Gravity Balancer, 150 LBS, No Suspension Kit, ZG2W01508000B ZGS00 Bullard Hook Zero Gravity Balancer, 150 LBS, ZRA1 Mount, ZG2W015080A1B ZGSA1-150 Bullard Hook Zero Gravity Balancer, 150 LBS, ZRA2 Mount, ZG2W015080A2B ZGSA2-150...
- Page 18 Model Driver Description Suspension Balancer Prop 65 Label Zero Gravity Balancer, 500 LBS, No Suspension Kit, ZG2W05008000B ZGS00 Bullard Hook Zero Gravity Balancer, 500 LBS, ZRA1 Mount, ZG2W050080A1B ZGSA1 Bullard Hook Zero Gravity Balancer, 500 LBS, ZRA2 Mount, ZG2W050080A2B ZGSA2 Bullard Hook BW050080 Zero Gravity Balancer, 500 LBS, ZRAT Mount,...
- Page 19 Model Driver Description Suspension Balancer Prop 65 Label Zero Gravity Balancer, 350 LBS, No Suspension Kit, ZG2W03508000C ZGS00 Snap Hook Zero Gravity Balancer, 350 LBS, ZRA1 Mount, Snap ZG2W035080A1C ZGSA1 Hook Zero Gravity Balancer, 350 LBS, ZRA2 Mount, Snap ZG2W035080A2C ZGSA2 Hook BW035080...
- Page 20 Model Code Explanation - Kit Parts Example: -KIT Type of Control Kit Zero Gravity Gen 2.0 Capacity 150 lb. (68 kg) 200 lb. (91 kg) 350 lb. (158 kg) 500 lb. (227 kg) Type of Hook Bullard Steel Snap Zero Gravity 2.0 - Kit List Balancer Balancer...
- Page 21 Controller Box - Exploded View Controller Box - Parts List Item Part Description Quantity Part Number (CCN) Set of Valve for FSB015 (47563675001) Set of Valve for FSB020 (47563676001) Set of Valve for FSB035 (47563677001) Set of Valve for FSB050 (47563678001) Pressure Sensor ZHSEA0080 (04709614)
- Page 22 Zero Gravity Command Handle Gen 2 w/o Hook - Exploded View Zero Gravity Command Handle Gen 2 w/o Hook - Parts List Item Part Description Quantity Part Number (CCN) UXT 500 kg Tension Load Cell (47784991001) Adaptor (47784994001) Shaft Assembly (47784996001) Composite Handle Assembly (47784998001)
- Page 23 Handle Enclosure Assembly - Exploded View Handle Enclosure Assembly - Parts List Item Part Description Quantity Part Number (CCN) Power Button (green) RS248-8913 (47563683001) Release Button (orange) RS408-038 (47563685001) Clamp Button (blue) RS322-041 (47802734001) Enclosure Top Plate Machined (47787987001) Enclosure Bottom Plate Machined (47787988001) Plastic Bolt, M3x16 (47798036001)
- Page 24 Bottom Plate Assembly - Exploded View Bottom Plate Assembly - Parts List Item Part Description Quantity Part Number (CCN) Capteur, RS RS317-780 (47563682001) Bottom Holder (47785000001) Stud, M5x20 (47798156001) Bolt, M5x20 (47801361001) Bolt, M5x16 (47801362001) Washer, M5 (47802158001) Shaft Assembly - Exploded View Shaft Assembly - Parts List Item Part Description...
- Page 25 Composite Handle Assembly - Exploded View Composite Handle Assembly - Parts List Item Part Description Quantity Part Number (CCN) Force Sensor Tube (47784997001) Composite Handle (47785011001) Brass Bushing (47791327001) Lower Cup (47791331001) Upper Cup (47796366001) Bellow (47796367001) Spring Steel, 35 mm (47801363001) 47804819_ed3 EN-24...
- Page 26 Notes:...
- Page 27 Notes:...
- Page 28 ingersollrand.com © 2023 Ingersoll Rand...
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