Ingersoll-Rand Zero ZG Series User manual

47804819
Edition 3
May 2023
Zero Gravity Air Balancer 2.0
ZG Series
B
A
Save these Instructions
User Manual

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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 oce or distributor.
Manuals are available at ingersollrand.com
Table 1. Product Information Manuals
Publication CCN
Product Safety Information Manual 16598831
Product Information Manual 54072541
Product Parts Information Manual 16598849
Product Installation Manual 47646669001
Product Maintenance Manual 16598856
Declaration of Conformity 47808318001

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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.
●Do not use this product or attached equipment for;
- lifting, supporting or transporting people.
- lifting or supporting loads over people.
●Do not operate this product in wet or explosive environments.
CAUTION
To reduce the risk of electric shock, do not expose to rain. Store indoors.
Specications
This device needs to be connected to a standard E type plug or B type plug (for other option, contact factory). It works from 100-150 V AC at
50 to 400Hz and the power consumption is 3.5A Max. This system is protected by 2 fuses (characteristics: T type, dimension 5x20 mm, 3.15A
250 V AC). Working pressure of 100 psi (6.9 bar) dry and clean air (30 microns lter must be used).
Model Code Explanation
Example:
Type of Control Kit
ZG = Zero Gravity
Wire
W = Wire Rope
S = Z-Stop
2 = Gen 2
Inches of Travel
080 = 80 in. (203 cm)
120 = 120 in. (305 cm)
Capacity
015 = 150 lb. (68 kg)
020 = 200 lb. (91 kg)
035 = 350 lb. (158 kg)
050 = 500 lb. (227 kg)
Type of Suspension Kit
00 = No Suspension
AT = ZRAT Rail
A1 = ZRA1 Rail
A2 = ZRA2 Rail
HM = Top Hook Mount
S2 = ZRS2 Rail
ZG 2W020 120 00S B
Type of Hook
B = Bullard
C = Steel Snap
Installation
WARNING
Prior to installation, refer to Product Safety Information Manual for all sections of installation.
1. To mount the ZG balancer, use brackets provided.
2. Connect air supply line to main air inlet using a 3/8" coupling.
3. Use 10 mm pipe for pneumatic connection.
Fig. A

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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. D).
Fig. C Fig. D
B
A
B
A
Handle Connection
1. Connect the handle eye bolt to the wire rope eyelet.
2. Connect the electric spiral wire to the electronic box.
3. Connect the electric spiral wire to the plug on the top of the handle.
4. Tighten the ring clockwise for a secure connection.
Fig. E
3
4
1
Turn ON Power
5. Switch ON the controls using the power switch on the main box.
a. To disengage the operation, press the Emergency Stop Button located on the top of the handle.
WARNING
Do not touch the control handle during initialization of the controller kit.
6. Release the Emergency Stop Button by rotating clockwise until it pops.
7. Push the power button (green) on the handle to begin operation.

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Fig. F
6
7
B
A
Deate the Chamber
8. Three yellow lights indicate completion of initialization of the controller. When lit, pull down sleeve of the handle to deate the chamber.
Fig. G
B
A
Operation
WARNING
●Press Emergency Stop button to stop movement in case of an emergency.
●Make sure electrical wiring to the ZG balancer conforms to all relevant safety codes and regulations.
●Make sure all electrical connections are secure before applying power.
●Never operate equipment with damaged, frayed or twisted electrical cables.
●Before each shift or initial use, inspect the ZG balancer for visible wear and damage.
●Immediately disconnect main power if the ZG balancer is damaged.
●Only licensed electrical technicians, trained on this product, should be allowed to access electrical components to perform
troubleshooting and/or repair.
●Troubleshooting of the system by licensed electrical technicians is limited to visual inspection of components and sub assemblies
once the enclosures are opened.
●Before accessing electrical components, follow ‘lock-out, tag-out’ procedures to make sure that power to the system has been
disconnected.
●Disconnect air supply to the ZG balancer prior to maintenance.
Standard Operation
Red light stays ON for two seconds immediately after powering up the ZG balancer. During this time, load cell and the handle sensor resting
values are calculated by the controller. When the red light turns OFF, the ZG balancer is ready for operation. If the resting values of the handle
and load cell sensors are out of expected range, red light ashes rapidly. During this state, the ZG balancer is not able to operate.
Fig. H
B
A

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Float Mode
Engage Float Mode
To engage oat mode, release the handle. Float mode will be triggered by lack of contact with the handle. While oat 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.
WARNING
Do not apply force on the load (upward/downward) while oat mode is calculating as this will cause faulty calculation of the weight
and drift of the load.
Move loads up and down by acting direclty on the load itself.
Disengage Float Mode
Float mode disengages automatically once the handle is touched resulting in yellow lights on the controller to turn OFF. When yellow lights
turn OFF, use the handle sleeve to move load upward/downward.
Conguration Tool
This is a windows application which communicates with the controller over USB serial port and helps the user to change settings and
enable/disable the ZG balancer features.
Steps to be followed for using Conguration tool
●Turn ON the ZG balancer and wait for the red light to turn OFF.
●Connect the controller to laptop using a USB cable.
●Run the conguration tool by double clicking its executable le.
●Select the communication/serial port number from the drop down box of the conguration tool.
●Click on the connect button. Tool will read data from the controller and present the last stored data in the controller.
When there is a communication loss between the controller and the conguration tool, a dialog box pops up as shown below:
If above message is frequently reported by the tool, restart communication by power cycling the controller. Unplug the USB cable and restart
the conguration tool.
Cycle Count
This counter indicates how many times a load weighing more than 10 kg is lifted in air and lowered to ground. Cycle count is incremented
when the load on the handle becomes less than or equal to the handle weight after lifting approximately 10 kg load.
No Load Balancing
Set the no load balancing if a handling device is permanently suspended to the unit. This will keep the handling device balanced in oat
mode and help to prevent damaging the part during loading/unloading.
The set value is the minimum weight limit the ZG balancer will handle. When the weight on the handle goes below no load balancing limit
then red light ashes rapidly and downward movement of load is disabled. During this stage, only lifting operation must be performed.
Steps to Enable/Disable No Load Balancing
●Using the handle mode, lift the handling device or gripper load to a height where it is clearly suspended in air.
●Connect the controller to laptop with a USB cable.
●Run the conguration tool .

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●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. Conguration tool will indicate the status of write operation with a write successful message box.
●No load balancing weight measured by the controller is displayed in conguration tool.
●This completes the enable no load balancing setup.
●To disable no load balancing feature, click the option “Clear no load balancing weight”, and save this setting by clicking on “Write settings“
button. Last, no load balancing weight will be set to zero.
●When the settings are saved successfully in the controller, conguration tool noties the user with message box as shown below:

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Interlock
The interlock feature will not allow the handling device to open while it is suspended. This feature can be enabled using the conguration
tool. Once enabled, the yellow lights indicate the user the state of interlocking operation as below:
●Yellow light1, indicates that the part is clamped.
●Yellow light2, indicates that the part is released.
●Yellow light3, indicates that the part is ready to be removed from the controller and load is no longer supported.
Note: Yellow lights status indication for oat mode ready is not available when interlocking is enabled.
Steps to Enable/Disable Interlocking
●Using the handle mode, lift the handling device or gripper load to a height where it is clearly suspended in air.
●Connect the controller to laptop with a USB cable.
●Run the conguration tool.
●To enable no interlocking feature, click the option“Set new interlock weight” , and save this setting to the controller by clicking on “Write
settings“ button. Conguration tool will indicate the status of write operation with a write successful message box.
●This completes the enable interlocking feature setup.
●To disable no interlock feature, click the option “Clear interlock weight” and save this setting by clicking on “Write settings“ button. Last,
interlock weight will be set to zero.
●When the settings are saved successfully in the controller, conguration tool noties the user with message box as shown below:
Note : The controller does not allow to disable/clear previously set interlock weight when the load weight measured by the controller is more
than the handle weight. Make sure to clear last interlock weight, the handling device should be lowered fully to the ground. Conguration tool
displays below message box when interlock disable is attempted while the load is still suspended in air.

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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 eld in conguration tool to set the
maximum weight.
Make sure to enter the load value in the controller less than 80% of the ZG balancer capacity. Else, the controller will reject the request. During
lifting operation, the controller allows the weight of the load to exceed the set limit by approximately 5
kg .
If the controller reads a weight more than the set maximum weight then upward movement is stopped and red light ashes rapidly. During
this stage, only downward movement is allowed.
Speed Settings
Speed settings are calibrated in factory for dierent weight ranges and dierent ZG balancer capacities. The default factory setting is set to
medium speed. A dierent speed setting can be programmed separately for lowering and lifting by selecting Low/Medium/High from the
respective drop down boxes. Save the settings by clicking on the “Write settings“ button.
Sensitivity Control Settings
Sensitivity Control settings are related to oat mode operation only. Higher the setting number, lower the sensitivity. Eort required to move
the load by directly applying force on the load is more when the sensitivity number is high and vice-versa.

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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.
Use release button (blue) on the controller handle to activate clamping action. Pull down the sliding part of the handle (bimanual action).
Use orange button on the controller handle to activate release action. Pull down the sliding part of the handle (bimanual action).
Orange and blue buttons must be wired outside of the handle sleeve using connection pins.
- Pin C and F: Additional clamp push button (NO contact).
- Pin C and G: Additional release push button (NO contact).
Schematics
Fig. J
A
Zero Gravity Extension Plug
Ready to Release Air Power
Clamping Device
Additional
Release Button
Additional
Clamp Button
B
C
D
L
E
H
MJ K
G
F
Extension Plug Pinout
Pin Function
A Not used
B Not used
C Ground
D +5 V for input
E Additional force sensor input
F Additional clamp button input
G Additional release button input
H Input 4
J +12 V for output
K Clamping output
L Release output
M Ready to release output
Input/Output Hardware
Kit ZGB00-I/O is required to connect to extension plug. Contact your service or sales representative for availability.
To activate, input switch unit to ground; to deactivate, input switch unit to +5 V DC or open wire.
To activate the controller, output switch output pin to ground. Output power supply voltage is 12 V DC. Do not exceed total of 3A.