electronic control system air balancers
Contents
1. Inte LIFT Electronic Control Balancers are designed and constructed to provide long trouble free service In time it may become necessary to order and install new parts to replace those that have been subjected to wear The use of other than Ingersoll Rand replacement parts may result in decreased balancer performance and may invalidate the warranty For prompt service and genuine Ingersoll Rand parts provide your nearest Distributor with the following 1 Complete model number and serial number as they appear on the labels 2 Part number and part description as shown in the parts section 3 Quantity required The model and serial number label is located on the balancer housing Model Serial Number Label Plate InteLIFT System MODEL NO SERIAL NO CAPACITY 100 PSIG PMAX 6 9 bar 120 V AC 50 60 Hz GD ingersollRand Ce US White House TN 37188 EU Wigan WN2 4EZ U K MADE IN USA For your convenience and future reference it is recommended that the following information be recorded Model Number Serial Number Date Purchased Return Goods Policy If it becomes necessary to return the complete balancer or certain parts to the factory contact the Distributor from whom you purchased the balancer or the nearest Ingersoll Rand Distributor in your area Ingersoll Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and w2. E8 ETA 8 Aluminum Rail Voltage Options 1 115V 50 60Hz 1PH 2 230V 50 60Hz 1PH Z Stop Options 0 None S P Stop Power Cord Options 0 None P Power Cord 6 ft 1 8 m Balancer Models Capacity at 100 psig Nominal Vertical Balancer Weight e Model 6 9 bar 690 kpa Hook Travel Diameter Wire Rope Number Reeving Ibs kg inches mm inches mm Ibs kg I W015080 1 150 68 80 2032 6 5 165 60 LT I W020120 200 91 114 2896 7 33 1 I W033080 330 150 70 1778 1 W040060 400 182 57 1448 10 254 65 30 2 I W050080 500 DAI 74 1880 120 54 I W066040 660 300 35 889 77 35 gt I W 100040 1000 455 37 940 125 57 Refer to control pendant designation 1 not available with Z Stop Option 4 MHD56222 Edition 3 INSTALLATION Prior to installing the Inte LIFT Electronic Control Balancer carefully inspect components for possible shipping damage A CAUTION e Owners and users are advised to examine specific local or other regulations including American National Standards Institute and or OSHA Regulations which may apply to a particular type of use of this product before installing or putting balancer to use NOTICE e This supplement contains information only for the Inte LIFT Electronic Control system used with an air balancer Use this supplement in conjunction with Balance Air Service Manual Form Number MHD561
3. Refer to Dwg MHP2159 on page 9 The InteLIFT control panel contains printed circuit boards which when programmed from the display face or pendant control will provide Balancer operating parameters InteLIFT Electronic Control system set up is performed at the control panel and with the pendant Control panel provides function indicator lights and a LCD window to assist setup and operation Inte LIFT Electronic Control settings are stored and are not lost in the event of a loss of power or power failure The CLAMP UNCLAMP switch will remain at its initial setting INTERLOCK SMART DROP or NONE ON OFF Circuit Breaker Switch Located on the top edge right hand side as viewed facing control panel of the electric control panel the ONT OFF switch incorporates a circuit breaker The circuit breaker will automatically open if a problem occurs with the electronic circuitry MHD56222 Edition 3 LCD Window The two line LCD window provides function setting and adjustment parameters or current operating mode Control Panel Functions and Locations UP ON OFF ce Solenoid Circuit olenoi Green Breaker InteLIFT Green Indicator Switch Operation Indicator Lights and Fault Lights Red Indicator Power Light Connection a Ve Ss qs IK sa Lal Power ON Green Set U Indicator H Control Handle Light Shift Cable Connection
4. 15 Green power light on control panel LOAD CELL CAPABLE is illuminated After 3 seconds the LCD will automatically change to the run ICW INTELI screen OPTION 511 as possible Set up Menu Press Set up button on main control panel Green power and red Inte LIFT lights are NOT illuminated PUSH NEXT FOR NEXT SCREEN Press NEXT button To change selections PUSH UP TO CHANGE SELECTION Set Model Press NEXT button Press UP button to select model Identification ICW IAW or ISW Unit is factory SELECT MODEL programmed and should not require cw changing Change InteLIFT Press NEXT button Press UP button to select operating Operating Mode mode FLOAT DUMP or NONE Select Options Press NEXT button Press UP button to select operating mode INTERLOCK SMATDRP or NONE SELECT OPTIONS EEK TARE End Effector Press NEXT button Push UP button to TARE Hook must be supporting end effector and PUSH UP KEY TO TARE hanging freely END EFFECTOR TARE Control Press NEXT button Note number in bottom right of Handle LCD Use UP DOWN button on SET UP DOWN TO control panel to adjust as close to APPROX 511 Exit Set up Menu Press Set up button on main control panel Return to run screen PRESS SETUP KEY TO FINISH SETUP Will be displayed if a Load cell is present If there is no Load cell the will not appear Will display either FLOAT DUMP or NONE dependin
5. If the InteLIFT option is not required NONE will be programmed at the control panel and the red light will not illuminate on the control panel when the pendant Inte LIFT button is depressed Float Allows operator to grasp attached load to raise lower and position load without use of control handle Float mode is achieved with a load cell hook or via the pressure transducer on the unit Refer to Dwgs MHP2473 and MHP2474 on page 28 for available load cell hook assemblies Model ISW Units do not use a load cell hook assembly 1 Ensure the correct capacity load cell hook is attached to the Balancer 2 Plug the load cell connector into the back of the control pendant 3 Ensure all connections are clean and secure CAUTION e When depressing the Inte LIFT pendant button for FLOAT mode operation ensure end effector and load are freely suspended with no obstructions or supports FLOAT mode cannot be turned on prior to lifting the load FLOAT mode and load cell control handle provide the same results and cannot be used together Dump Holds original position regardless of an increase or decrease in weight None When InteLIFT function is off balancer functions as a lifting and lowering device To change the mode of the main control unit refer to Balancer Control Adjustments on page 12 Remote Tare Provides the capability to change the end effector tare configuration with the pendant cont
6. PARTS DRAWING NOTE Item 44 location may vary depending upon balancer model Dwg MHP2155 22 MHD56222 Edition 3 ELECTRONIC CONTROL ASSEMBLY PARTS LIST 46 52 53 and 60 Item Description Qty Part Number No of Part Total 150 1b 68 kg 200 1b 91kg 330 1b 150 kg 500 Ib 227 kg 1 Capscrew 1 10017 2 Washer 2 74516 3 End Cover Assembly w o Z Stop 1 ZHSEA0010 ZHSEA0012 End Cover Assembly w Z Stop ZHSEA0016 4 Z Brake Assembly 1 ZHSEA0034 ZHSEA0032 ZHSEA0038 5 Ball Nut Stop 1 ZHSEA0163 ZHSEAO011 ZHSEA0030 6 Capscrew 3 Y99 41 7 Loop Bracket ISW Models 1 ZHSEA0087 Loop Bracket IAW and ICW Models ZHSEA0232 8 Thimble 2 31477 9 Nut 1 Y192 1 Z 10 Loop Strap 1 ZHSEA0086 11 Clamp 1 ZHSEA0195 12 Electrical Harness Encoder 1 ZHSEA0106 13 Screw Main Enclosure 4 ZHSEA0088 14 Screw 2 ZHSEA0085 15 Z Stop Plate 1 ZHSEA0035 ZHSEA0036 16 Sleeve 1 32356 17 Washer Grounding 2 ZHSEA0091 18 Nur Grounding 1 ZHSEA0092 19 Sideplate Enclosure 2 ZHSEA0084 20 Screw 10071 2 10072 8 21 Screw 2 ZHSEA0029 22 Housing Assembly 1 ZHSEA0009 ZHSEA0005 ZHSEA0039 23 Nut 2 10124 Screw 1 10120 24 Plate 1 10125 25 Wire Ro
7. While supporting the control panel remove one capscrew 13 then tilt and remove control panel from sideplates 19 19 Cleaning Inspection and Repair Use the following procedures to clean inspect and repair the components of the unit Cleaning e Do not use trichloroethylene to clean parts The use of a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on the end covers and housing Keep control panel surface clean Inspection All disassembled parts should be inspected to determine their fitness for continued use Pay particular attention to the following 1 Inspect all wiring and connections for worn cracked or broken insulation wires and connectors Check for uneven edges on ribbon cable ends 2 Inspect all threaded items and replace those having damaged threads 3 Check electrical connectors to ensure prongs and locking rings are not damaged 4 Check that all connectors are fully seated and not offset by one pin Repair Repairs are limited to minor replacements For major component replacement or repair it is recommend that maintenance work be performed by an Ingersoll Rand service repair center 1 Worn or damaged parts must be replaced Refer to the applicable parts listing for specific replacement parts information 2 Replace any electrical components that have tested faulty 3 Inspect all remaining parts for evidence of damage Replace or repair any par
8. form your basis for claim against the carrier 31 United States Office Locations For Order Entry and Order Status Ingersoll Rand Distribution Center P O Box 618 510 Hester Drive White House TN 37188 Phone 615 672 0321 Fax 615 672 0801 Technical Support Ingersoll Rand ECOE 1725 US Hwy 1 North Southern Pines NC 28387 Phone 866 284 5509 Fax 910 692 7822 Web Site www irco com Printed in USA Regional Sales Offices Ingersoll Rand 1872 Enterprise Drive Rochester MI 48309 Phone 248 293 5700 Fax 248 293 5800 International Office Locations Offices and distributors in principal cities throughout the world Contact the nearest Ingersoll Rand office for the name and address of the distributor in your country or write fax to Canada National Sales Office Regional Warehouse Toronto Ontario 51 Worcester Road Rexdale Ontario MOW 4K2 Phone 416 213 4500 Fax 416 213 4510 Order Desk Fax 416 213 4506 Latin America Operations Ingersoll Rand Production Equipment Group 730 N W 107 Avenue Suite 300 Miami FL 33172 3107 USA Phone 305 559 0500 Fax 305 222 0864 Europe Middle East and Africa Ingersoll Rand Douai Operations 111 Avenue Roger Salengro 59450 Sin Le Noble France Phone 33 3 27 93 08 08 Fax 33 3 27 93 08 00 Asia Pacific Operations Ingersoll Rand 42 Benoi Road Jurong Singapore 629903 Phone 65 861 1555 Fax 65 861 0317 Ru
9. of control panel assembly as viewed facing control panel Lock cable in place by screwing locking ring in a clockwise direction until fully engaged Ensure pendant control handle is supported by strain relief cable attached to loop bracket 6 Connect power supply cord and turn on power Pendant Assembly e Do not allow pendant control handle cable to support the weight of the pendant control handle Weight must be supported by strain relief cable assembly to prevent damage to electrical wires 1 Ensure loop bracket 7 is securely attached to end cover assembly 3 Place cable into loop strap and secure in place with capscrew 6 and nut 9 Ensure cable has a short loop between loop clamp and control panel 2 Attach pendant assembly 35 cable to control panel 29 by inserting cable plug into port located on bottom right hand side of control panel assembly as viewed facing control panel 3 Lock cable in place by screwing locking ring in a clockwise direction until fully engaged 4 Install strain relief cable if supplied Testing Refer to Balancer Control Adjustments on page 12 Conduct intial control panel setup steps first followed by specific adjustments for balancer operation Refer to Balance Air Service Manual Form Number MHD56151 for balancer testing to be conducted upon completion of Inte LIFT Electronic Control Panel and Control Handle setup and testing 21 ELECTRONIC CONTROL ASSEMBLY
10. 2 in Orifice ZHSEA0076 47 Capscrew 2 Y99 478 48 Standoff Tube 1 ZHSEAO0158 49 End Enclosure 1 ZHSEA0081 ZHSEA0146 50 Standoff Screw 1 ZHSEAO188 51 Screw 3 ZHSEA0190 52 Loop Strap 1 ZHSEA0157 53 Screw 1 ZHSEA0095 54 Encoder Disc 1 ZHSEA0023 55 Spacer w o Z Stop i ZHSEA0025 ZHSEA0161 Spacer w Z Stop ZHSEA0162 56 Screw 2 4 ZHSEA0027 2 ZHSEA0027 4 57 Plate 1 ZHSEA0026 58 Encoder 1 ZHSEA0024 59 Bracket 1 ZHSEA0186 60 Pipe Plug 1 ZHSEA13500 62 Screw 1 ZHSEA0017 63 Nylon Tie 1 ZHSEA0196 G Recommended spare for one balancer 2 years normal operation For 400 660 and 1000 Ib 182 300 and 455 kg reeved balancers refer Balance Air Service Manual Form MHD56151 for additional information Additional Parts and Kits Power Supply Cord 3 ft 0 9 m 1 ZHSEA0103 ES e SS Pre Coil Cable Assembly 1 ZHSEAO180 12 ft 3 7 m Straight electric cable 1 ZHSEA0067 Loctite 222 1 ZHSEA0235 Grease 4cc 10549673 Replacement fuses for the control panel are available from RadioShack or Digi Key 1 800 244 4539 www digikey com Refer to the following fuse capacities and part numbers 5 x 20 mm SLO BLO Fuses Ingersoll Rand Part Numbers Manufacturers Part Numbers 1 2 Amp ZHSEA0237 F972 ND 2 Amp ZHSEA0238 F978 ND 4 Amp ZHSEA0239 F981 ND 24 MHD56222 Edition 3 Z BRAKE ASSEMBLY 150 LB 68 KG BALANCER Refer to unit breakd
11. 51 Mounting Balancers can be hook or trolley mounted Refer to Balance Air Service Manual Form Number MHD56151 for suspension kit installation instructions There are five major subassemblies comprising the Inte LIFT Electronic Control system Refer to Dwg MHP2166 on page 5 Control Panel Manifold Assembly Encoder Sensor Assembly Control Pendant Handle Hook Load Cell Assembly CAUTION e Do not lift or support the balancer by the manifold assembly The manifold assembly is not designed to support the weight of the balancer SOP Pe Control Handle Connection Disconnect power from system e Avoid clamping knotting and crushing of electrical cable Check cable clamps and anchoring devices are securely attached and tight 1 Attach control handle assembly 35 cable to control panel assembly 29 by inserting cable plug into port located on bottom right hand side of control panel assembly as viewed facing control panel The plug has orientation keys and must be properly aligned to engage MHD56222 Edition 3 2 Lock cable in place by screwing locking ring in a clockwise direction until fully engaged 3 Place cable into cable loop strap 10 and secure with capscrew 6 and nut 9 Ensure cable between control panel and loop strap has a small loop and loop strap is not overtight Strain Relief The control handle and electrical cabling are supported by a strain relief cable 31 for all str
12. Form MHD56222 PARTS INSTALLATION AND MAINTENANCE SUPPLEMENT InteLIFT ELECTRONIC CONTROL SYSTEM for AIR BALANCERS READ THIS MANUAL BEFORE USING THESE PRODUCTS This manual contains important safety installation operation and maintenance Dwg MHP2156 information Make this manual available to all persons responsible for the installation operation and maintenance of these products AWARNING This equipment is intended for industrial use only and should not be used for lifting supporting or transporting people or lifting or supporting loads over people 0 Always operate inspect and maintain this balancer in accordance with applicable safety codes and regulations Use this supplement in conjunction with Balance Air Service Manual Form Number MHD56151 Form MHD56222 Edition 3 0 SC GP Ingersoll Rand 2002 Ingersoll Rand Company SAFETY INFORMATION This manual provides important information for all personnel involved with the safe installation operation and proper maintenance of this product Even if you feel you are familiar with this or similar equipment you should read this manual before operating the balancer Danger Warning Caution and Notice Throughout this manual there are steps and procedures which if not followed may result in an injury The following signal words are used to identify the level of potential hazard Danger is used to indicate the pre
13. Strain Relief Cable Note Red light will blink when one of the InteLIFT modes is activated When light is on but not blinking a system fault is indicated Dwg MHP2159 Control Panel Set Up There are five buttons labeled Shift Set up Next Up and Down on the face of the control panel System operating modes and settings are implemented through these button which allow for e Changing operational modes e Running operational self test Performing TARE adjustments e Enabling Interlock or Smart Drop feature e Configuring for Capacity Set up Allows electronic system functions to be configured Next Advances to the next LCD screen within a menu Up Down Range of options based on the function feature displayed Up Down buttons change selected feature or feature parameter displayed in the LCD window float dump interlock smart drop etc NOTICE e Up Down buttons on control panel do not perform the same functions as UP DOWN rocker switch on control handle MHD56222 Edition 3 Balancer Direction and Solenoid Indication Lights Balancer direction and solenoid operation are indicated by the row of six green lights located on the right hand side of the LCD window Two groupings of three lights on the control panel surface flash as the load is lifted and lowered Power ON and Inte LIFT Indicator Lights Located to the left of LCD windo
14. Subject each balancer to a regular inspection and maintenance program 4 Be aware of the balancer capacity and weight of load at all times Operators must be physically competent Operators must have no health condition which might affect their ability to act and they must have good hearing vision and depth perception The balancer operator must be carefully instructed in his duties and must understand the operation of the balancer including a study of the manufacturer s literature The operator must thoroughly understand proper methods of hitching loads and should have a good attitude regarding safety It is the operator s responsibility to refuse to operate the balancer under unsafe conditions Initial Operating Checks Balancers are tested for proper operation before leaving the factory Prior to placing balancer into service the following initial operating checks should be performed 1 After installation check to ensure the balancer is centered and secure 2 Check connections and position of all electrical supply cords and plugs 3 If balancer is attached to a trolley operate along the entire length of the beam 4 Check balancer performance when raising moving and lowering test load s Balancer and trolley must operate smoothly prior to being placed in service The balancer is not designed or suitable for lifting lowering or moving persons Never lift loads over people Control Panel
15. WN control Shifting rocker switch left operates balancer in down direction shifting rocker switch right operates balancer in up direction Releasing rocker switch automatically causes switch to shift to neutral position and stops operation Operating speed is additionally controllable within the selected speed range by the amount the rocker switch is depressed Partially depressing the rocker switch will provide slower balancer speeds NOTICE e UP DOWN rocker switch on control handle does not perform the same functions as the UP and DOWN buttons on control panel When operating mode is set to FLOAT and InteLIFT button on control handle is on the operator may grasp attached load to raise lower and position load without use of control handle Load will remain in last position FLOAT mode and a load cell handle cannot be used together Clamp Unclamp Operation The pendant CLAMP UNCLAMP button engages or disengages an end effector clamping device if used with balancer as part of a system Interlock is a standard feature which prevents dropping of a supported part through inadvertent operation of the CLAMP UNCLAMP button CLAMP UNCLAMP operation is achieved through the 12 pin plug located in the back of the handle MHD56222 Edition 3 Set TARE for end effector prior to using Clamp Unclamp feature Refer to Balancer Control Adjustments on page 12 Smart Drop Combines the oper
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17. ad until only the weight of the end effector is supported The clamp will then open disengaging the load Up Control Disable mode prevents lifting of the load until an end effector clamp or vacuum cup has fully engaged and secured the load The Inte LIFT Electronic Control system can incorporate Part Present optional feature consisting of photoelectric eyes infrared sensors proximity switches and non contact switches These can be individually designed to add functionality to the system Contact your distributor or technical support for additional information Model Code Explanation Example IAW020120A21SP IA W 020 120 A2 1 S P Control Pendant IA InteLIFT Pendant Control Handle with 12 ft 3 7 m Pre coil Cable IB InteLIFT Basic unit no controls c Inte LIFT Load Cell based Load Sensing Control Handle with 12 ft 3 7 m Pre Coil Cable IS InteLIFT Control Handle with 12 ft 3 7 m Straight Cable Type W Wire Rope Capacity 020 200 lbs 91 kg for available capacities refer to Balancer Models Table Travel 120 120 inches 3048 mm for available travel refer to Balancer Models Table Upper Suspension Options 00 No Suspension Al ZRAT Aluminum Rail A2 ZRA2 Aluminum Rail S2 ZRS2 Steel Rail S3 ZRS3 Steel Rail HM Top Hook Mount TR TRail I Beam AT ZRAT Aluminum Rail K1 KBKI Steel Rail K2 KBK2 and KBK2L Steel Rail E4 ETA 4 Aluminum Rail
18. aged or inoperable The following instructions describe how to remove pendant from control cable 1 Remove three screws 51 that secure hanger plate 59 to back of pendant body 2 Remove two 6 32 screws located on underside of pendant body 3 Carefully lift and partially separate front face from pendant body Do not stretch or damage wires 4 Remove two 3 48 screws securing circuit board to the handle body lower left and upper right 5 Remove ring nut from 12 pin plug in back of handle body using suitable nut wrench ZMS20 Lumberg 6 Carefully separate circuit board from pendant body far enough to allow removal of 16 pin pendant control cable connector The following instructions describe how to attach pendant to control cable 1 Install 16 pin pendant control cable connector to pendant handle circuit board 2 Carefully press circuit board back into pendant handle and install ring nut on 12 pin plug from the outside of the pendant body Tighten nut using suitable nut wrench ZMS20 Lumberg 3 Apply a small amount of Loctite 222 to threads and install two 3 48 screws to secure circuit board to the handle body lower left and upper right 4 Carefully tuck wires into pendant body and assemble front face to pendant body Secure with two 6 32 screws 5 Attach hanger plate 59 to back of pendant with three screws 51 Manifold Removal Manifold assembly 41 is located on left hand side of balancer canis
19. aight cable pendant applications Refer to control pendant designation IS in Model Code Explanation on page 4 e Straight cable pendants must never be suspended without a supporting strain relief cable End Effector Refer to the supplemental documentation provided with the end effector Component Locations Power Connection ON OFF Encoder Circuit Breaker Sensor Assembly Manifold Assembly west gor Kan Si ST Control Handle Cable Connection Strain Relief Cable Dwg MHP2166 Electrical Power Connection Refer to Wiring Diagram Dwg MHP2158 on page 13 for electrical connections Power Supply conductors must be sized for 1 Amp in accordance with NEC 310 15 b specifications AWARNING e Electrical installation should be performed by licensed electricians in accordance with the latest edition of National Electrical Code ANAI NFPA 70 and any applicable local state and national electrical codes and ordinances e Before connection of the Inte LIFT Electronic Control Balancer check to ensure that voltage specified on serial number label matches that which is available The Inte LIFT Electronic Control system should be installed and connected by a licensed electrician who is knowledgeable with NEC article 430 and local regulations Ensure voltage and frequency of electrical supply corresponds with data on balancer serial number label before connection I
20. an inspection process should be conducted to determine the full extent of the problem as well as the likely cause if applicable The balancer should not be operated until the problem and cause if applicable have been corrected Ensure the Inte LIFT Electronic Control balancer is tested by personnel qualified in the maintenance and service of this product before placing back in service Cleanliness Routine cleaning of the control panel display surface will improve visibility and prevent the accumulation of dirt 1 Clean the face of the control panel with non abrasive cleansers only Dry completely 2 Periodically clean surfaces to prevent the accumulation of dirt and debris If using liquid cleaners carefully mist and wipe to ensure excess liquids do not leak into the control panel housing 3 If required as a result of dirt or debris accumulation at the contacting edges of the balancer and control panel housing the control panel can be opened to access this area Use low pressure air commercially available canned air is recommended to carefully blow debris away from electronic components Balancers Not in Regular Use Standby balancers and balancers which have been idle for an extended period should be checked to ensure they are functioning properly and that the electronic control settings are correct for the balancer application Conduct intial control panel setup steps first followed by specific adjustments fo
21. ation 26 MHD56222 Edition 3 LOAD SENSING ASSEMBLY DRAWING AND PARTS LIST Dwg MHP2243 Wen Description Qty Part Number 51 Screw 3 ZHSEA0190 70 ee incl s electrical connector and 30 in 1 ZHSEAO181 71 Load Cell Bracket 1 54037635 72 Handle Bracket 1 54037627 Order separately MHD56222 Edition 3 27 LOAD CELL ASSEMBLY DRAWINGS Reeved Bottom Hook Capacities 400 Ib 660 Ib and 1000 Ib Single Fall Hook Dwg MHP2473 Dwg MHP2474 28 MHD56222 Edition 3 LOAD CELL ASSEMBLY PARTS LIST Ke Total Part Number Load Cell Assembly incl s items 80 to 85 80096480 eege 80102130 80 Eye Bolt 1 80105612 81 Load Cell 250 kg 1 80096407 82 Washer 1 Y13 4 C 83 Nut 1 10431 84 Pin 1 Y178 23 85 Bottom Hook 1 80096423 86 Plate 1 10428 87 Nut 4 10431 88 Nut 1 10437 89 Bearing 2 65012 90 Sheave 1 40689 91 Spacer Block 1 10438 92 Thrust Washer 1 65061 93 Capscrew 1 95841839 94 Thrust Washer 4 65061 95 Thrust Bearing 1 65059 96 Guard 2 10423 97 Drive Pin 2 10440 98 Retainer Block 1 10421 99 Plate 1 10442 100 Pin 2 10435 101 Capscrew 1 10426 102 Capscrew 4 10429 103 Nut 1 Y11 108 C 104 Load Cell 1000 kg 1 80101983 105 Bottom Hook 1 80102437 106 Label Warning 1 10444 MHD56222 Edition 3 29 PARTS ORDERING INFORMATION
22. ations of lowering and unclamping It is a programmable feature selected through the control panel menu When selected the unloaded end effector must be zeroed to insure proper operation Once Smart Drop is enabled and the CLAMP UNCLAMP button is pressed and held down the part will be lowered until only the weight of the end effector is supported and then the clamped part will be released Interlock Interlock provides additional protection during normal operation The unloaded end effector must be zeroed as a preset to allow for proper operation This programmable option enables the system to determine if there is an unsupported load on the end effector when CLAMP UNCLAMP button is depressed If the system detects more weight than the unloaded end effector the end effector will not be allowed to unclamp Once the load is completely supported the Unclamp function will work UP Control Disable Up Control Disable mode prevents lifting of the load until an end effector clamp or vacuum cup has fully engaged and secured the load Up Control Disable is available through the 12 pin connector located in the back of the control pendant handle Refer to Wiring Diagram on page 13 Up Disable is achieved by closing the circuit between pin H and J Opening the circuit allows UP operation Load Sensing Handle optional feature The load sensing handle is designed to respond to forces that are much smaller than the
23. bly observe the following 18 1 Turn off and tag electrical disconnect switch before performing any maintenance Disconnect electrical cable from control panel 2 Never disassemble balancer any further than is necessary to accomplish needed repair A good part can be damaged during the course of disassembly 3 In general balancers are designed to permit easy disassembly and assembly The use of heat or excessive force should not be required 4 Keep the work area clean to prevent dirt and other foreign matter from getting into balancer 5 When grasping a part in a vise always use leather or copper covered vise jaws to protect the surface of part and help prevent distortion This is particularly true of threaded members machined surfaces and housings 6 If repair work can only be conducted above body height suitable working platforms or ladders must be made available 7 Work on electrical equipment should only be conducted by licensed electricians in accordance with all appropriate electrical codes and regulations Disassembly The following instructions provide the necessary information to disassemble inspect and repair the InteLIFT Electronic Control system Parts drawings are provided in the Parts Section to assist in locating components If an InteLIFT Electronic Control Balancer is being completely disassembled for any reason follow the order of topics as they are presented When working on a balan
24. ce of this equipment Inspection intervals depend upon the nature of the critical components of the equipment and the severity of usage The inspection intervals recommended in this manual are based on intermittent operation of the unit eight hours each day five days per week in an environment relatively free of dust moisture and corrosive fumes If the unit is operated almost continuously or more than the eight hours each day more frequent inspections will be required Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages allowing corrective action to be taken before the condition becomes dangerous Deficiencies revealed through inspection or noted during operation must be reported to designated personnel trained in safety operation and maintenance of this equipment A determination as to whether a condition constitutes a safety hazard must be decided and the correction of noted safety hazards accomplished and documented by written report before placing the equipment back in service 14 InteLIFT Control System The Inte LIFT Electronic Control system should be visually inspected on a daily basis prior to initial operation at the beginning of each shift and monitored during balancer operations Visual inspections should include those items noted in the Preventive Maintenance Inspection Schedule on page 15 At any indication of damage or a potential problem
25. cer it is recommended that the balancer be removed from its mounting and placed on a clean work bench in a well lighted area In the process of disassembling the balancer observe the information provided in the General Maintenance Instructions e Never perform maintenance on a balancer system while is supporting a load Disconnect power and remove all load from balancer system NOTICE The following disassembly instructions apply only to the Inte LIFT Electronic Control system subassemblies To further disassemble the balancer for maintenance or repair refer to Balance Air Service Manual Form Number MHD56151 Unless otherwise noted part names and item numbers are from the assembly drawing and parts list Refer to Dwg MHP2155 on page 22 Pendant Removal 1 Disconnect pendant cable from control panel by rotating locking ring counterclockwise until free of threads 2 Pull downward to disconnect pendant cable plug from control panel plug interface 3 Remove capscrew 6 nut 9 and loop strap 10 from loop bracket 7 MHD56222 Edition 3 4 To disconnect strain relief cable remove clamp 11 from cable 31 and pull cable through hole in loop bracket 7 Remove cable thimble 8 Pendant and or Control Cable Replacement NOTICE e Pendant maintenance and repair should be performed by an authorized Ingersoll Rand service repair center Pendant component repair parts are not available Replace pendant if dam
26. cer order new labels WARNING LABELS AND TAGS and install them Refer to the parts list for the part numbers Labels may be shown smaller than actual size Hazardous voltage can cause severe injury or death Disconnect power and lockout before removing cover or servicing Do not operate without cover in place 71125751 Failure to follow these warnings may result in death severe injury or property damage Do not operate this balancer before reading operation and maintenance manual Do not lift people or loads over people Do not lift more than rated load Do not operate unless load is centered under balancer Do not operate with twisted kinked or damaged chain or wire rope Do not operate a damaged or malfunctioning balancer Do not remove or obscure warning labels Do not remove load or handling device until tension is released from wire rope Do not operate with more than 100 psi air pressure Do not leave a suspended load unattended Do not use handling devices or hook that does not securely hold the load Do not attempt to lift a load that is not free to move GD Ingersoll Rand Failure to follow these warnings may result in death severe injury or property damage Do not operate balancer before reading operation and maintenance manual Do not operate balancer when damaged or malfunctioning Do not lift more than rated ca
27. cer the end enclosure houses the valve and manifold assembly This subassembly is the electric to air balancer operation interface The manifold assembly regulates air flow into balancer The pressure transducer is used in conjunction with the Float mode for the control system Located on right hand end as viewed facing control panel of balancer the encoder sensor and wheel assembly control the balancer when operated in Dump mode MHD56222 Edition 3 The Inte LIFT Electronic Control system provides additional features and benefits not currently available with controls for air balancers The Inte LIFT Electronic Control provides the combined functionality of a range of pneumatic controls and other benefits through the use of electronics The control panel provides the means by which each of the control features are selected Dynamic Lift and Lower mode requires operation of the control handle or force sensing load cell to move the load up or down Float mode allows load to be moved up or down without operator input to a control switch or handle Sensor feedback provides continuous float operation Dump mode establishes a fixed position configuration When engaged the handling device will remain steady at a predetermined position as load is added or removed Smart Drop mode allows the operator to select the Clamp Unclamp button regardless of load position The balancer will automatically operate to lower the lo
28. e axis only as indicated by the arrows One end of the load cell should be attached to the end effector and the other should be connected to the handle The force sensing axis of the load cell should be oriented in the vertical axis up down direction If load cell is not properly oriented it will not correctly interpret operator input it may move up or down when operator tries to move load laterally or it may not readily move up and down This can cause unstable or unsafe operation Wires located in the load cell compress stretch when deflection occurs causing voltage fluctuations that are detected by the control panel The load cell is symmetric in shape so it is possible for it to be inadvertently installed upside down This will reverse signals causing the Balancer to go down when handle is pressed up and vice versa Ensure proper installation prior to operation Force Dwg MHP2249 The load cell can be attached using two M6 tapped holes set on 9 16 ins 15 mm centers located on each end Brackets designed for mounting the handle and load cell are shown in the PARTS section For Balancer to function properly up down control tare must be set Refer to OPERATION section H OPERATION The four most important aspects of operation are 1 Follow all safety instructions when operating balancer 2 Allow only personnel trained in safety and the operation of this product to operate balancer 3
29. g on the operating mode selected Will display SMATDRP INTERLOCK or NONE depending on what is selected 12 MHDS56222 Edition 3 13 SON SUD OV HOA OEZ 104 UODEULOD BETEN ER Nng Nya TIAJ IHM O0n Et Jf Ga N G aad 79 LZE LL oo op z HG 63 g8 b mo m ST S SS se n BBB sepoou 3 elelelelele 5 Pied BR Vom 8 GND Oe ett OVASHL no NI OVA OEZ 60L0WASHZ 924 ND 1g1zg1691t81991981 a i jqw ssy Pee CES PHE Ze G elelelelele aided pouaioglelele g ep 9 pe TT g m ji Al SEI a rl DIS e Es IHM 199 CO 3 5 S a gt wg 9 SS ED ya 3 3 LHM g L8LOVISHZ jqw ssy
30. h to ON position Intermittent operation Poor grounding earth Correctly ground earth power supply Check wiring for broken wires Foreign material or moisture on electrical con nectors Dry or remove foreign material which may have accu mulated on electrical parts Open Short in power supply system Check all switches connections and circuit breakers in power supply line for damaged insulation Fault light stays on Improper operation Do not press any of the control handle buttons during startup or TARE operation Control handle is not TARED or TARE needs resetting Reset Control Handle TARE Refer to Balancer Control Adjustments on page 12 MHD56222 Edition 3 17 MAINTENANCE AWARNING e Never perform maintenance on the balancer while it is supporting a load e Before performing maintenance tag controls WARNING DO NOT OPERATE EQUIPMENT BEING REPAIRED e Only allow personnel trained in service and repair of the Inte LIFT Electronic Control system to perform maintenance e After performing any maintenance test balancer before returning to service e Shut off and tag electrical disconnect switch before performing any maintenance e Electrical procedures should be performed by licensed electricians in accordance with the latest edition of National Electrical Code ANAI NFPA 70 and any applicable local state and national elec
31. he X indication operating mode or setup condition of the control panel Control Handle Damaged housing Control handle must not be damaged or buttons X loose buttons worn and loose in housing Strain relief Strain relief must support weight of pendant X handle Wiring must not be allowed to support weight of pendant Control Handle Control handle functions must provide smooth and X operation accurate operation Electrical Insulation Wire insulation must not have breaks be brittle or X Wiring supply support any component Insulation must be pliable MHD56222 Edition 3 15 INSPECTION AND MAINTENANCE REPORT Ingersoll Rand Inte LIFT Electronic Control System for Air Balancers Model Number Date Serial Number Inspected by Reason for Inspection Check Applicable Box 1 Scheduled Periodic Inspection Quarterly Semiannually Yearly Operating Environment 2 Discrepancy s noted during Frequent Inspection 3 Discrepancy s noted during maintenance Normal Heavy Severe 4 Other Refer to the Parts Operation and Maintenance Manual INSPECTION section for general inspection criteria Also refer to appropriate National Standards and codes of practice If in doubt about an existing condition contact the nearest Ingersoll Rand Distributor or the factory for technical assistance CORRECTIVE CONDITION COMPONENT ACHON NOTES Pass Fail Repair Replace Fasteners C
32. heck pendant cable control connections at pendant and electronic control panel Check 0 5 amp fuse in control panel Control Handle TARE needs resetting Reset control handle TARE Refer to Balancer Control Adjustments on page 12 Pressed UP DOWN rocker switch on control handle during start up 3 second self test Restart the Inte LIFT Electronic Control system without pushing UP DOWN rocker switch during 3 second start up self test Dump Mode does not work Pendant or system malfunction Depress Inte LIFT button and ensure red light on control panel is flashing Loose or disconnected electrical connection Check connection at encoder sensor Check encoder connection at control panel Float mode does not work Pendant or system malfunction Depress InteLIFT button and ensure red light on control panel is flashing Loose or disconnected electrical connection Check pressure sensor connection at manifold Check pressure sensor connection at control board Clamp Unclamp mode does not work Loose or disconnected electrical connection Check wiring to the servo unit on end effector Check pendant connection at handle and main board Set Interlock TARE No response from balancer Emergency Stop engaged Depress ON button on control ON OFF switch in OFF position Shift switc
33. housing 5 Install capscrew 1 and washer 2 in center of end cover assembly 6 Install capscrews 20 attaching end cover assembly to housing 7 Install loop bracket 7 to end cover asembly and secure with capscrews 6 Manifold Assembly 1 Install solenoid valve 46 in manifold 41 a Hold coil to prevent rotation and tighten valve seat until snug b Tighten nut on top of solenoid valve assembly 46 2 Repeat step 1 through 1b for remaining solenoid valves 3 Install O ring 39 in recess on back face of manifold 41 Install muffler pads 40 4 Align holes in end cap 38 with manifold 41 Install capscrews 47 to secure manifold to end cap NOTICE e Ensure wire color to solenoid information is followed during assembly Refer to Manifold Solenoid Valve Identification Table on page 21 5 Connect wires from electrical harness control panel to solenoids 37 to solenoid valves Ensure correct wires are connected to solenoids Use wire color and location information documented during removal Refer to Dwg MHP2170 on page 21 and Identification Table on page 21 6 Secure loop strap 52 to manifold with capscrew 53 to secure electrical harness 7 Attach air hose to manifold MHD56222 Edition 3 Manifold Solenoid and Pressure Transducer Locations Outlet Valves Right Side Inlet Valves Left Side Manifold Dwg MHP2170 Manifold Solenoid Valve Identification Table Refer t
34. ight hand capscrews 13 which attach control panel 29 to sideplates 19 4 Allow control panel to swing down and hang freely from the two remaining screws 5 Locate two screws on underside of control panel just to left of pendant connector Loosen or remove 2 nuts to allow access to the terminal block Remove nuts and numbered terminal cover 6 Loosen screw at terminal 5 and reroute white wire to terminal 1 7 Loosen screw at terminal 6 and reroute brown wire to terminal 1 8 Tighten screws in terminal block Install numbered terminal block cover 9 Install screws and nuts to attach terminal block to control panel 10 Swing control panel up and secure to sideplates 19 with capscrews 13 11 Attach pendant control handle and connect power 230v Wiring Connections Dwg MHP2231 Care must be taken to ensure air supply hose and electrical supply cable are correctly installed to avoid entanglement which can cause damage and affect balancer operation Contact factory for information on additional electric power cable festooning systems ON OFF Switch and Circuit Breaker Located on the top edge right hand side from facing view of the electric control panel the ON OFF switch incorporates a circuit breaker The circuit breaker will automatically open if a problem occurs with the electronic circuitry Ground Earth Connections The power supply connection includes a gro
35. n addition the following points are of primary importance when installing and connecting the balancer Location The balancer must be installed in an area where it will be protected from direct exposure to rain and moisture Protect balancer from corrosive gases vibration air borne dust and metallic particles Electrical Connections If not tight and secure may cause operational problems During installation electricians must make sure that all electrical connections including the ground connection are secure Make sure all junction boxes and switch enclosures are adequately sealed and protected for the environmental conditions to be encountered Inte LIFT Electronic Control Balancers are supplied with a power connection plug The supplied connection plug must be installed on the power cord to connect the main control and the electrical power source An optional 3 ft 0 9 m three prong AC power supply cable is available The nominal electrical input is 115v 50 60Hz single phase 10 98 to 127v Optional 230v 50 60Hz single phase 10 207 to 253v can be specified for selected applications Contact factory for additional information Refer to Wiring Diagram on page 13 Converting System from 115v to 230v 1 Power down switch off and disconnect power plug to Balancer control panel 2 Remove pendant control handle cable by rotating locking ring counterclockwise until free of threads 3 Remove upper left and r
36. o Dwg MHP2170 on page 21 Solenoid Description Wire Number of Function Color 1 Balancer Up Hi Flow Brown 2 Balancer Up Medium Flow Red 3 Balancer Up Low Flow Orange 4 Balancer Down Hi Flow Yellow 5 Balancer Down Medium Flow Green 6 Balancer Down Low Flow Blue Pressure Transducer 1 Install reducer bushing 43 in end cap 38 Install pressure transducer 44 in reducer bushing Do not over torque Attach electrical harness control panel to transducer 36 to pressure transducer End Enclosure 1 Install standoff tube 48 and end enclosure 49 and secure with capscrew 50 Control Panel Assembly 1 Ensure sideplates 19 are attached to the outside of tack welded nuts located on housing body with capscrews 14 MHD56222 Edition 3 2 Place control panel assembly 29 on sideplates Install capscrews 13 through bottom hole on each side When assembled control panel should swing freely in vertical direction 3 Attach electrical harnesses to control panel locations a Electrical harness control panel to encoder 12 b Electrical harness control panel to transducer 36 c Electrical harness control panel to solenoids 37 4 Close control panel by swinging up and securing in place with capscrews 13 located on upper left and right edges of housing as viewed from control panel face 5 Insert pendant cable plug into port located on bottom right hand side
37. ove pressure transducer and reducer bushing 43 from end cover 38 Encoder End Cover Removal End cover 3 is located on right hand side of balancer housing 22 as viewed from control panel 1 Disconnect electrical harness control panel to encoder 12 at circuit board 2 Remove two screws 6 and unscrew circular connector at pendant control cable 3 Remove capscrew 1 and washer 2 from center of end cover assembly 4 Remove screws 20 and pull end cover assembly out of housing 5 Remove ball stop nut 5 6 Additional disassembly should only be conducted if brake or encoder parts require replacement Control Panel Removal Printed circuit boards are not field repairable The main control panel must be replaced if a problem is traced to the unit Disassembly steps are described as viewed facing the control panel 1 Turn off all power and disconnect balancer from power supply 2 Disconnect pendant control handle cable by rotating locking ring counterclockwise until free of threads 3 Remove upper right and left capscrews 13 which attach control panel 29 to sideplates 19 4 Allow control panel to swing down and hang freely from the two remaining screws 5 Carefully disconnect wire harnesses at the control panel connections a Electrical harness control panel to encoder 12 b Electrical harness control panel to transducer 36 c Electrical harness control panel to solenoids 37 6
38. overs Control Panel Electrical System Control Handle Labels and Tags Other Components Balancer Refer to Balancer manual MHD56151 This page may be photocopied and used by inspectors or maintenance personnel 16 MHD56222 Edition 3 TROUBLESHOOTING These instructions apply only to the InteLIFT Electronic Control system and should be used in conjunction with the TROUBLESHOOTING section provided in the Balance Air Service Manual Form Number MHDS56151 Specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety operation and maintenance of this equipment The chart below provides a brief guide to common symptoms probable causes and remedies If this guide does not solve your problem call our Toll Free Number for assistance 1 866 284 5509 Symptom Cause Remedy Power ON does not work No power to system Check external electrical system connections cords and 4 amp fuse in control panel Check electronic control connections and cords Main cable not connected Check electronic control panel connections and cords ON OFF circuit breaker switch in OFF position Check ON ON position OFF circuit breaker switch is in Lift and or Lower pendant control does not function properly Pendant control cable connections C
39. own for applicable end cover assembly Note Apply Loctite 242 on screw threads during assembly Dwg MHP1959 Item Description Qty Part No of Part Tota Number Z Brake Assembly 150 lb 68 kg Balancer Unit 1 ZHSEA0034 2 Shaft 1 13112 3 Pivot Shaft 1 13113 4 Brake Rotor 1 ZHSEA0033 5 Brake Shoe 1 13116 6 Bushing 1 65054 7 Radial Bearing 1 65074 8 Screw 1 ZHS70427 9 Spring 1 76517 Refer to Balance Air Service Manual Form MHD56151 for parts information and additional information MHD56222 Edition 3 25 Z BRAKE ASSEMBLY 200 330 500 LB 91 150 227 KG BALANCER Note Apply Loctite 242 on screw threads during assembly Dwg MHP1960 Refer to unit breakdown for applicable end cover assembly Item Description Qty Part Number No of Part Tota 200 Ib 91 kg 330 Ib 150 kg 500 Ib 227 kg Z Brake Assembly 1 ZHSEA0032 ZHSEA0038 2 Shaft 2 13112 13142 3 Shaft Retainer 1 13122 4 Pivot Shaft 1 13123 5 Brake Rotor 1 ZHSEA0020 ZHSEA0037 6 Brake Shoe 1 13125 7 Thrust Washer 2 65063 8 Bushing 1 65073 9 Radial Bearing 1 65074 10 Screw 2 ZHS70232 11 Screw 2 70427 ZHS70445 12 Spring 1 76517 12A Heavy Spring 1 76520 Heavy Brake Spring Item 12A replaces Spring Item 12 Refer to Balance Air Service Manual Form MHD56151 for parts information and additional inform
40. pacity Do not operate with twisted kinked frayed or damaged wire rope or chain Do not lift people or loads over people Do not remove load or handling device until tension is released from wire rope or chain Do not remove or obscure warning label Comply with federal state and local rules P N 71148175 INGERSOLL RAND for balancars MATERIAL HANDLING PECIFICATION NOTICE e This supplement contains information only for the InteLIFT Electronic Control system used with an air balancer Use this supplement in conjunction with Balance Air Service Manual Form Number MHD56151 Description of Operation The Inte LIFT Electronic Control system is integrated with the air system of the balancer to provide an alternative method of operation Designed for a 115 230v 50 60Hz single phase electrical power supply the electronic control system reduces input to 24 VAC operating voltage The system can also be integrated with an end effector clamp device used in conjunction with the balancer Balancer operation is established at the control panel module mounted to the balancer The control panel module allows simple programming of functions with a keyboard and indicator lights and confirms settings in the display window Balancer control is achieved via a control handle that is in a location convenient to the operator Located on left hand end as viewed facing control panel of balan
41. pe Guide 1 10116 10114 10115 10118 26 Nameplate 1 ZHSEA0120 27 Warning Label Balancers 1 71148175 28 Housing Liner 1 ZHSEA0041 ZHSEA0042 ZHSEA0040 29 Control Panel Assembly 1 ZHSEA0001 e 30 Power Plug AC 1 ZHSEA0147 31 Cable 1 33323 XXX X A 32 Warning Label Electrical 1 71125751 33 Capacity Label 1 10402 10403 10404 10398 34 Warning Label Pendant 1 10445 Pendant Assembly w Straight Cable ZHSEA0148 35 Pendant Assembly w Pre Coil Cable 1 ZHSEAO156 Load Cell Handle w Pre Coil Cable ZHSEAO152 36 Electrical Harness Transducer 1 ZHSEAO107 37 Electrical Harness Solenoids 1 ZHSEAO109 38 End Cap 1 15515 15016 39 IO Ring 1 15751 e 40 Muffler Pads 2 ZHSEA0078 41 Valve Manifold 1 ZHSEA0069 42 Capscrew 1 10013 10018 43 Reducer 1 4 x 1 8 NPT 1 ZHSEA0079 e 44 Pressure Transducer 1 ZHSEA0080 us Manifold Assembly includes items 37 41 1 1 Z2HSEA0068 1 ZHSEA0068 2 ZHSEA0068 3 ZHSEA0068 4 MHD56222 Edition 3 23 Item Description Qty Part Number No of Part Total 150 1b 68 kg 2001b 91kg 3301b 150 kg 500 Ib 227 kg Solenoid Coil 1 32 in Orifice ZHSEAO071 Solenoid Coil 3 64 in Orifice ZHSEA0072 et Solenoid Coil 5 64 in Orifice 2 ZHSEA0073 Solenoid Coil 3 32 in Orifice ZHSEA0074 Solenoid Coil 1 8 in Orifice ZHSEA0075 Solenoid Coil 5 3
42. r balancer operation Refer to Preventive Maintenance Inspection Schedule on page 15 as a guide to conducting visual inspections of Inte LIFT Electronic Control system and components Refer to Balancer Control Adjustments on page 12 to setup Inte LIFT Electronic Control system settings and operational tests NOTICE e Refer to Balance Air Service Manual Form Number MHD56151 for balancer testing to be conducted upon completion of Inte LIFT Electronic Control Panel and Control Handle setup and testing MHD56222 Edition 3 Preventive Maintenance Inspection Schedule Frequent and harnesses to the touch dry and installed with enough slack in the line to prevent pulling on the wire to make connections Wire installaton should not contact any moving or rotating component during operation Criteria for Daily Periodic Component Inspection Operation Ast operation of resi mane More than 6 pera shift eiert months annual Manifold End Cracks wear damage Cover protects electrical connections from x Cover moisture and dirt End cover must be secure and undamaged Control Panel Moisture Control panel must be dry inside and out X Dirt dust airborne In environments where small airborne particles X particles dust or dirt are present care must be taken to ensure these materials do not enter control panel LCD window LCD window indication must clearly reflect t
43. ritten authorization has been provided from the location where the goods were purchased Continuing improvement and advancement of design may cause changes to Inte LIFT Electronic Control Balancer which are not included in this manual Manuals are periodically revised to incorporate changes Always check the manual edition number on the front cover for the latest issue Disposal When the life of the balancer has expired it is recommended it be disassembled degreased and parts separated as to materials so that they may be recycled For additional information contact Ingersoll Rand 1872 Enterprise Drive Rochester MI 48309 Phone 248 293 5700 Fax 248 293 5800 or Europe Middle East and Africa Ingersoll Rand Douai Operations 111 Avenue Roger Salengro 59450 Sin Le Noble France Phone 33 3 27 93 08 08 Fax 33 3 27 93 08 00 intelitt Intelligent Lifting Systems Associated Publication References Publication Part Number Balance Air Service Manual MHDS56151 Control Panel Replacement Kit MHD56233 Load Sensing Handle Kit MHDS56231 Z Rail System MHDS56159 Manuals are available at the Ingersoll Rand web site www irhoist com 30 MHD56222 Edition 3 WARRANTY Limited Warranty Ingersoll Rand Company I R warrants to the original user its Products to be free of defects in material and workmanship for a period of one year from the date of purchase I R will repair
44. rol by a special combination of button activation Changes can be accomplished from the pendant control handle without accessing the main control panel Whenever this Handle Set Up mode is active the Power LED light on the pendant handle will be off the InteLIFT LED light on the pendant handle and the Low Speed LED light on the pendant handle will both be flashing Use the following steps 1 With power off depress both the grey Speed and yellow Inte LIFT buttons 2 Turn power on and release both buttons after 1 or 2 seconds LED s will flash 3 Push and release the yellow InteLIFT button this takes the tare 4 Cycle power off and on and use normally Speed Selection Button Allows operator to select from three maximum speeds from the control pendant Depress grey speed button to cycle through and select desired balancer operating speed Operating speeds are Hi Medium and Low When one light is on it indicates low speed The two left LED s will light for medium speed All three LED s will light for high speed 10 Pendant Operation RED Power OFF Inteliff Emergency Stop Indicator Button Speed Light Indicator Lights Power Indicator Light GREEN Power ON Button UP DOWN Rocker Switch BLUE Clamp Unclamp Button Dwg MHP2157 Up Down Operation The rocker switch located on control handle provides the operator with UP DO
45. sence of A DANG ER a hazard which will cause severe injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe injury death or substantial property damage if the warning is ignored AWARNING Caution is used to indicate the presence of A CAUTION a hazard which will or can cause injury or property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance information which is important but not hazard related NOTICE Safety Summary Do not use balancer or attached equipment for lifting supporting or transporting people or lifting or supporting loads over people e The supporting structures and load attaching devices used in conjunction with balancers must provide a liberal safety factor This is the customer s responsibility If in doubt consult a registered structural engineer e Electrical installation should be performed by licensed electricians in accordance with the latest edition of the National Electrical Code ANSI NFPA 70 and any applicable local state and national electrical codes and ordinances SAFE OPERATING INSTRUCTIONS The following safe operating instructions have been adapted in part from American National Safety Standards are intended to avoid unsafe operating practices that could lead to injury or property damage These instructions apply onl
46. ssia Ingersoll Rand Kuznetsky Most 21 5 Entrance 3 Moscow 103895 Russia Phone 7 501 923 91 34 Fax 7 501 924 46 25 Australia Ingersoll Rand Ltd Landmark Corporate Center Level 2 454 472 Nepean Highway Frankston Vic 3199 Australia Phone 61 3 8781 1600 Fax 6138781 1611
47. t which is in questionable condition The cost of the part is often minor in comparison with the cost of redoing the job 4 Remove all nicks and burrs caused by lockwashers Assembly Unless otherwise noted part names and item numbers are from the assembly drawing and parts list Refer to Dwg MHP2155 on page 22 NOTICE e The following assembly instructions apply only to the Inte LIFT Electronic Control system subassemblies For additional balancer assembly instructions refer to Balance Air Service Manual Form Number MHD56151 e References to electrical connections during assembly require correct harness attachment During assembly refer to the Wiring Diagram Dwg MHP2158 on page 13 to ensure the correct electrical connections are made 20 Encoder End Cover Assembly 1 Ensure white lettering on encoder module is visible when mounted to end cover 2 With encoder module pins pointing outward toward assembler green harness wire must be located on the left 3 Install electrical harness control panel to encoder 12 to connector on end cover assembly 3 if removed Secure with nylon tie 63 through loops in encoder 58 and around harness connector 4 Install ball nut stop 5 and brake assembly 6 into end of housing 22 Install end cover assembly 3 onto end of housing with the electrical connection located at bottom During assembly align holes on outside edge of assembly with holes located in
48. ter 22 as viewed from control panel 1 Disconnect air line 2 Remove standoff screw 50 in center of end cover 49 3 Remove end cover and standoff tube 48 4 Tag and record the colors of the individual wires connected to the six solenoids 46 Refer to Wiring Diagram Dwg MHP2158 on page 13 Disconnect wires from solenoids 5 Remove screw 53 holding loop strap 52 to separate wire harnesses from manifold 41 6 Remove capscrews 47 attaching valve manifold 41 to balancer end cover 38 7 Remove O ring 39 and muffler pads 40 To remove individual solenoid valves 46 from manifold assembly 45 conduct the following MHD56222 Edition 3 e Tag and record the colors of the individual wires before disconnecting from solenoid valves 46 This information will be necessary to correctly reconnect the wires to the solenoid valves during reassembly 1 Disconnect wire harness from solenoid valves 2 Loosen nut on top of solenoid valve assembly 46 3 Holding coil to prevent rotation loosen valve seat and continue to turn it until detached from manifold 4 Repeat steps 2 and 3 for remaining solenoid valves Pressure Transducer Pressure transducer 44 is located on left hand side of balancer canister 22 as viewed from control panel To remove pressure transducer 44 from balancer end cover 38 1 Disconnect wire harness 36 from pressure transducer 44 and move to side 2 Rem
49. trical codes and ordinances NOTICE e This supplement contains information only for the InteLIFT Electronic Control system used with an air balancer Use this supplement in conjunction with Balance Air Service Manual Form Number MHD56151 Maintenance Intervals The Maintenance Interval chart is based on intermittent operation of the balancer eight hours each day five days per week If operation is more than eight hours per day or in severe applications or environments more frequent maintenance should be performed Interval Maintenance Check Make a thorough visual inspection of balancer for damage Do not operate balancer if damaged Start of each shift Operator or Maintenance 7 Personnel Operate balancer through normal operating cycle Balancer must operate smoothly Yearly Inspect balancer for wear and damage Maintenance Repair or replace damaged parts as Personnel necessary General Maintenance Instructions NOTICE e It is recommend that maintenance work be performed by an Ingersoll Rand service repair center All maintenance work performed on the balancer must be recorded with the date in the inspection report Proper use inspections and maintenance increase the life and usefulness of your Ingersoll Rand equipment It is recommended that all maintenance work on the balancer be performed on a bench in a clean dust free work area During the process of disassem
50. trol handle are depressed during the self test sequence the system will become inoperable and the Inte LIFT indication light will be constant RED indicating the presence of a fault MHD56222 Edition 3 If Inte LIFT RED fault indication light illuminates press the emergency stop button and then press ON Ensure no button on control handle or handle load cell is depressed during self test If RED fault indication light stays ON refer to TROUBLE SHOOTING section on page 17 to determine cause Lift Lower and Balancer Speed Indication Depress the Lift then Lower rocker switch located on the control handle in each direction alternately Note the solenoid indicator lights on control panel The green indicator lights denote movement in the UP direction green indicator lights denote movement in the DOWN direction Depress grey speed button located on top row right hand side of control handle to change balancer speed setting There are 3 settings available Low Medium or High which are indicated by the lights above the speed button A single light indicates low speed The two left LED s will light for medium speed All three LED s will light for high speed e Speed settings are factory preset InteLIFT Button Depress yellow Inte LIFT button on control handle located top row center of pendant handle Indicator light yellow above pendant handle bu
51. tton will illuminate if float or dump mode is selected and InteLIFT red indicator light on control panel will flash If the Inte LIFT mode was set to NONE during setup the red indicator light on the control panel will not flash Depress Inte LIFT button on control handle to turn selected mode off If InteLIFT mode was set to NONE then the light on the control panel will not illuminate and the yellow indicator light above the InteLIFT button on the pendant will not illuminate Load Sensing Handle optional feature The Inte LIFT load sensing handle provides a low effort highly intuitive user interface Ingersoll Rand Integrated Balancer and end effector systems are designed and tested to assure stable predictable operation It is imperative that third party or self built end effectors are correctly integrated with the load sensing handle Technical assistance with load sensing handle mounting and integration can be obtained by calling 1 866 284 5509 InteLIFT Balancers with the optional load sensing handle do not raise and lower objects by pressing buttons or switches as in a conventional Balancer The standard control handle rocker switch is removed The signal to move an object comes from a load cell Thus it is possible to move an object up or down simply by pushing the handle in that direction Drawing MHP2249 on page 8 shows the components of a load sensing handle assembly The load cell is designed to measure force in on
52. uld maintain this orientation when resting on the floor or be suspended such that it cannot be lowered to floor level The pendant weight which is approximately 5 lb 2 27 kg should not cause end effector to tip Lighter end effectors may require handle be installed over the center of gravity Failure to follow these guidelines may cause Balancer to be less stable or more difficult to correctly tare Refer to Dwg MHP2252 on page 11 which shows a typical end effector with load sensing handle that utilizes these practices Dwg MHP2252 11 Balancer Control Adjustments The Balancer controller is preprogrammed at the factory and the factory default setting must be verified upon initial installation or a change in the application Changes are easily made by powering up the unit with the new end effector or hook installed but no payload or work part on the system Position the hook or end effector approximately two feet off the floor and push the Set up button on the main control panel Set up or Adjustment Step Performed Procedure Control Panel Set up Adjustments Tests and Visual Indications Window Indication LCD Initial Set up Switch ON OFF circuit breaker on main control panel to ON position None BLANK LCD Press green power ON button on the Control panel will conduct self test pendant control handle and display results for 3 seconds 200 Ib 2
53. unding earth conductor green wire Ensure grounding earth conductor is connected to the green yellow connector terminal The ground earth green or green yellow wire must not carry any power Air Connection It is recommended that an air line strainer filter be installed within 3 feet 1 metre of the balancer to prevent dirt from entering the balancer The strainer filter should provide 20 micron filtration and include a moisture trap Clean strainer filter periodically as indicated by the operating environment to maintain its operating efficiency Attach air supply to balancer Refer to Balancer Control Adjustments table on page 12 in OPERATION section to setup Inte LIFT Electronic Control system for balancer operation Initial Setup Refer to Dwg MHP2159 on page 9 and MHP2157 on page 10 Once the balancer has been installed the InteLIFT Electronic Control system must be verified that the default factory presetting are correct for your application to establish operational readiness Refer to OPERATION section on page 8 for set up information MHD56222 Edition 3 e Each time the power is turned off and back on the Inte LIFT Electronic Control system performs a self audit to ensure all components are connected and working properly The controller is pre programmed at the factory based upon the order information this information is stored in nonvolatile memory and is not lost in the e
54. upon opening the crate or container loss or damage has taken place while in transit notify the carrier s agent immediately MHD56222 Edition 3 I R makes no other warranty and all implied warranties including any warranty of merchantability or fitness for a particular purpose are limited to the duration of the expressed warranty period as set forth above I R s maximum liability is limited to the purchase price of the Product and in no event shall I R be liable for any consequential indirect incidental or special damages of any nature rising from the sale or use of the Product whether based on contract tort or otherwise Note Some states do not allow limitations on incidental or consequential damages or how long an implied warranty lasts so that the above limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state Notice Damage Claims You must file claims for damage with the carrier It is the transportation company s responsibility to reimburse you for repair or replacement of goods damaged in shipment Claims for loss or damage in shipment must not be deducted from the Ingersoll Rand invoice nor should payment of Ingersoll Rand invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery You may return products damaged in shipment to us for repair which services will be for your account and
55. vent of power failure or shutdown If the self audit indicates a fault or operating problem the setup menu must be run to verify the data is correct for this application and both end effector and handle tare has been performed If correctly installed and problem remains refer to the TROUBLESHOOTING section on page 17 or call the toll free number 1 866 284 5509 for assistance The LCD window on the control panel provides information on function setting adjustment parameters and current operating mode Power ON Switch ON OFF Circuit Breaker to ON position Then press the Power ON button green on control handle Operator should hear an audible beep indicating control power is on and the Inte LIFT Electronic Control system is conducting a self test for 3 seconds Check Power On and Low Speed LED s are lit on control handle along with Power LED light on control panel LCD window indication This information will momentarily be displayed Software Revision No Balancer Capacity 200 Ib 2 15 LOAD CELL CAPABLE Blank if unit is not equipped with Load cell or is not to current revision Unit will operate if blank After three seconds of self test the LCD window will indicate the last set mode of operation Model No ICW INTELI OPTION FLOAT or DUMP or NONE INTERLOCK or SMART DROP or NONE e If the UP DOWN buttons on con
56. w are two lights The green power light indicates when on that power is supplied to the control panel Next to the power light is the InteLIFT indication light The red indicator light will blink when one of the Inte LIFT control modes is activated When light is on but not blinking a system fault is indicated Control Operation Refer to Dwg MHP2157 on page 10 The control handle allows the operator to control balancer operation and if used an end effector clamping device attached to the balancer while maintaining operator position at the work location allowing exact positioning of the load Standard pendant cable length is 12 feet 3 7 m Pendants provide operator with the following control functions Power Off Emergency Stop Power On InteLIFT Dump or Float ON or OPE Selecting Variable Speed Up Down Operation Clamp Unclamp Power Off Emergency Stop Located on top of pendant the Power Off Emergency Stop button when depressed shuts off electric power to the pendant controls and control panel stopping balancer operation Once stopped balancer will not operate until the power ON button located on the control handle is pressed Power On After the power ON button is depressed a green light will remain lit on the control panel and pendant handle if the balancer is ready for use Inte LIFT InteLIFT button activates either Float or Dump when programmed at the control panel
57. weight of the object being manipulated AWARNING e All loads must be lifted with the Balancer not the load sensing handle The force transmitted through the handle must not exceed 40 Ib 18 kg Overloading the load cell can cause permanent damage The handle control tare is factory calibrated before shipment If it is necessary to retare refer to the Balancer Control Adjustments on page 12 The load sensing handle is sensitive and minor changes to its installation may necessitate resetting the tare Indications of a Balancer that is not correctly tared include moving up or down without operator input and entering fault mode indicated by a steady Inte LIFT red light on the control panel when Balancer is turned on Do not push on handle immediately after turning on Balancer There is a delay of approximately three seconds after green on button is pressed before Balancer is ready to operate The green light on the panel designated Power will light at this time If load cell is activated before Power light is illuminated Balancer will enter fault mode indicated by a steady Inte LIFT red light on the control panel A Balancer in fault mode will not respond to input from the handle To exit fault mode toggle power off and then on If this does not correct problem retare handle MHD56222 Edition 3 End effectors with a load sensing handle should naturally hang in the same orientation when loaded or unloaded It sho
58. without cost any Product found to be defective including parts and labor charges or at its option will replace such Products or refund the purchase price less a reasonable allowance for depreciation in exchange for the Product Repairs or replacements are warranted for the remainder of the original warranty period If any Product proves defective within its original one year warranty period it should be returned to any Authorized I R Service Distributor transportation prepaid with proof of purchase or warranty card This warranty does not apply to Products which I R has determined to have been misused or abused improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine I R parts Important It is our policy to promote safe delivery of all orders This shipment has been thoroughly checked packed and inspected before leaving our plant and receipt for it in good condition has been received from the carrier Any loss or damage which occurs to this shipment while enroute is not due to any action or conduct of the manufacturer Visible Loss or Damage If any of the goods called for on the bill of lading or express receipt are damaged or the quantity is short do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt Concealed Loss or Damage When a shipment has been delivered to you in apparent good condition but
59. y einsojouy 04u00 ue Dwg MHP2158 MHD56222 Edition 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICE This supplement contains information only for the Inte LIFT Electronic Control system used with an air balancer Use this supplement in conjunction with Balance Air Service Manual Form Number MHD56151 Preventive Maintenance e All new altered or modified equipment should be inspected and tested by personnel trained in safety operation and maintenance of this equipment to ensure safe operation at rated specifications before placing equipment in service These preventive maintenance recommendations are designed to prevent unexpected breakdowns and problems through periodic inspection and maintenance Maintenance intervals should be based on frequency of usage and operating environment Frequent use or dirty operating conditions require more frequent servicing Refer to the INSPECTION AND MAINTENANCE REPORT on page 16 Using this report will aid in tracking component failures and faults We recommend the use of this report as a preventive maintenance tool Frequent and periodic inspections should be performed on equipment in regular service Frequent inspections are visual examinations performed by operators or service personnel and include observations made during routine equipment operation Periodic inspections are thorough inspections conducted by personnel trained in the safety operation and maintenan
60. y to the operating system of the Inte LIFT Electronic Control Balancer and should be used in conjunction with the SAFE OPERATING INSTRUCTIONS provided in the Balance Air Service Manual Form Number MHDS56151 Safe operating instructions are provided to make operators and maintenance personnel aware of dangerous practices to avoid and are not necessarily limited to the following list 1 Ensure electrical wiring to the balancer conforms to all relevant safety codes and regulations N 2 Ensure all electrical connections are secure before applying power 3 Never operate equipment with damaged frayed or twisted electrical cables 4 Before each shift or initial use inspect balancer for visible wear and damage 5 Immediately disconnect main power if balancer is damaged 6 Only licensed electrical technicians trained on this product should be allowed to access electrical components to affect troubleshooting and or repair 7 Troubleshooting of the system by licensed electrical technicians is limited to visual inspection of components and subassemblies once the enclosures are opened 8 Before accessing electrical components follow lock out tag out procedures to ensure that power to the system has been disconnected 9 Disconnect air supply to balancer prior to maintenance MHD56222 Edition 3 Each balancer is shipped from the factory with the warning labels shown If the labels are not attached to your balan
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