Air Balancers Advanced
Contents
1. Prevent dropping a load Submitted by Daniel K Richards Field Service Manager I R Assembly Solutions Reviewed by Joe Paulin Field Service I R Assembly Solutions Umesh Cooduvalli Marketing R Assembly Solutions Page 21 of 212. the Engagement Pin will extend and engage one of the slots in the plate The Z Stop will engage before the load lowers 6 inches When supply air pressure is re enabled and exceeds the balancer pressure the air cylinder will begin to retract However because of a notch in the end of the Engagement Pin the load must be raised slightly before the Pin will disengage from the slot in the Engagement Plate The Z Stop is not available on the 50 or 150 Ib balancers All required fittings and tubing are supplied The Z Stop can be added to balancers with the Z Brake installed using the appropriate retrofit kit The Z Stop should be inspected annually as part of the balancer service Connect an airline to the Z Stop housing and apply air pressure to extend the Z stop pin Engagement Pin Check pin engages fully through plate Bent or deformed Plate Security to brake rods Warped or bent End Cover Leakage at pin inside Leakage at Z Stop housing Security and leakage at fitting Housing Security of screws Security and leakage at fitting Cracks Page 8 of 21 Exercise 2 at V J ____ Annually ____ Monthly ___ Every Cycle ___ Annually ___ Weekly ____ Annually 3 What is the purpose of a Z Stop Disable the balancer if air supply is lost ___ Stop an uncontrolled load 4 When should the Z Brake engage 1 How often should the balancer be inspected and lubricated ____ Monthly 2 Ho
3. 400 70 35 105 140 245 350 60 30 90 120 210 300 gt Balancing or Lifting The Balancer stalls when the total load is equal to its operating capacity as the load increases maximum speed decreases For balancing applications the total load on the balancer should not be greater than 60 of its operating capacity for optimum performance For lifting applications the total load on the balancer should not be greater than 80 of its operating capacity for maximum performance gt Reeve or Tandem Option To increase the operating capacity of the balancer a reeve block can be used pass the wire rope through the pulley and tie the dead end of the rope to the pad eye at the bottom of the Balancer housing this action doubles the capacity of the Balancer A 500 lb Balancer becomes a 1 000 Ib Balancer The disadvantage of this action is that it cuts maximum travel in half A Balancer with 80 in of travel is cut to a maximum of 40 in Reeve blocks are not available for the 50 and 150 lb balancers The second option is to use Balancers in tandem Two balancers are tied to a common control system and a single hook Two 500 lb Balancers become a 1000 lb system The advantage is that there is no reduction in travel The disadvantage of this method is the expense of two balancers Each Balancer is supplied with a predetermined amount of wire rope The total length of rope is greater than the capacity of the reel Not all of the supplied rope
4. decrease speed until the desired speed is achieved 13 Lower to the bottom of normal travel with tension on the wire rope 14 Adjust the UP flow control on the manifold counterclockwise to increase speed clockwise to decrease speed until the desired speed is achieved The BA control installs on the 50 lb and 150 lb capacity Balancers for suspending balancing and or manipulating a load The BA control is for single weight loads only The BA control is a regulator that mounts to the Balancer manifold 150 Ib Units It is manually adjusted to balance a load at a desired height but can also be set to slowly raise a load up and out of the operator s way The BA control is easy to install and adjust There is an acorn nut at the base of the regulator to make adjustments The regulator will supply or exhaust air as the operator moves the load There is a check valve supplied with the control to be installed in the inlet of the regulator If air supply is lost the check valve will prevent the air in the balancer from escaping allowing the load to lower Connect regulator to balancer Rotate regulator adjustment knob counterclockwise until it stops Turn on main air supply Adjust regulator to required air pressure Rotate the adjustment knob clockwise slowly until the wire rope begins to raise move to the full up position Ensure the Z brake does not engage 150lb units only poe I Page 11 of 21 5 Install the
5. effector 12 Lower the handling device and release the part at the pick up point 13 Hold the aluminum housing and tighten the jam nut on the Interlock screw to prevent the setting from changing Exercises 3 af 1 Turning the Z Servo nut clockwise will ____ Raise the load ___Lowertheload ___No effect 2 Where is the Z Servo installed ___Wire rope ____ Balancer ___ Tool 3 How many loads can be balanced with the EA Basic control 1 10 3 4 How does the EA control balance lighter loads ___Magic _Weightsand pulleys ___Bleed air to atmosphere 5 When does the 2PS flow control release air ___ Shutdown ___ Empty device ___ Loaded device IR Zimmerman offers suspension kits that will fit most any rail type enclosed track or beam T rail The enclosed track suspension kits incorporate a cast aluminum trolley body with Delrin molded wheels and precision life lubricated sealed wheel bearings The beam T rail kits are stamped and machined steel components The wheel assemblies have a flat flange and slight taper that will allow adaptation to I beam T rail Patent track styles with running surface flange width adjustable up to 4 inches Consult the factory for flange widths larger than 4 inches custom suspension kits can be designed All suspension kits come complete with all hardware trolleys and brackets required to mount the balancer and an instruction sheet If the instruction sheet is not available
6. is the purpose of the B port on the EA regulator ____ Connect control No purpose _ filtered air 5 Ifthe load is hard to push down what EA regulator setting may need adjustment __ Auxiliary Flow Trim ___ Hook Balance Inherent friction within the Balancer is 10 of a load so manipulating loads over 100 Ibs can be fatiguing over time The BA Z Servo addresses this issue The BA Z Servo uses a spring actuating valve to amplify inputs from the operator to reduce the required effort to move a load to 3 5 of the load This allows the operator to use less effort to move or manipulate a very heavy load Air flows from the A port of the EA regulator through the control tube to the Z Servo valve The Z Servo vents pressure to atmosphere continuously to keep the load in balance A die spring placed on the bolt mounted in the base of the Z Servo compresses the servo valve against the knurled nut At all times air can be heard or felt venting at the Z Servo this keeps the load in balance when not being manipulated When the load lowers the spring pushes against the Z Servo valve venting air to atmosphere until the EA regulator begins to exhaust air to lower the load When the load moves up the spring relaxes and the amount of air vented at the Z Servo valve reduces sending a signal back Page 13 of 21 to the EA regulator to increase pressure to the balancer to lift The knurl nut at the top of the servo provides fine tunin
7. load hook and tooling or fixture to the wire rope in the required position Refer to Lash up instructions in the Balancer Service Manual form MHD56151 Rotate the adjustment knob clockwise until the load is suspended The correct setting will require equal effort to lift and lower the load If they require the unit to raise the load out of the way turn the adjustment knob clockwise until the desired speed is achieved 9 Tighten the jam nut just above the adjustment knob to maintain the proper setting All applications balancing one or more loads with the 200 500lb capacity balancers use the EA regulator The EA regulator is a versatile regulator specially designed for operation with the balancer o N O The EA regulator has an inlet port with a bronze filter on the right side to remove debris in the air supply The plugged B port can provide a filtered supply of air that powers handling device components The center section is the control and main regulator The main regulator is the larger upper portion to provide adequate airflow to the balancer The control regulator uses a very small volume of air for faster response to operator inputs The control regulator adjusts with the brass acorn nut at the base of the EA regulator The trim valve located on the left side of the regulator body sets the balance pressure of the control regulator If the trim valve is not set correctly it will make the load difficult to move The nor
8. pendent is in the HI LOAD position the EA P regulator setting balances the heaviest load When the pendent is in the LO LOAD or UN LOAD position balancer pressure releases to atmosphere at the flow controls in the pendent Set the pendent to the desired load position and the load can be moved by hand with minimal effort The flow adjustments on the pendent to compensate for LO LOAD and UN LOAD are in line with the corresponding position Install the regulator to the balancer Install the EA pendent to the A port of the regulator Rotate the control handle to the HI LOAD position Rotate the regulator adjustment knob counterclockwise until 1 2 inch of thread is visible Rotate the trim valve clockwise until snug then counterclockwise 2 full turns Rotate the auxiliary flow valve clockwise until snug Turn on main air supply Adjust regulator to required air pressure Rotate the adjustment knob clockwise slowly until the wire rope begins to raise move to the full up position ensure the Z brake does not engage RON ONO Page 15 of 21 9 Install the load hook and tooling or handling device to the wire rope in the required position Refer to Lash up instructions in the Balancer Service Manual form MHD56151 10 Rotate both the LO LOAD and UN LOAD flow controls clockwise until snug 11 Apply the heaviest load to the tooling or handing device 12 Rotate the auxiliary flow valve clockwise until snug then count
9. Zimmerman Air Balancers Advanced Learning Objectives At the conclusion of this module you will understand IR Zimmerman Air Balancer e Capabilities e Balancer Operation e Controls Operation and Adjustment Audience Ingersoll Rand sales distributors customer service engineering and service personnel Executive Summary The Balancer has smooth operation variable capacity multiple control choices multiple mounting options and minimal air consumption The Balancer replaces hoist applications or as part of a complete lifting system to improve ergonomics and increase production Understanding the operation and function of the balancer and various controls is an important factor in the proper use of the balancer system We will discuss the adjustment inspection and operation of the balancer and controls Module Preview 1 Ifa balancer with ZA controls allows a load to drift to the floor in less than a minute what is the problem ____ Leak to atmosphere ____ Hook balance incorrectly set ____ Low air supply pressure 2 When facing the end cover which direction does the reel rotate ____ Counterclockwise ____ Clockwise 3 If air pressure is released from the piston chamber the load will ____ Raise ____ Lower ____ Stay in place 4 Which control is best suited for a lifting or hoisting application ZA BA Page 1 of 21 The Balancer is a configured product The sequence of letters and numbers represent the balan
10. alancer To lower the load depress the Down lever allowing pressure to escape through the pendent to atmosphere The top center of the manifold is the Hook Balance Adjust in the event of a leak pressure is supplied to the piston chamber to prevent a load from drifting down The normal setting for this valve is flush with the top of the manifold block which turns the regulator off Install the manifold to the end cap 2 Connect the black UP hose to the UP port on the manifold 3 Connect the gray yellow hose handling device applications to the DN port on the manifold Connect main air supply to the right side port of the manifold Turn on main air supply Adjust regulator to required air pressure Rotate hook balance screw clockwise slowly until the wire rope begins to raise move to the full up position ensure the Z brake does not engage Page 10 of 21 oor 7 Install the load hook and handling device to the wire rope in the required position Refer to Lash up instructions in the Balancer Service Manual form MHD56151 8 Rotate the UP flow control clockwise until snug 9 If the wire rope is slack ensure the Z brake does not engage 10 Feather the UP lever until tension is applied to the wire rope then fully depress the UP lever until the load is in the full up position 11 Depress the DN lever and check speed 12 Adjust the DN flow control on the manifold counterclockwise to increase speed clockwise to
11. alancers Above 600lbs total load the control will lose the ergonomic effect The variation between UN LOAD and HI LOAD can be a maximum of 40 Ibs If the total load is above 200lbs the control will lose the ergonomic effect 80 of operating capacity overall speed will begin to decrease The ZA is best suited for applications where it would be uncomfortable for an operator to reach for the load The requirements for operators to bend or reach for a load are reduced through use of the pendent The ZA control operates similar to a hoist control When the levers on the pendent are depressed the Balancer will raise or lower the load The valves in the pendent operate like an accelerator in a car The harder you press the faster the load will move The levers can be feathered to make the load move at a comfortable rate for different operators and loads There are three adjustments on the ZA manifold Flow controls on either end of the manifold control the UP and DOWN speed The center adjustment is a non relieving regulator that adjusts pressure to the Balancer to prevent the load from drifting down The air flows across the UP speed control valve on the right side of the manifold down the black hose to the UP lever When the lever is depressed the air will flow past the Down DN lever valve up the hose to the Balancer raising the load When the controls are inactive the load is in balance and pressure traps in the B
12. cers controls rated capacities travel and options The graphic below depicts a configured balancer model number Zimmerman has 5 basic models of Balancers with rated capacities of 50 150 200 350 and 500 lb The rated capacity is based on a supply pressure of 100 psi at the balancer The capacity of the Y Balancer decreases as the air pressure decreases The Balancers can be configured to handle up to 2000 Ibs by adding reeve blocks or operating units in re tandem gt Operating Capacity of a balancer is determined by actual plant operating air pressure Plant operating pressure is the pressure that is available during normal operations Each pound of pressure below 100 psi is a 1 decrease in Balancer capacity To determine the operating capacity of a Balancer at any air pressure convert the air pressure into a decimal Air Pressure 100 Capacity Factor 50 psi pressure 100 50 Factor Multiply the capacity factor by the rated capacity of the Balancer to determine the operating capacity Capacity Factor x Rated Capacity Operating Capacity 50 Factor x 350 lb Rated Capacity 175 lb Operating Capacity Page 2 of 21 Plant 50 Ib 150 Ib 200 Ib 350 Ib 500 Ib operating Balancer Balancer Balancer Balancer Balancer air operating operating operating operating operating pressure capacity capacity capacity capacity capacity PSI 100 50 150 200 350 500 90 45 135 180 315 450 80 40 120 160 280
13. down the heaviest load and rotate the pendent to the UN LOAD position 30 Maneuver the tooling or handling device to the medium weight load and engage the load 31 Rotate the pendent to the LO LOAD position 32 The load should be in balance 33 Set down the medium load and rotate the pendent the UN LOAD position The EA 2PS control integrates with either a clamp or a vacuum handling device The best applications for the EA 2PS control are single weight parts that are to be picked up and set down above the knees and below the shoulders This control is designed to remain in balance with or without a load attached The operator maneuvers the load by hand providing superior control Page 16 of 21 The 2PS valve mounts to the A port of the EA regulator The valve releases balancer pressure through an adjustable flow control to balance the handling device while empty A limit switch mounted on the handling device actuates the clamp or vacuum circuit and sends a pilot signal to the 2PS valve The 2PS valve shifts to a blocked port so pressure does not release The EA regulator is set to balance the handling device with a load attached Whether the handling device has a part attached or not it is in a balanced condition so the operator can maneuver the handling device by hand without having to manipulate any controls 1 Install the regulator and 2PS valve to the balancer 2 Rotate the regulator adjustment knob co
14. ent perform on the ZA manifold ____Send pressure to the piston chamber ____Change down speed ____Change up speed 5 What is the function of an Interlock valve ___ Shutdown handling device _ Prevent dropping a load _ Prevent lifting of a load Page 20 of 21 Glossary Balancing application a single load that is continuously supported Core Pop occurs in a wire rope when the core strand of the rope breaks or stretches Design standard pressure the minimum available air pressure Lifting application the picking and placing of a load that generally requires the operator to reach or bend in order to perform the task Rated capacity the maximum capacity of the balancer Operating capacity the balancer capacity at a specific air pressure Operating pressure the maximum sustainable air pressure during normal plant operation Reeve block a block or similar device through which a rope is passed a pulley Mechanism Static Seal an O ring or seal that does not move or rotate once installed Total load the total amount of weight of everything that is suspended from the balancer Answers Module Preview 1 Leak to atmosphere 2 Counterclockwise 3 Lower 4 ZA Exercises 1 1 Lift 2 Never 3 Core pop 4 First signs of fraying Exercises 2 1 192 5 Ib 190 0 Ib 2 500 Ib 3 120 4 A Exercises 3 1 BA 2 ZA 3 EA2PS 4 EA2PS Module Review 1 80 2 80 3 Three 4 Send pressure to piston chamber 5
15. erclockwise until 1 8 inch of the screw head protrudes from the side of the regulator body 13 Rotate the regulator adjustment knob clockwise until the load is balanced 14 Lift and lower the load several times Equal effort should be required to raise and lower the load If the load is hard to pull down turn the trim valve clockwise 1 2 turn and check If the load is hard to raise turn the trim valve counterclockwise 1 2 turn and check 15 Rotate the pendent to the LO LOAD position 16 Slowly rotate the LO LOAD flow control counterclockwise until the load drifts to the floor or full down position The wire rope should go slack 17 Remove the heaviest load from the tooling or handling device 18 Apply the medium weight load to the tooling or handling device 19 Rotate the LO LOAD flow control clockwise until the load is balanced 20 Tighten the jam nut to maintain the proper setting 21 Lift the load to the full up position 22 Rotate the pendent to the UN LOAD position 23 Slowly rotate the UN LOAD flow control counterclockwise until the load drifts to the floor or full down position Allow the wire rope to go slack 24 Remove the medium weight load from the tooling or handling device 25 Rotate the UN LOAD flow control clockwise until the load is balanced 26 Maneuver the tooling or handling device to the heaviest load and engage the load 27 Rotate the pendent to the HI LOAD position 28 The load should be in balance 29 Set
16. g adjustment of the control The BA Z Servo control is supplied on all 200 500Ib Balancers for balancing applications Install the regulator to the balancer 2 Install the Z Servo as close to but below the ball stop Refer to the Balancer Service Manual Z Servo Installation instructions Rotate the regulator adjustment knob counterclockwise until 1 2 inch of thread is visible Rotate the trim valve clockwise until snug then counterclockwise 2 full turns Rotate the auxiliary flow valve clockwise until snug Turn on main air supply Adjust regulator to required air pressure Rotate the adjustment knob clockwise slowly until the wire rope begins to raise move to the full up position ensure the Z brake does not engage Install the load hook and tooling or fixture to the wire rope in the required position Refer to Lash up instructions in the Balancer Service Manual form MHD56151 9 Rotate the regular adjustment knob clockwise until the load raises to the full up position The speed should be relatively slow Pull down and release the load and check the speed 10 Connect the black tube to the A port on the regulator 11 Rotate the auxiliary flow valve counterclockwise until the lowering speed is the same as the lifting speed Pinching off the black tube will pressurize the regulator to raise the load 12 Raise and lower the load two or three times to verify the speeds are the same If the speed in one direct
17. ion is much faster than the opposite direction the load will be difficult to move and may provide erratic operation 13 Pinch off the black tube and connect the free end to the Z Servo fitting 14 Turn the knurled nut at the top of the servo until the load is balanced Rotating the nut clockwise will increase the balance setting or raise the load Counterclockwise rotation of the nut will reduce the balance setting and lower the load 15 Lift and lower the load several times Equal effort should be required to raise and lower the load If the load is hard to pull down turn the trim valve clockwise 1 2 turn and check If the load is hard to raise turn the trim valve counterclockwise 1 2 and check ered W Page 14 of 21 The EA basic control balances three loads without the need to readjust the control The EA control is suited for applications where the various loads are within a 40lb range If the load variation is greater than 40 Ibs the lightest load may be difficult to lower or may drift up The port sizes in the pendent prevent any additional air from being released at the pendent flow controls Air from the A port of the EA Regulator flows through the control hose to the EA Pendent The EA pendent has a rotary thumb switch with three settings HI LOAD Balances heaviest load LO LOAD Air vents at the pendent to balance medium load UN LOAD Air vents at the pendent to balance lightest I load When the
18. kwise if the handling device raises or counterclockwise if it lowers until the handling device is balanced 15 Lift and lower the load several times Equal effort should be required to raise and lower the load If the load is hard to pull down turn the 2PS flow control counterclockwise 1 2 turn and check If the load is hard to raise turn the trim valve clockwise 1 2 turn and check o N D Page 17 of 21 16 Engage and disengage the part checking the balance condition of both the loaded and unloaded handling device The Interlock is a pilot operated adjustable spring return valve that will prevent the accidental release of the load while suspended The air supply to the clamp open vacuum release button is routed through the Interlock ports In the normal state the valve will allow air to these buttons for normal operation When interlocked the valve will shift supplying air directly to the clamp cylinder or vacuum generators The pilot signal is from the piston chamber of the balancer The spring return is set for the weight of the empty device When a load is attached to the end effector additional pressure is required to lift the load The pressure increase will be sufficient to shift the valve to the interlocked condition The operator will not be able to release the part until the weight of the load is removed from the end effector or the load is set down The Interlock valve will return to the normal state and allow the
19. mal setting is two turns from closed Fine tuning may be required for some applications If the trim valve is opened too far the load will be difficult to push down If not opened far enough the regulator will be slow to respond making the load feel heavy The correct setting will require equal effort to raise and lower the load To the left of the trim valve is the auxiliary flow valve which controls the amount of air delivered to the A port where the control valve connects The normal setting for the auxiliary flow has 1 8 inch of the screw head protruding from the regulator body If the valve is not set properly the control handle valve will not receive sufficient air pressure causing erratic operation The A port connects to the control valve The type of valve varies with different applications A check valve in the left side of the EA regulator installs over the port to the balancer to trap air in the piston chamber and may prevent a load from drifting Page 12 of 21 down if the air supply is disabled The spring behind the check valve requires 50psi to open Exercises 3 af 1 What is the normal setting for the hook balance adjust d ___ Two turns clockwise ___Flush with manifold top Screw removed 2 Turning the Up speed control on the ZA manifold clockwise will Increase speed Decrease speed No effect 3 What would be the best control for balancing a 25lb air tool BA __ ZA ___ EA 2PS 4 What
20. on the Z Brake will engage The Z Brake should be checked during installation for proper operation of the brake in the work area The Z Brake sensitivity can be adjusted Moving the spring inward will cause the brake to engage more quickly the lifting speed will be slower Sensitivity is decreased by moving the spring outward which causes the brake to engage more slowly and allows faster lifting speeds Operate the balancer very slowly in the up direction until a load is attached to avoid accidental engagement of the Z Brake Train operators to release the up lever if the load stops suddenly or begins to jerk Then depress the down lever to reset the Z Brake Page 5 of 21 Maintenance personnel should be notified to adjust the Z Brake or slow the lifting speed The Z Brake should never be used to limit travel as this will cause increased wear and reduce the life of the balancer If the Z Brake engages repeatedly during normal operation it will damage the wire rope end cover reel and brake rods The force generated by the piston when the Z Brake engages can be sufficient to bend the brake rods crack the reel or cause core pops in the wire rope The Z Brake should be inspected annually during the normal balancer service Remove balancer from service Remove the end cover of the balancer Brake Rods Check for security Bent or deformed Bearing Check for smooth rotation Brake ring Check for excessive gouging and wear B
21. part to be released Perform the Interlock adjustments as the last portion of the installation after all control adjustments have bee completed 1 Raise the handling device to a mid travel position so the balancer is supporting the entire weight The Interlock screw threads into an aluminum housing that will rotate with the screw Hold the aluminum housing while turning the screw 2 Turn the screw counterclockwise until the Interlock light illuminates green light or until 1 1 2 inch of thread is visible 3 Depress and release repeatedly the clamp vacuum release button while rotating the Interlock screw clockwise until the clamp opens or blow off air is heard at the vacuum cups or the Interlock indicator extinguishes 4 Raise and lower the device several times Check for proper operation of the clamp and vacuum controls 5 Raise the handling device to the full up position Page 18 of 21 6 Depress and hold the up lever of the ZA control for three seconds This will simulate an additional load on the balancer 7 Depress and release the clamp vacuum release button The clamp should remain closed or not blow off air to the vacuum cups 8 Check that the Interlock indicator has illuminated green light 9 Lower the handling device and engage a part with the end effector 10 Raise the load 1 inch above the pick up point 11 Depress and release the clamp vacuum release button The part should remain attached to the end
22. rake arm pad Check spring holes for excessive wear Check pad area for excessive wear Brake Spring Check for deformation and over center wrap for attachment Check engagement Grasp the brake rods and rotate them clockwise with a rapid motion The brake shoe should engage the end cover and stop rotation Zimmerman Air Balancers incorporate wire rope because it is an inexpensive means to support a load and has excellent wear characteristics It should provide approximately 250 000 cycles SUG We use 7 X 19 galvanized 3 16 wire rope with a working capacity of 1 400 Ibs A fitting is swaged onto the end of the rope that installs into the reel Page 6 of 21 The wire rope should be inspected daily Replace wire rope with any bulges more than one wire frayed kinks or abnormal bends A damaged wire rope will have one or more of these faults Depress the down lever or lower the handling device to the bottom of balancer travel Use a gloved hand to carefully slide up the rope if the glove snags on the wire rope inspect for frays and core pops in this area Check the entire length of rope up to the wire rope guide Replace any wire rope found faulty Repeated loading and unloading of the wire rope causes core pop The core strand of the rope stretches beyond its limits then the load releases rapidly The core strand of rope will break and fray or curl into a knot causing a bulge or bend in the wire rope To prevent core pop the wi
23. re rope should always have tension on it or do not allow the wire rope to go slack Frays occur as part of normal wear Replace a wire rope at the first sign of fraying The load hook is a Crosby Bullard Golden Gate Lif Lok self closing swivel bail load hook The hook has a working limit of one half ton and an ultimate load of four times the working limit The load hook should be inspected daily as part of the wire rope inspection Check the following Top bail of hook should swivel freely Tip of hook should align with the self closing gate No more than 10 wear is allowed at the base of the hook No more than 5 wear in all other areas Quic Check marks must align with an inch or half inch increment Page 7 of 21 The Z Stop is a patented mechanism that will disable the operation of the Balancer if the main air supply is disabled It consists of an Engagement Plate and a Double Acting Air Cylinder with engagement pin The Engagement Plate is installed on the Z Brake rods and rotates with the Reel It contains slots for the Engagement Pin Both ends of the Double Acting Cylinder are pressurized Air pressure from the Piston Chamber attempts to extend the engagement pin through the red 5 32 inch tube Supply air pressure routes to the front of the Cylinder through the yellow 5 32 inch tube and acts to hold the Engagement Pin back If the main air supply is disabled or supply pressure drops below the balancer pressure
24. refer to the Balancer Service Manual for an exploded view of the suspension kits that can be used for assembly reference Page 19 of 21 All bolted connections have self locking nuts that should be replaced when removed The suspension kits should be inspected with the balancer annually Remove the balancer from service Remove trolley from brackets Check for evidence of wear or elongation of bolt and hole Check trolley wheels for cracks smooth rotation and no flat spots Check trolley body for evidence of cracks or damage Remove brackets from balancer Check brackets for signs of wear and elongation of bushing and bracket holes and bolt We have discussed the operation and inspection of the balancer load hook suspension kits wire rope Z brake and Z Stop You now have the required expertise to inspect and maintain the balancer We have also reviewed the operation installation and adjustment of the standard control kits The adjustment of the controls is a critical element in the proper operation of the balancer system Module Review gt Z 1 What is the maximum recommended load for a ZA controlled Q Balancer ____ 50 of operating capacity ___80 of operating capacity Q 100 of operating capacity 2 How many inches of travel do tandem 500lb Balancers have 60 40 80 3 How many loads can be balanced with the EA Basic control 1 10 3 4 What function does the hook balance adjustm
25. um air consumption The balancer consumes approximately 1 8 of a cubic foot of air per complete cycle An average hoist will consume up to 4 cubic feet of air per cycle A fixed Ball Screw runs through the Page 4 of 21 center of the Balancer A Valox Reel with a Ball Nut pressed into one end and a Thrust Bearing pressed into the other rides on the Ball Screw A Piston pushes against the Thrust Bearing The Reel rotates counterclockwise facing the end cover along the length of the Ball Screw lifting the load When pressure in the piston chamber releases the load counter rotates the Reel and lowers When the load is stopped the air trapped in the piston chamber acts as a cushion balancing the load until the load is moved or the controls are manipulated The balancer should be inspected annually for condition of the internal components and lubrication The balancer may be serviced while installed on the overhead rail Refer to the Balancer Service Manual form MHD56151 for Preventive Maintenance instructions Z Brake is the name of our patented Safety Retraction System The Z Brake will prevent uncontrolled upward travel of the wire rope if the load is lost or the wire rope breaks It is installed in the End Cover as a standard part of the balancer except in the 50 Ib Balancer The Z Brake activates by centrifugal force through Brake Rods that engage the Reel When the speed of the Reel overcomes the Brake Spring tensi
26. unterclockwise until 1 2 inch of thread is visible 3 Rotate the trim valve clockwise until snug then counterclockwise 2 full turns 4 Rotate the auxiliary flow valve clockwise until snug then counterclockwise until 1 8 inch of the screw head protrudes from the side of the regulator body 5 Rotate the 2PS flow control clockwise until snug then counterclockwise 1 turn Ensure the tube is connected at the 2PS valve and handling device Turn on main air supply Adjust regulator to required air pressure Rotate the adjustment knob clockwise slowly until the wire rope begins to raise move to the full up position ensure the Z brake does not engage 9 Install the load hook and tooling or handling device to the wire rope in the required position Refer to Lash up instructions in the Balancer Service Manual form MHD56151 10 Engage the load with the tooling or handling device 11 Rotate the regulator adjustment knob clockwise until the load is balanced 12 Lift and lower the load several times Equal effort should be required to raise and lower the load If the load is hard to pull down turn the trim valve clockwise 1 2 turn and check If the load is hard to raise turn the trim valve counterclockwise 1 2 turn and check 13 Set the part down The handling device may raise or lower unexpectedly when the part is released Ensure you are clear of the vertical path at all times during adjustments 14 Rotate the 2PS flow control countercloc
27. w often should the wire rope be inspected Daily ___To limit travel ____Rope fails or load is lost ___ When supply pressure is lost Weekly 5 When should the wire rope be replaced _ First signs of fraying IR Zimmerman Balancers provide superior load control for precision placement of parts When properly applied a balancer can increase production and reduce employee injuries and fatigue The following table identifies the control options available and their proper application CONTROL BA Z Servo EA 2PS DESCRIPTION Pressure regulator control Pressure regulator control with input amplifying servo Pressure regulator control with adjustment for multiple loads Pendent actuated Pressure regulator control with adjustment for empty device and loaded device Integrated to device or manually actuated Manifold control with speed adjustments capable of lifting up to operating capacity of balancer Pendent actuated APPLICATION Balancing a single load Weld Gun Multi spindle Nut Runner Checking Fixture Balancing a single load Weld Gun Multi spindle Nut Runner Checking Fixture Balancing of three loads Three mode pendent HI LOAD LO LOAD UN LOAD Balancing control integrated into a handling device that will pick up only one size or weight part All lifting applications Page 9 of 21 LIMITATIONS Supplied only on the 50 and 150lb capacity Balancers Supplied with 200 500lb b
28. will wind onto the reel The purpose of the excess rope is to accommodate various installation heights Remove excess wire rope at the completion of installation Each balancer is also supplied with a maximum amount of straight travel which is more than an operator s reasonable and comfortable ergonomically sound reach Page 3 of 21 The 150 350 and 500lb Balancers have 80 inches of travel The 200 Ib Balancer has 120 inches of travel The 50 Ib Balancer has 60 inches of travel Remember that installing a reeve block will reduce the travel by half Note 50 amp 150 Ib units reeve block is unavailable Balancer Length of Rope Straight Travel Reeved Travel Capacity Feet Inches A wow m 200 I 2 oo sow o o o Exercise 1 a f 1 How many models of balancers does IR provide ___One __Three ___Five 2 What is the operating capacity of Q 350 Ib Balancer at 55 psi 200 lb Balancer at95psi 3 What does the S represent in the balancer model number ___ Stand Alone ___ Secondary ___Z Stop 4 Ifa 200lb balancer is reeved how many inches of travel will it have 120 60 40 5 How many inches of travel do 500lb Balancers have 80 60 120 The Balancer uses the same principle as a single acting air cylinder Air pressure passes into the piston chamber to raise the load while gravity and the release of pressure allow the load to lower This design requires minim
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